description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
BACKGROUND OF THE INVENTION
The present invention is directed in general to an apparatus and method for decreasing the locomotive smoke emissions when the operator advances the locomotive throttle position, and more specifically to an apparatus and method that delays the application of load to the engine and modifies engine timing.
Recent amendments to United States environmental statutes and regulations require lowering of the permitted emissions from locomotive diesel engines, including visible smoke. One such requirement is the reduction in NO x emissions, which can be effected by retarding the fuel injection timing of a locomotive diesel engine. But this timing modification negatively impacts fuel consumption and, therefore, it is desirable to increase the engine compression ratio to gain back some of the fuel consumption losses.
However, increasing the compression ratio also increases the visible smoke emissions at partial engine loading. The problem of visible smoke is especially acute during transient load and speed changes, i.e., when the locomotive operator advances the throttle (i.e., moves the throttle to a higher notch position) to call for higher speed and/or greater load pulling capacity (i.e., locomotive horsepower). The smoke emissions tend to be worse when the throttle is advanced to higher throttle positions when starting from lower positions.
In the prior art locomotives, when the throttle is advanced from one position to the next (where the throttle positions are commonly referred to as notches) the diesel engine speed and the load (or current excitation) applied to the traction motors are simultaneously increased to the speed and horsepower point of the new notch position. In response to the notch position change the engine acceleration to the new speed point is controlled by an electronic governing unit. Also, the locomotive control system applies more excitation current to the main alternator, which in turn supplies more current to the traction motors, increasing the motor horsepower. While the speed and load are increasing to their new respective points, the fuel injection timing is determined from a look-up table based on engine speed. As discussed above, during these notch or transient changes, undesirable smoke emissions are produced.
In the prior art locomotive systems, the electronic governing unit acts as the speed governor in response to speed changes requested by the locomotive control system. In the prior art, the speed governor does not receive a signal from the throttle when it is changed from one notch position to another and therefore does not know when a notch change has occurred; the speed governor knows only the engine speed demand. In fact, there are multiple notch settings that vary the horsepower delivered by the traction motors, but not the engine speed.
BRIEF DESCRIPTION OF THE INVENTION
The above-mentioned undesirable visible smoke emissions during throttle notch changes (also referred to as transients) can be mitigated by the present invention, relating to a novel and nonobvious apparatus and method for controlling the engine timing and load application to favorably impact the visible smoke emissions during engine transients.
According to the teachings of one embodiment of the present invention, a parameter indicative of an increase in throttle notch setting is monitored and data representative of the notch increase is provided to a locomotive controller. In response, a locomotive electrical power generator is controlled to apply additional load on the engine as a ramp function over a predetermined period of time, so as to reduce emissions from the engine as the engine responds to the increased load.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention can be more easily understood and the further advantages and uses thereof more readily apparent, when considered in view of the description of the preferred embodiments and the following figures in which:
FIG. 1 is a flow chart illustrating the operation of the present invention;
FIG. 2 illustrates an engine timing angle advance ramp function according to one embodiment of the present invention for limiting smoke emissions;
FIG. 3 illustrates a load application ramp function according to one embodiment of the present invention for limiting smoke emissions; depicts a load application parameter according to one embodiment of the present invention for limiting smoke emissions;
FIG. 4 is a block diagram of locomotive components associated with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Before describing in detail the particular transient smoke reduction system in accordance with the present invention, it should be observed that the present invention resides primarily in a novel combination of steps and apparatus related to smoke reduction in a railroad locomotive. Accordingly, these hardware components and method steps have been represented by conventional elements in the drawings, showing only those specific details that are pertinent to the present invention, so as not to obscure the disclosure with structural details that will be readily apparent to those skilled in the art having the benefit of the description herein.
FIG. 1 is a flow chart illustrating the operation of the present invention. At a step 10 , the locomotive operator's movement of the throttle handle toward a higher notch position is detected. A transient operational period ensues as the engine and locomotive operational parameters change to those commanded by the new notch position. There are several engine and locomotive operational parameters that can be monitored to detect a notch increase, including, for example, engine speed (revolutions per minute), engine acceleration excitation current to the traction alternator, engine horsepower, engine fuel value (the quantity of fuel injected into an engine cylinder), traction motor alternator output current and manifold air pressure (which is influenced by the turbine speed and thus the engine speed). In response to one or more of these monitored parameters, at a step 12 , the locomotive control system (not shown in FIG. 1 ) determines that a notch change has occurred and sends a representative signal to an excitation controller and an electronic governing unit (EGU) of the locomotive diesel engine. The excitation controller controls the current provided to the traction alternator field windings and thereby the affects the power (i.e., current) delivered by the traction alternator to the traction motors. The electronic governing unit controls the fuel value delivered to each engine cylinder and thereby affects the engine speed. Refer to commonly-owned U.S. Pat. No. 5,826,563; issued on Oct. 27, 1998, for further details of the excitation controller and electronic governing unit.
At a step 14 , a timing angle look-up table is consulted to determine one or more of the various parameters that are used to govern the process of advancing the engine timing angle during the notch transient, with the result of limiting smoke emissions. At a step 16 , the engine timing angle is advanced in accordance with the one or more parameters.
In one embodiment, the timing angle is not advanced immediately (i.e., not a step change), but instead is ramped (or slewed) from the current or base value to the desired value. When the monitored operational parameter that determined a notch change reaches a steady-state value, the engine timing advance angle is slewed back to the value associated with the new notch position.
There are several parameters that can be used to define the process of slewing to the final timing advance angle, and these parameters can be selected according to various embodiments of the present invention. One such parameter is the slew rate (or line slope), which in one embodiment is linear and is approximately ten degrees per second. This parameter is identified by a reference character 32 in FIG. 2 . The slew rate can also follow a curvilinear curve. In another embodiment the slew rate is dependent on the operative notch position prior to the change initiated by the locomotive operator.
Also, the onset of the slew or ramp can be delayed by a predetermined time, as represented by a time period between time t=0 and t 1 in FIG. 2 . The duration of the slew can also be selected as desired, as represented by an interval between t=0 and t 2 . In another embodiment these slew parameters are determined as a function of the initial notch position, and thus as a function of the timing angle advance (θ 1 ) at the initial notch position, as indicated in FIG. 2 . These various slew parameters can be set forth in a look-up table or calculated from one or more functional equations. In one embodiment, the slew parameters can be modified for high-altitude operation of the locomotive. It is known that due to the lower air density at higher altitudes, the notch settings for high altitude operation have different speeds associated therewith than the notch settings for conventional operation.
It is known in the art that advancing the engine timing angle at high loads can cause excessive engine cylinder pressure. Thus, for a transient condition (i.e., a throttle notch position change) that ends in a high load condition, the timing angle can be returned to the nominal value before full load application is achieved. According to the present invention, this is accomplished by discontinuing the timing angle advance and returning to the nominal timing angle when the fuel value reaches a predetermined limit. This feature is implemented at a decision step 18 of FIG. 1 , where the fuel value is compared to a predetermined fuel value limit. If that limit is exceeded, then the result from decision step 18 is true and processing moves to a step 20 where the timing angle is returned to its nominal value. At a step 22 , the process terminates.
Alternatively, at the decision step 18 it is also determined whether a predetermined time duration for advancing the engine timing has expired. If the result is true, processing also continues to the step 20 where the timing angle is returned to the nominal value associated with the new notch position. Also, when a steady state condition is reached the engine timing advance angle returns to the advance angle of the new notch position.
As was the case with the increase in the timing advance angle at the step 16 , here too at the step 20 it is not required to change the timing angle advance as a step function, but instead the timing angle can be ramped or slewed from the current value to the new value (as determined by the end notch position). In conjunction with this process of slewing to the new advance angle, the various slew parameters (e.g., slew rate, and delay until beginning of the slew interval) can be selected as desired. For example, in one embodiment the slew rate at the step 20 is two degrees per second.
If the result from the decision step 18 is false, processing moves to a step 21 , which simply indicates that the advanced timing angle condition continues.
In an embodiment where one or more of the timing angle advance parameters (the slew rate, for example) are dependent on the final notch position, an operational parameter representative of the final notch position is required. This can be determined from the monitored locomotive operational parameters, as described above in conjunction with the step 10 of FIG. 1 .
Returning to FIG. 1 , the right branch illustrates the process by which, according to the teachings of the present invention, the application of the additional load associated with the new notch position is controlled, that is, the load may not be applied instantaneously (which would be accomplished by using a step function to control the load application). Once a notch change has been detected, initiating a transient operational condition, as described above in conjunction with the step 10 , at a step 26 one or more parameters governing the application of a new load value are determined. At a step 28 these parameters are operative to control the load application. Once the full load at the new notch position has been applied, the load application control process ends at a step 30 .
In one embodiment the operative load application parameter is simply delaying the load application for a predetermined time. In this embodiment, the delay period can be determined from a look-up table. Typical delay times are generally less that about 10 seconds, measured from the onset of transient operation
In another embodiment, the additional load can be applied as a ramp function over a predetermined period of time following the indication of a notch increase, i.e., transient operation. The ramp can be a linear or a curvilinear function over the predetermined time. The predetermined time period can be based on the degree of notch change (i.e., the number of notch settings between the initial throttle position and the final throttle positions). Also, the initiation of the ramp function (i.e., application of the additional load) can be delayed based on the degree of notch change. The slew rate (or the slope of the ramp) can also selected, and in one embodiment is based on the degree of notch change. A representative ramp function 34 is illustrated in FIG. 3 , where it is assumed that a notch increase is detected at t 1 . In an embodiment where one or more of the load application parameters are dependent on the final notch position, an operational parameter representative of the final notch position is required. This can be determined from the monitored locomotive operational parameters, as described above in conjunction with the step 10 of FIG. 1 .
FIG. 4 illustrates the hardware elements associated with the present invention. A throttle 40 , including the notch positions discussed above, is controlled by the locomotive operator. In one embodiment, when the operator moves the throttle handle from one position to another, a signal indicating that change is supplied to the locomotive controller 42 . In other embodiments, various engine and locomotive operational parameters are monitored to detect a notch change. In response to a notch change, and in accordance with one or more of the load application delay parameters determined at the step 26 , the locomotive controller 42 controls an excitation controller 43 , which in turn supplies excitation current to a traction alternator 44 . The output current of the traction alternator is supplied as an input current to the traction motors 45 for developing the horsepower associated with each notch position.
Also in response to an indication of a throttle notch adjustment, the locomotive controller 42 sends a corresponding signal to the electronic governing unit 46 . The electronic governing unit 46 controls the engine speed as discussed in conjunction with the flow chart of FIG. 1 . The engine timing angle is advanced in response to the timing angle advance parameters determined at the step 14 .
The flow chart of FIG. 1 , including determining the parameters associated with the timing angle advance and the load application delay, can be executed by a processor, such as a computer. This implementation is well known in the art, and in fact the processor can be embodied within the locomotive controller 42 and the electronic governing unit 46 shown in FIG. 4 . Instructions in a read-only memory control operation of the processor and in an exemplary embodiment the flow chart of FIG. 1 can be set forth in a random access memory. Execution of the FIG. 1 flowchart includes the generation of control signals input to the diesel engine 48 and the excitation controller 43 , as shown in FIG. 4 .
Additional details of certain aspects of the present invention are set forth in commonly-owned U.S. Pat. No. 6,341,596, which is hereby incorporated by reference.
While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalent elements may be substituted for elements thereof without departing from the scope of the present invention. In addition, modifications may be made to adapt a particular situation or application 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 appended claims. | A method and apparatus for reducing the smoke emissions of a railroad locomotive during throttle notch changes. For certain throttle notch increases the present invention advances the engine timing angle and controls application of the load at the new throttle notch position, according to certain predetermined parameters. These strategies, when used together or separately, minimize visible smoke during transient operation. | 5 |
BACKGROUND OF THE INVENTION
The invention relates to a method for the high-speed precision clamping of a rotationally symmetrical workpiece for its outside circumference to be ground, utilising a clamping device for the axial and radial positioning of the workpiece, for clamping the workpiece in its processing position and for transferring the torque from the driving spindle head to the positioned and clamped workpiece. The invention also relates to a high-speed precision clamping device for clamping a rotationally symmetrical workpiece for its outside circumference to be ground, in accordance with the above-mentioned method. The invention thereby provides such an improvement in the clamping method and in the clamping device used therefor that a hitherto unattained accuracy is achieved for the positioning of the workpiece associated with the clamping operation and is maintained during processing of the workpiece.
Clamping methods and clamping devices for rotationally symmetrical workpieces, which have to be rotated past the tool whilst their outside circumferences are being ground, have been known for a long time. The same is also true of workpieces which are processed by grinding the outside circumference. Generally, such workpieces are clamped in a three-jaw chuck which is located on the driving spindle head and wherein the three clmaping jaws, which are directed towards the axis of rotation, radially and axially position the workpiece in a single combined positioning and clamping process and thereby clamp the workpiece so securely that the driving torque is transferred from the driving spindle to the workpiece. This known type of clamping method can keep within manufacturing tolerances which are sufficient for most of the usual manufacturing tasks. More recently, however, according to the standards set by modern techniques for grinding outside circumferences, narrower manufacturing tolerances are demanded and, consequently, the manufacturing waste--which occurs due to tolerances being exceeded--increases and makes manufacture more expensive.
SUMMARY OF THE INVENTION
A basic object of the invention is to provide a positioning and clamping method which permits narrower manufacturing tolerances, thereby keeping manufacturing waste low and preventing further increases in the manufacuring cost.
In a method of the above-described type, the object is achieved, in accordance with the invention, in that the workpiece is initially radially positioned in a first device member which is secured to a frame, in that the radially positioned workpiece is then clamped in a second device member which is displaceably and rotatably mounted and transfers torque, and in that the radially positioned and clamped workpiece is finally axially positioned by axial displacement as far as a stop member on a third device member which is secured to the frame. This arrangement permits the method steps of positioning and clamping to be very largely separate from one another, so that the reaction forces occurring during clamping and during transfer of the rotary force no longer also act upon and change the positioning operation, and increase the positioning tolerances due to wear in the positioning region. The consequence is that the workpieces may be processed with narrower tolerances and that, at the same time, the manufacturing waste caused by tolerances being exceeded is reduced. Consequently, the invention permits a considerable increase in quality to be achieved at a reduced manufacturing cost. Practical experiments have shown that, with the invention, radial and axial tolerances can easily be kept within the lower um range for circumference grinding.
According to a further feature of the invention, a high-speed precision clamping device is proposed for implementing the method according to the invention, such a device including a prism-shaped support member which is known per se and forms the first device member, the support member being secured to the frame and being provided with a hydraulically adjustable pressure roller for the radial positioning of the workpiece. The device also includes a driving spindle, head which is known per se and forms the second device member, the driving spindle head being rotatably mounted in the frame and being provided with a collet for clamping the workpiece so as to transfer the torque, and finally the device includes an axial stop member which is known per se and forms the third device member, the stop member being secured to the frame and serving for the axial positioning of the workpiece, wherein the collet, which is displaceably mounted by means of radially acting centering springs in a collet housing secured to the driving spindle head and is rotated via the intermediary of a driver, is drawn into its closed position by means of a collet closing spring and is provided with hollow cone segments on its rear end at both collet arms, the hollow cone segments together forming a hollow cone when the collet is closed, and also wherein a sleeve-like piston is axially displaceably mounted on the axial stop member which is secured to the frame and is engaged by the piston which is hydraulically driven and supports, on its front end, a collet expanding cone corresponding to the hollow cone, and finally wherein a collet compression spring, which presses the collet forwardly, is provided between the piston and the collet and, in addition, a plurality of collet lifting springs are provided between the collet and the collet housing, the springs being disposed at equal angular spacings from one another and pressing the collet rearwardly. By means of a single, compact device which automatically controls the operating sequence, this arrangement of the clamping device permits the positioning and clamping method, which basically comprises three steps, to be implemented just as easily as with known (but disadvantageous) clamping devices, because the machine operator only needs to "insert and clamp" the workpiece, as usual.
A further feature of the invention proposes that the collet lifting springs produce in their entirety a gentle spring action compared with the collet compression spring, while the collet closing spring produces a stronger spring action compared with the collet compression spring. This arrangement permits the multiple-stepped operating sequence to be controlled in an extremely easy manner by adapting the various springs relative to one another.
A further feature of the invention proposes that the axial stop member which is secured to the frame have a fixed, inserted spherical segment--formed from hardened steel and provided with a ground plane surface --at the location where the rear end of the workpiece abuts against the stop member during the axial positioning operation. This arrangmenet permits the axial stop member which is secured to the frame to be subjected only to very slight wear at the location where the rotating workpiece slidingly abuts, thereby ensuring that the high degree of positioning accuracy is maintained for a long time.
A further feature of the invention proposes that slightly protruding hardened steel balls be securely inserted in the front end of the collet which slidingly abuts against the wall of the collet housing during expansion of the collet, the balls establishing the contact with the wall of the collet housing during expansion of the collet. This arrangement permits friction and wear to be kept to a minimum, even between the collet and collet housing, thereby also ensuring that the high degree of positioning accuracy is maintained for a long time.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained more fully hereinafter with reference to the accompanying drawings illustrating one embodiment of the invention, in which:
FIG. 1 is a sectional view, taken along the line II--II of FIG. 3, through a high-speed precision clamping device which is also used to explain the method according to the invention;
FIG. 2 is a sectional view, taken along the line III--III of FIG. 3, through a portion of the device of FIG. 1, namely through the collet and the collet housing;
FIG. 3 is a side elevational view of the collet and a longitudinal sectional view through the collet housing taken along the line I--I of FIG. 1; and
FIG. 4 is a side elevational view of the prism-shaped support member provided with the pressure roller.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This high-speed precision clamping device is incorporated in a grinding machine frame 1, a few device members being secured to the frame whilst other device members are rotatably mounted and driven.
The purpose of the clamping device is to position a workpiece 2 radially and axially and to clamp the workpiece so that its circumference can be ground.
The clamping device comprises three device members, namely a first device member for the radial positioning of the workpiece 2, a second device member for clamping the workpiece 2, and a third device member for the axial positioning of the workpiece 2. According to the invention, because the tasks of radial positioning, clamping and axial positioning are assigned to three different, though co-operating, device members, the workpiece 2 can be positioned without being adversely affected by the clamping of the same workpiece 2. The consequence is that the workpiece is clamped in a positioning operation which meets particularly high demands for accuracy.
The first device member for radially positioning the workpiece 2 comprises a prism-shaped support member 3 which is secured to the frame and is provided with a pressure roller 4. This arrangement is known per se, but it is new in terms of its co-operation with the other device members.
The second device member for clamping the workpiece 2 largely comprises a collet 5, 6 which is formed from a first collet member 5 and a second collet member 6 which is pivotably mounted on the first collet member. The two collet members 5 and 6 are drawn towards one another, by means of a collet closing spring 7, into the closed position which is shown in FIGS. 1, 2 and 3. In the closed position, the clamping jaws of the collet member 5 and 6 engage with the workpiece 2 so tightly by means of spring pressure that the rotary movement, which is needed for grinding the circumference of the workpiece 2, can be transmitted from the collet 5, 6 to the workpiece 2. Such collets are known per se. However, the collet according to the invention is new in terms of its special structural form and in terms of its co-operation with the other device members. The collet 5, 6 is connected to a collet housing 9 via the intermediary of a driver 8 so as to transfer the rotary force, the collet 5, 6 being displaceably mounted in the collet housing by means of centering springs 11, 12, 13. The collet housing 9 is securely mounted on a driving spindle head 10 which is driven by a drive motor (not shown) via intermediary of the belt 14.
The third device member for axially positioning the workpiece 2 is formed by an axial stop member 15 which is secured to the frame and is also know per se, though it is novel in terms of its co-operation with the other device members.
The clamping method according to the invention now initially comprises radially positioning the workpiece 2 in the first device member by means of the prism-shaped support member 3, which is secured to the frame, and by means of the pressure roller 4. The workpiece 2, which is already radially positioned, is then clamped in the second device member by means of the collet 5, 6 which is displaceably mounted in the centering springs 11, 12, 13. Due to the displaceable mounting of the collet 5, 6, no reaction forces can occur relative to the collet housing 9 during clamping, such forces possibly adversely affecting the position of the collet 5, 6 and hence also the position of the workpiece 2 and its radial positioning. Finally, the workpiece 2, which is already radially positioned and is even already clamped, is also axially positioned by means of axial displacement as far as the axial stop member 15 which is secured to the frame. This terminates the positioning and clamping of the workpiece 2, and the workpiece 2 can start being processed.
In the clamping device, which is shown by way of example in the drawings, the operating sequence according to the invention is automatically controlled by simple, structural means.
For the automatic opening and closing of the first device member for the radial positioning of the workpiece 2, the pressure roller 4 is mounted at one end of a double-ended lever 16, a hydraulic adjusting member 17 engaging with the other end of lever 16 and, after insertion of the workpiece 2 by a control means (not shown) of conventional construction, the adjusting member causes the pressure roller 4 to abut against the workpiece 2 and hence ensures the radial positioning of the workpiece.
For the automatic opening and closing of the second device member for clamping the workpiece 2, the collet 5, 6 is provided at its rear end (remote from the workpiece 2), on both collet members 5 and 6, with hollow cone segments 18 and 19 which form a continuous hollow cone 18, 19 when the collet 5, 6 is closed. A sleeve-like piston 20 is axially displaceably mounted on the axial stop member 15, which is secured to the frame, and piston 20 engages with stop member 15 and supports, at its front end, a collet expanding cone 21 corresponding to the hollow cone 18, 19. A collet compression spring 22 is provided between the piston 20 and the collet 5, 6 and presses the piston 20 and the collet 5, 6 apart, i.e. spring 22 presses the collet 5, 6 forwardly and presses the piston 20 rearwardly. Four collet lifting springs 23, 24, 25 and 26 are also provided between the collet 5, 6 and the collet housing 9 and press the collet 5, 6 rearwardly away from the front wall of the collet housing 9. The piston 20 is a hydraulic piston of known construction which can be advanced through hydraulic conduits 27 and 28 in opposition to the collet compression spring 22 and is moved back by the restoring force of the collet compression spring 22. The hydraulic control means (not shown) is of conventional construction.
The working cycle commences with the hydraulically advancing piston 20. The force exerted upon the collet 5, 6 via the intermediary of the collet compression spring 22 moves the collet 5, 6 forwardly as far as the stop member on the front wall of the collet housing 9 due to compression of the collet lifting springs 23, 24, 25, 26 and subsequently, as the piston 20 advances further, the collet expanding cone 21 of said piston abuts against the hollow cone segments 18, 19, presses segments 18, 19 apart and thereby opens the collet 5, 6 in opposition to the force of the collet closing spring 7. At the same time, the pressure roller 4 is lifted from the prism-shaped support member 3, which is secured to the frame, by the control means (not shown) via the intermediary of the adjusting member 17. In these circumstances, the clamping device is open and ready to have a new workpiece 2 inserted therein.
After insertion of the workpiece 2, the control means (not shown) is activated, for example by pressing a control button, to start the working cycle which now commences.
After the workpiece 2 has been clamped in position in the radial and axial direction, the workpiece is radially positioned as the third process step. The piston 20 is moved back hydraulically; it travels back by the pressure of the collet lifting springs 23, 24, 25, 26 and of the collet compression spring 22. Because this movement also causes the collet expanding cone 21 to travel back, the collet 5, 6 initially closes by the action of the collet closing spring 7 and thereby clamps the workpiece 2 which has already been radially positioned. As the piston 20 travels further back, the collet 5, 6 is lifted from the front wall of the collet housing 9 by the action of the collet lifting springs 23, 24, 25, 26. The collet 5, 6 thereby takes back with it the radially positioned and clamped workpiece 2 until the rear end of the workpiece abuts against the axial stop member 15 which is secured to the frame, the radially positioned and clamped workpiece 2 then being axially positioned also. When the piston 20 has moved back fully, the collet compression spring 22 is entirely relieved of tension. The workpiece 2 may now be processed and may be rotated for this purpose via the intermediary of the belt 14, the driving spindle head 10, the collet housing 9, the driver 8 and the collet 5, 6 without thereby causing the transfer of torque via the radial or axial positioning means. The positioning of the workpiece 2 is not affected by the transfer of torque and is therefore maintained very accurately. The automatic sequence of the method steps is achieved very easily by adapting the various springs to one another when the collet lifting springs 23, 24, 25, 26 produce in their entirety a gentle spring action compared with the collet compression spring 22, while the collet closing spring 7 produces a stronger spring action compared with the collet compression spring 22.
Subsequent to the processing of the workpiece 2, the clamping device is re-opened by the advancing movement of the piston 20, whereby the method steps described for clamping purposes are carried out in the reverse sequence until the working cycle is completed and the clamping device is opened for the removal of the processed workpiece 2.
To reduce sliding friction between the workpiece 2 and the stop member 15 which is secured to the frame, stop member 15 in the region of the contact surface is in the form of an inserted spherical segment which is formed from hardened steel and is ground on its plane surface (this segment can be seen in FIG. 1 but it does not have a special reference numeral).
To reduce the sliding friction between the collet 5, 6 and the front wall of the collet housing 9, hardened steel balls 29 are securely inserted into the front end of the collet 5, 6, balls 29 protuding slightly and establishing contact with the front wall of the collet housing 9. In practical manufacturing use, it has proved easy and economical to insert the steel balls 29 into blind bores and glue them therein.
In the practical embodiments of clamping devices according to the invention, various modifications are possible. The essential feature of the invention is that the device members which are used for clamping purposes are in practical terms independent of the device members which are used for positioning purposes. | A method of clamping rotationally symmetrical workpieces for their circumferences to be ground, whereby the radial positioning, the clamping and the axial positioning of the workpiece are effected independently of one another, so that the positioning operation is not affected by the clamping operation and is accurately maintained. In addition, a clamping device for implementing the method includes a first member which radially positions the workpiece, a second member which clamps the workpiece for transferring torque, and a third member which axially positions the workpiece. | 8 |
FIELD OF THE INVENTION
The subject matter generally relates to mining industry and may be used to develop fields and for the most complete extraction of oil having varying viscosity and gas, as well as other mineral resources, from oil and gas fields, shale and other layers and geological formations.
BACKGROUND OF THE INVENTION
A method is known for increasing oil and other mineral liquids rate of extraction from oil layers of the earth or sea (RU 1838594 A3). As a device for transmitting energy for subsequent impact on oil layer electrodes located in two neighboring wells and mercury, preliminarily placed within wells up to the level of oil layer bedding, are used. Then, in the oil layer, the vibration is created via vibrators with the frequency that is the closest to the resonating frequency of the layer. For this purpose, the mercury vibration is created via those inserted vibrators and the electric stimulation of the vibration process is simultaneously performed via voltage alternating current applied to the electrodes in the neighbor wells. Those resonant vibrations in the said field spread outside and provide oil extraction from the field. Energy of vibrations also produces heat in the field, which is released due to the friction between the field and oil, located within, thus creating the increase in pressure that results from the evaporation of some part of oil and water.
However, the method described above has the following disadvantages:
use of mercury as liquid electrodes is very dangerous due to unhealthy exhalations and ecological pollution of the environment and the ground water;
large areas of contact between vibrating surfaces and oil layer are needed to spread resonant vibrations outside the field and extracting oil, power consumption is large, and the method implementation is costly;
the efficiency of oil extraction from the field via this method is insufficient.
A method is also known for increasing extraction of oil, gas and other mineral resources from the earth interior, formations drilling and control (RU 2104393). According to this method, at the specified well sites, the productive layers are drilled via cutting or perforating the material of wells casing columns with a high-power laser beam with subsequent evaporation, via those slots, of solid and liquid phases of substances, included into structure of layers and the mountain rock comprising the layers, with optical fiber cables having operating heads on their tips emitting light energy to be used as a device to transfer energy, the optical fibers (light guides) of the optical fiber cables connected to the high-power lasers on the surface to create areas within the layers having the specified high temperature with the high pore pressure to improve oil and gas extraction rate, and move those areas, within the in-situ spaces, by moving the emitting tips of optical fiber cables with the operating heads on within the wells, wherein the process of layer treatment via high-power laser beams at the fields is repeated multiple time with necessary time intervals and with simultaneous emission by several sectors mutually shifted at the specified angle to each other, and with divergence of beams in each sector onto the specified angle, thus conducting non-contact and remote control of temperature values and pressures created within layers, as well as sizes and forms of cavities formed within layers and rocks and their linkage, to get the information relating to the composition of evaporating substances within the layers and rocks, to be performed simultaneously, via special optical fibers.
However, the above method has following disadvantages:
it is impossible to implement complex development of fields and to use high-power laser beams not only for the in-situ spaces treatment to increase oil and gas extraction, but also to drill the wells from the surface to uncover oil and gas, shale, coal and other layers with mineral resources;
low efficiency and capacity of treatment of the in-situ spaces in the formation layers via the high-power laser beams and increase of pore pressures and temperatures through perforation holes and slots in metal pipes casing that reinforce the production wells due to small areas of in-situ spaces processed with the beam;
it is impossible to substantially increase the diameters of wells that are reinforced with pipes within the in-situ spaces in order to increase areas of inflows and to improve filtration from oil and gas layers into wells;
increased oil and gas production costs, together with the time consumed to put wells into operation for production, due to the need to involve other expedient methods for bore-holing of wells and cleaning of bottomhole zones of layers from deeply penetrated drilling and cement solutions with formation of impermeable mud cakes in layers, resulting from the wells drilling with the use of the casing pipes.
SUMMARY OF THE INVENTION
The objective of the invention is to achieve the most complete and efficient extraction of all types of oil, including high-viscosity oil and bitumens, shale oil from kerogens, gas condensates and shale gas from oil and gas, shale and other layers, under most common conditions, via high-power laser beams. Use of the method of the present invention results in a substantial profit derived from the most complete extraction of oil and gas out of layers, thus substantially improving ecology in territories having the fields. The proposed method provides the most technologically efficient and ecologically friendly, almost complete extraction of oil and gas reserves on-shore and off-shore, including those considered difficult and non-recoverable, and, most importantly, allows for drilling of wells in oil and gas layers from earth and sea surface without the need for drilling liquids and reinforcement of well walls with casing pipes, and allows for both continuous and major repairs of wells without the traditional reinforcement of wells walls with casing pipes and cementing external casing in formation layers and rock material. The method of the present invention allows for cleaning of production wells and field equipment used therein from asphalt, tar and paraffin deposits using a high-power laser beam. The proposed method, when used for developing shale layers and for extracting shale gas, allows for opening of maximum number of closed cavities containing gas and achieving the highest level of its extraction with optimal decrease of separation distance between long drill-holes with small diameters that are drilled from neighboring production wells towards each other within in-situ spaces with specified movement of axis of the drill-holes under specific conditions for various layers in order to prevent passing over closed cavities filled with shale gas. This method also allows for destruction of subsurface waste disposal sites and mortuaries containing harmful radioactive and chemical substances via evaporating them under the ground, and also provides for melting of various metals from ore bodies, lens and metal veins into subsurface workings. Due to intensive extraction of oil and gas from fields, time needed to develop the field is reduced in order to obtain additional profit and eliminated any ecological issues throughout neighboring territories around the field.
The objectives of the invention are achieved by implementing a method for developing oil and gas fields using high-power laser radiation for more complete oil and gas extraction, comprising the steps of opening up producing formations in predetermined regions of the wellbores by cutting or perforating material of the wellbore casing strings using high-power laser radiation with subsequent evaporation of solid and liquid phases of substances contained in the formations and in the matrix rock through these openings, wherein the optical fiber cables with light energy-emitting working heads on the ends thereof are used as energy transmitting devices, high-power lasers positioned at the surface are coupled to the optical fibers (light-emitting diodes) of the optical fiber cables and regions with a predetermined high temperature and a high pore pressure are generated in the formations in order to increase the degree of extraction of oil and gas, wherein the process of treating the field formations with high-power laser radiation is repeated multiple times with the necessary time intervals therebetween, wherein a plurality of sectors which are mutually offset from one another by a certain angle are irradiated simultaneously, the beams of each sector diverging at a given angle, wherein non-contact and remote control of temperatures, pressures, sizes and shapes of cavities created in the formation layers and their linkage is carried out simultaneously and information about content of evaporated material of the formation layers is being collected, wherein laser equipment is positioned at a predetermined depth in preexisting wells having reinforced walls with casing columns comprising pipes by using pipes with attached pumps or flexible pipes with coiled-tubing units, a plurality openings are drilled in the wellbore walls at predetermined locations via the laser equipment, wherein the plurality of openings comprise elongated drill-holes having a diameter in a range from less than about 20 mm to more than about 40 mm that are formed at high speed by evaporation and high temperature fracture of formation layers and rock material by high-power laser radiation emitted from the light energy-emitting working heads positioned at tips of the drill crowns, wherein the openings are drilled in the neighboring wells towards each other until they cross each other in formation layers and formation rock material, wherein flexible composite drilling rods are repositioned during the drilling process at a predetermined angle of about 0 degrees to at least 180 degrees, wherein a direction of drilling and a repositioning angle of the openings are controlled by a direction of laser radiation beams emitted from the optical fibers, wherein material drilled out of the elongated small-diameter openings is evaporated by the high-power laser radiation, wherein wells are drilled at new formation development fields by mechanical-laser drilling, wherein the optical fiber cables with the light energy-emitting working heads coupled to the high-power lasers positioned at the surface are in internal lumens of mechanic drilling equipment having hollow-type actuating rods and crowns, wherein rock formation material is fractured by the high-power laser radiation emitted from the working heads in order to achieve a desired diameter of the well by treating them with high-temperature laser radiation emitted from the working heads positioned at tips of drill crowns to fracture and evaporate the rock material during the drilling process, wherein secondary laterally positioned working heads are used to simultaneously deposit a reinforcement layer on the well walls by using a high-power laser radiation, wherein the reinforcement layer is made of mixtures of material remaining after evaporation of the material drilled out of the openings and substances and materials prepared at the surface and supplied into the wells, or, in cases of weakened areas or carbonate rocks having cracks and cavities formed therein, the secondary laterally positioned working heads are used to simultaneously deposit one or more reinforcement layers to the well walls, wherein the reinforcement layers are formed from the material drilled out of the openings by extracting it via compressed air from the bottom-holes towards ring deposit welding/burn-off devices equipped with high-power laser radiation emitters, and mixtures of quartz sand with necessary substances and materials supplied to the wells from the surface to be melted on walls of wells to improve their quality and toughness, wherein the material drilled out of the openings is completely evaporated and mixtures with necessary ingredients prepared at the surface are supplied to the wells and are deposited on the well walls via ring deposit welding or burning-off devices equipped with secondary laterally positioned working heads having high-power laser radiation emitters located at specified distance from working heads centrally positioned at the tips of the crowns of the drilling tools, wherein the secondary laterally positioned working heads are moved radially and rotationally separately or together with hollow-type actuating rods, wherein, after the drilling of wells to a desired depth is completed, the well walls are polished by removing the artificially created reinforcement layers of the well walls and creating smooth wall surfaces, and creating consistent diameters along the entire length of the wells, wherein well repairs are carried out by cleaning the well walls, pipes with pumps or other field equipment via tubing pipes and other field equipment from asphalt, tar and paraffin deposits by melting and evaporating them with high-power laser radiation while repeatedly moving multi-sided laser radiation emitters along the pipes or wells in a downward and then upward direction, wherein at fields that were opened by drilling wells in oil and gas and other layers via the laser-mechanical drilling diameters of vertical, angular or horizontal production wells are gradually increased by laser-mechanical drilling equipment having expandable well wideners, wherein the artificial layers made out of mixtures of well material and deposited on the well walls during the drilling process to reinforce the walls are removed to increase areas of oil and gas inflow from the formation layers into the wells, wherein diameters of production wells are repeatedly increased and multiple layers of specified thickness having asphalt, tar and paraffin deposits accumulated therein during the field development are removed from the well walls to improve filtration of oil and gas from the formation layers into the wells, wherein diameters of the wells are increased to maximum sizes possible under particular formation layer conditions and capabilities of the laser-mechanical drilling equipment, wherein within the oil and gas and shale layers, in particular, within layers having low permeability and porosity, after diameters of production wells are increased to their maximum, elongated drill-holes having small diameters are drilled in well walls by the high-power laser radiation equipment, to increase areas of inflow of oil and gas into the wells and to increase extraction from the formation, wherein, during treatment of formations having multiple oil and gas layers, diameters of production wells are gradually increased based on power, outstretch and falling within one or more layers being treated, and elongated drill-holes with small diameters are drilled therein, while neighboring formation layers located above or below the layer being treated and not having drilled wells and drill-holes are under-holed or over-holed to cause shifts of formation rock material between neighboring layers and within layers, to change crack systems within the rock material and to change stressed-deformed state thereof, to form oil and gas cross-flow channels between the formation layers and the drilled production wells in the neighboring layers that are being treated to speed up treatment of all layers within the formation with significantly lower costs and time consumed, wherein, in the presence of high-viscosity oil at the fields, a temperature and a pressure within the layers are increased, and a viscosity of oil is decreased by applying high-power laser radiation to spaces between the layers through production wells and elongated drill-holes having small diameters by inserting a plurality of optical fiber cables therein, wherein the production wells and the elongated drill-holes having small diameters drilled in the well are positioned at a specific distance from each other based at least in part on power, outstretch and falling of the layers, and wherein the number of the production wells and the drill-holes drilled therein is increased and a distance between them is decreased to achieve and maintain a target level of extraction of oil and gas from the formation field.
The method is implemented as follows. At the fields that are being treated and already have wells drilled therein, and have their walls fixed with casing columns of pipes, and, especially, within layers with low permeability, the existing net of vertical, inclined and horizontal wells is optimized by drilling additional production wells at a predetermined distance from each other. High-power laser units are set within some or all of the neighboring production wells at a specified depth via pipes with pumps connected to the laser units via screw type connectors. The lasers are used to drill long drill-holes with small diameters, to be optimized by power, outstretch and falling of the formation layers, via optical fiber and electrical cables connected to high-power lasers and alternating-current sources positioned on the surface, and a plurality of openings of desired dimensions and shapes are cut in the well walls via the lasers based on locations determined by suitable computer software. Then, a plurality of elongated drill holes are drilled from said plurality of openings at high speed via evaporation and high-temperature fracturing of the pipe materials, formation rock material and the layer materials via the high-power laser beams delivered by light energy emitters positioned on tips of drill crowns. The plurality of elongated drill-holes having small diameters are drilled from adjacent production wells towards each other until they cross with each other within space between the formation layers, optimized by power, outstretch and falling of the layers. The fact that axes of the drill-holes diverge from the axis of crossing of the bottom-holes within in-situ spaces in a range from about several dozens centimeters to several meters has no impact on efficiency of treatment of oil and gas layers and other layers with the high-power laser beams and has not impact on inflow of oil and gas into the wells. Length of the drill-holes having small diameters, which is typically in a range from less than about 20 mm to more than about 40 mm, may be increased when the drill-holes are drilled from adjacent wells to a range from less than about 20 m to more than about 200 m, depending on a distance between the wells at the formation field. A plurality of elongated drill-holes with small diameters may also be drilled in a single well separated from other wells, which results in increased extraction of oil and gas from the formation layers. During drilling, flexible composite short drilling rods are turned at a specified angle from about 0 degrees to more than about 180 degrees, and a direction of the drilling of the elongated drill-holes with small diameters is monitored via marked optic fibers (light guides) and via laser beams transmitted through said optic fibers to specify the direction of drilling and angles of their rotation in the formation layers and rock material, as well as to determine components of rock and layer material and temperature and pressure values within in-situ spaces. Data control and analysis are performed via suitable computer devices located at the surface, which are also used for mathematic modeling in 3D format of the processes within the formation layers and for real-time optimization of positioning and arrangement of the wells and elongated drill-holes with small diameters within in-situ spaces, especially with layers having low permeability and porosity, to achieve maximum extraction rate of oil and gas from the formation layers.
The laser units positioned at the surface include one or more control elements, depending on the number of wells at the formation field, provided with sets of flexible composite short drilling rods having drill crowns, laser energy emitters for drilling elongated drill-holes with small diameters, optical fiber and electrical cables, and powerful computers. The control elements may be stationary or movable, may be installed on special all-terrain vehicles, and may be equipped with independent sources of electric power, and/or be capable of being connected to existing electric power lines.
The material drilled out of the elongated drill-holes with small diameters is completely evaporated via the high-power laser beams, thereby significantly increasing the speed of drilling of the drill-holes, and the high-power light energy emitters positioned at the tips of drill crowns are protected from rock particles and from penetration of water, oil and other substances by lenses made with high strength transparent materials, such as, for example, sapphire lenses made of artificial crystals, and the lenses are used to change the focus of the laser beams to increase or reduce their influence based on strength of the rock and layer materials or the mode of influencing them during the drilling. In order to increase inflow of oil and gas from layers into the wells, and to achieve the most efficient extraction thereof from the formation layers, the drilling of the long drill-holes with small diameters, which is optimized by power, outstretch and falling of oil and gas layers, from neighboring vertical, inclined or horizontal production wells is carried out under any geological conditions, and it is always considered to be the one of the most efficient operations of the method proposed to provide an increased inflow of oil and gas. Even when layers with low permeability and porosity are present in the formation, it is always possible to reach a significant increase of oil and gas inflow into the production wells by reducing the distance between the long drill-holes with small diameters, and by increasing their diameters and the number of such drill-holes up to optimal values, which are determined based on practical results of treating such layers and by mathematic modeling via computers in a real-time mode. If the field situation is complicated due to the presence of high-viscosity oil, bitumens or shale oil from kerogens in the layers, a temperature and pressure in the layers may be increased and the viscosity of oil and bitumens may be decreased, and the process of transformation of kerogens into shale oil is facilitated by raising the temperature, and the mining conditions are improved by using high-power laser beams in the in-situ spaces via the wells and the long drill-holes with small diameters by inserting a plurality of optical fiber cables with light emitters into the wells and long drill-holes. The production wells and long drill-holes with small diameters drilled from the wells are located at a specified distance from each other, optimized by power, outstretch and falling of the formation layers. When necessary, high-temperature treating of the layers with high-power laser beams from the wells and drill-holes is repeated multiple times to achieve a desired level of oil and gas extraction from the fields.
When the formation field contains oil with high content of asphalt, tar and paraffin material, the method of the present invention improves consistency and reliability of the production wells in extracting oil and gas from the formation layers during development of the fields. In the upper part of wells, sediments appear all year round and increase under low temperatures on the surface, sometimes causing complete clogging of the pipes. In such cases, especially during the winter season, it is necessary to clean pipes and other field equipment and the well walls from the asphalt, tar and paraffin deposits by melting and evaporating the deposits via high-power laser beams by repeatedly moving the optical fiber cables with light energy emitters up and down the pipes and wells by using a suitable mechanism, such as a lift with a reel suitable for this type of cable. Cleaning procedures, such as cleaning sediments from pipes, wells and other field equipment, are performed when necessary and are frequently carried out together with the drilling of long drill-holes with small diameters or together with increasing the temperature and pressure within layers in order to reduce loss of time for oil and gas extraction therefrom.
The above-mentioned procedures can also be utilized at new undeveloped fields. In such cases, the development procedures will be different from the development procedures used in the previously treated fields because there are new opportunities when production wells are drilled from the surface to the depth oil and gas layers bedding and other layers, and there are more efficient procedures for developing layers, with no need for use of complex drilling solutions for drilling the wells, no need for reinforcement of the well using casing pipes with subsequent cementing of casing annulus. Typically, complex drilling solutions made with special clays and compositions, as well as solutions including cement materials, penetrate deeply into cracks and pores of bottom-hole areas of layers and form impermeable mud cakes, thus completely preventing an inflow of oil and gas into the drilled production wells. In order to restore this inflow and to restore the filtration and permeability of the layers back to their natural state, additional expensive and time-consuming operations have to be carried out to clean near-mine zones of layers from mud cakes and to begin extraction of oil and gas. Such method does not always lead to desired results, and the filtration capacity within those layers remains below the values that occur under natural conditions.
The method according to the present invention avoids the significant disadvantages described above. Wells are drilled at the new undeveloped fields by using laser-mechanical drilling tools, wherein light energy emitters and optical fiber cables that transmit light energy from high-power lasers positioned at the surface are placed within internal openings of the mechanical drilling tools with hollow-type actuating rods and crowns. This equipment is used to completely break down the rock material to create wells with desired diameters by treating the wells with high-temperature high-power laser beams emitted from the ends of drill crowns, which break down and evaporate the rock material during the drilling process. At the same time, the high-power laser beams emitted from lateral or other emitters are used to deposit a layer of mixtures, consisting of premade substances delivered from the surface and portion of material drilled out of the wells, of the well wall in order to reinforce the walls, or, where suitable rock material is present, the inner surfaces of the well wall are melted in order to reinforce them. During drilling of the wells in very dense rock formations, such as basalts, the rock material drilled out of the bottom-holes is fully evaporated by the high-power laser beams, without the need for reinforcement of the well walls. This allows for quick and efficient drilling of wells within dense rock formations at wide range of depths within minimal consumption of time and resources. The use of the laser-mechanical drilling tools in accordance with the present invention allows for drilling of significantly larger number of production wells at any desired depth within shorter time periods, thus significantly improving the well drilling efficiency, as well as significantly reducing distances between the production wells at oil and gas, shale, coal and other production fields, to allow for full treatment of the fields with minimum waste of mineral resources and under a greater variety of conditions. The method of the present invention also allows for drilling of very deep wells drilling towards geothermal energy sources within Earth's crust.
Maximum outgoing power of the laser beams in accordance with the invention can achieve large values, such as dozens of megawatt and more, that is capable of destroying and evaporating any surrounding material. There many types of known lasers that can be used with the invention, as well as any type of lasers that may be developed in the future. The method of the invention may utilize multi-wire cables, suitable for use under extreme underground drilling conditions, that have a plurality of optical fibers (light guides). Such optical fiber cables are very strong and durable, have additional protective covers and steel shield, and light guides that are coated with polymer layers that protects them from mechanical damage. The inner structure of such cables is filled with a gel-like material that protects them against penetration by air and water. Optical fibers are suspended within the gel-like material that has anti-freeze properties and can withstand temperatures below −40° C. Steel cables positioned within the same covering with the optical fiber cables are used as strengthening elements. All light beams reach the ends of the optical fiber cables simultaneously. During drilling of the wells and drill-holes, the reflected laser beams are transmitted through separate optical fibers back to computers positioned at the surface to process information about evaporated mountain rocks and layers, ground waters, temperatures and pressures within layers, oil-and-gas properties and various other parameters and characteristics of the mountain formations. The high-power lasers positioned at the surface are connected to a power line and generate light beams that are transmitted along the light guides of optical fiber cables towards the target sites within the wells without energy losses. Known optical fiber cables have transmission bands with power of dozens of gigahertz, thus allowing transmission of laser beams to a distance of dozens of kilometers. Use of such cables in accordance with the invention allows for increasing a temperature of mountain rocks and layers temperature with high-power laser beams during the drilling of wells and long drill-holes to dozens of thousands of degrees Celsius, up to their plasma phase, and evaporating mountain rocks and layers, and solid and liquid substances and increasing pressure within formation to desired values to achieve most complete and efficient extraction of oil and gas from the fields.
After the drilling of wells to a desired depth, the well walls, covered by a reinforcement layer created mainly from melted artificially created mixture deposited on the walls, are polished by additional melting of wall layers to create smooth surfaces and consistent diameters along the entire length of wells. Whenever necessary, the above-discussed method for creating the wells may be used to carry out continuous and major repairs of the wells. The procedures aimed at maintaining the operation of wells are carried out beyond oil and gas, shale and other layers of mineral resources. At the sites where the production wells were initially drilled through oil and gas layers and the well walls are reinforced with melted layers, the extraction of oil and gas is initiated by cutting off the reinforcement layers created by depositing melted mixtures of drilled out material and artificial substances injected into the wells from the surface or melting the layers of suitable rock material. The reinforcement layers are cut stepwise in order to increase, by power, outstretch and falling, the diameters of the vertical, inclined or horizontal production wells to a desired value via the laser-mechanical drilling tools of the present invention, which include expandable devices for widening the wells that are hollow and accommodate optical fiber cables and emitters of high-power laser energy for high-temperature destruction and evaporation of rock material and layers substances contained therein, thus significantly increasing areas of oil and gas inflow into the wells. Then, during the operation of the production wells, their diameters may be increased repeatedly as necessary by cutting off subsequent layers of desired thickness from the well walls, together with asphalt, tar and paraffin deposits accumulated on the walls and rock particles stuck to them, thus improving filtration of oil and gas into the wells. The well diameters are increased to maximum sizes suitable under particular conditions of layers bedding, taking into account the capacities of the laser-mechanical drilling equipment, the design of which allows moving them within the wells in a closed configuration and gradually opening them to a desired degree to cut multiple layers off the well walls to increase diameters of the production wells. Once the maximum possible diameters of the production wells are achieved, the laser beams are used to drill long drill-holes with small diameters in order to increase inflow of oil and gas into the production wells, resulting from enlarged filtration areas within the formation layers. Areas of oil and gas inflow from the formation layers into the wells are maximized by increasing lengths and diameters of the drill-holes and decreasing the distance between the drill-holes. As a result, it is possible to extract oil and gas reserves from spaces beyond the perimeter of deposits at the fields, which are typically considered to be non-recoverable, and even from non-reservoir rocks and layers with very low permeability and porosity due to cross-flows and vast areas of contact with reservoir-layers with good permeability, due to production wells with big diameters drilled throughout the layers and resulting from maximizing of the diameters by cutting multiple layers off the well walls, especially within inclined and horizontal wells, which is particularly desirable during treatment of rock formation having many layers with varying thickness and complex geological conditions, such as thrust faults, hade faults, breaks in rock layer continuity and other similar issues. This sequence of operations during the development of fields results in significant increase of subsurface management efficiency and leads to the most efficient oil and gas extraction.
When the rock formations contain multiple oil and gas layers, the steps of increasing diameters of the production wells, optimized by power, outstretch and falling of the layers, and drilling of multiple drill-holes with small diameters in a single layer or several adjacent layers within the formation lead to under-holing or over-holing of adjacent closely-spaced layers positioned above or below the ones being treated, which in turn leads to changes in the stress-deformed state of the mountain rock material between the adjacent layers and within layers, movement of rocks and layers, formation of additional cracks systems, and multiple oil and gas cross-flows from the adjacent layers, which do not yet have drilled production wells or long drill-holes with small diameters. This creates cross-flows of oil and gas through the systems of new cracks and channels into the drilled wells in the adjacent layers being developed. This allows for extraction of oil and gas from the adjacent layers in the formation suits without the need of drilling production wells therein. In order to improve the inflow from such adjacent layer located below or above the layers being developed after some time, additional long drill-holes with small diameters may be drilled from the production wells into the adjacent layers to improve the development efficiency of the entire field comprising many layers by utilizing mutual influence of layers while performing under-holing and over-holing procedures, thus allowing treatment of layers with low permeability and porosity.
After such treatment of adjacent layers within the formation suits, a pressure exerted upon the under-holed or over-holed adjacent formation layers by the overlying rock mass is decreased due to the significant displacement of rocks and layers. This leads to increased permeability and increased rate of opening of cracks and pores in layers of oil and gas, shale oil, and coal, together with significant increase in filtration of oil and gas into the production wells, as well as formation of new draining and filtration macro-systems, allowing for extraction of all moving oil and gas from suits of layers, in particular during the final stages of field development when maximum displacement of layers and mountain rock containing them takes place. The method of the present invention allows for significant reduction of time required for treatment of all the layers in suits, thus improving efficiency of oil and gas extraction and significantly reducing expenses, while achieving significant economic benefit from developing the suits that include many oil and gas layers independently of geological conditions regarding their formation and tectonic issues of the layers' bedding arising therewith. According to the experimental results and utilizing computer modeling in 3D format, optimal arrangement of production wells and long drill-holes with small diameters in suites having many oil and gas layers is determined, as well as the order and the sequence of treatment of layers within the shortest period of time with maximum efficiency of oil and gas extraction and minimum expenses.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated in the drawings, wherein FIGS. 1A and 1B , and FIG. 2 illustrate the high-power laser beam system of the present invention and the implementation of the method of the present invention for developing fields and providing for the most complete extraction of oil and gas via high-power laser beam systems.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1A shows the vertical cross-section of the rock mass, which illustrates one exemplary embodiment of the arrangement of inclined-horizontal production wells 1 within oil and gas layer 9 of large thickness with the laser system 3 positioned in the wells at a specified depth via hydraulic pipes 2 coupled to the system via gear mechanism. FIG. 1B illustrates a horizontal cross-sectional view along the line A-A of the well 1 and through the layer 9 . In the embodiment shown in these figures, the high-power laser equipment is used in the field being under treatment for extended period of time and having drilled production wells 1 with casing columns made of metal pipes placed in the well to reinforce well walls. The laser system 3 with flexible composite drilling rods and crowns 4 having emitters of laser energy positioned at their ends is placed in the wells 1 and is connected via optical fiber cables to the high-power laser equipment positioned at the surface and to the alternating-current source via electrical cables, wherein the cables are positioned inside the pipes 2 . Based on predetermined coordinates programmed into the laser system 3 , a plurality of long drill-holes 5 and 6 with small diameters are dilled at high speed due to evaporation and destruction of layer material 9 at high temperatures, wherein the layer 9 is located between clay containing top layer 5 and bottom layer 7 , which are impermeable to oil, gas and underground layer waters and which isolate the layer 9 from the rest of the mountain rock mass. The high-power laser beams used in drilling are emitted from emitters of light energy positioned at distal ends of flexible composite drilling rods with the crowns 4 . The diameters of the long drill-holes 5 and 6 range from less than about 20 mm to more than 40 mm. The drill-holes 5 and 6 are drilled from adjacent production wells 1 towards each other until they intersect within the layer 9 by capacity (drill-holes 6 ) and by outstretch (drill-holes 5 ). During the drilling, the drill-holes may be angled from their axes at the intersection points in the range from about few dozens of centimeters to several meters during their drilling towards each other, and this has no impact on efficiency of oil and gas inflow therefrom into the production wells because the areas of inflow of oil and gas from the layer into the long drill-holes are still in the range of many dozens and hundreds of meters. During the drilling of long drill-holes with small diameters, flexible composite drilling rods having crowns positioned at their ends 4 are rotated to a specified angle from about 0 degrees to about 180 degrees and more, and the direction of the drilling of the long drill-holes in controlled via laser beams transmitted through the dedicated optical fibers within the cables. Wherein a high accuracy of intersection between the long drill-holes is desirable, the drilling is also controlled by gyroscopes, which, together with the laser beams, determine the direction of drilling and the angle of rotation of the long drill-holes within the layer 9 , as well as determine composition of rock material and temperatures, pressures and other characteristics within in-situ space by analyzing the measured data via computer processors positioned at the surface. Lengths of the drill-holes 5 and 6 may vary depending on a distance between the drilled production wells 1 from and may be in the range from less than about 20 meters to more than about 200 meters. Distances between axes of the long drill-holes with small diameters may vary depending on permeability of rock material within the layers, rate of filtration of oil and gas therefrom, and oil viscosity, and may be in the range from less than about 5 meters to more than about 50 meters. The rock dust displaced from the bottom-holes of the long drill-holes 5 and 6 by drilling is completely evaporated via the high-power laser beams, and the light energy emitters are protected from penetration by water, oil and fine rock particles via lenses made with high strength transparent materials, such as, for example, sapphire lenses, made of artificial crystals. The lenses are also used to refocus the high-power laser beams to increase or reduce their influence based on varying strength of the rock and layer material and based on various modes of use, for example, during complete evaporation of rock dust drilled from the wells and drill-holes, or during depositing of melted mixtures of drilled out material and artificial substances injected into the wells from the surface or melting the layers of suitable rock material. It is desirable to drill many closely-spaced long drill-holes with small diameters via the laser units in the production wells drilled in impenetrable oil and gas layers with high-viscosity oil, as well as in shale layers for extraction of shale oil and shale gas. In order to extract shale gas from the shale layers, the drill-holes with small diameters are drilled from the production wells located in the shale layers to maximum lengths possible under particular conditions, with optimal distances between the drill-holes based on sizes of closed cavities containing shale gas within the layers. This way, during the drilling by power, outstretch and falling of the layers, the long drill-holes will be introduced into a maximum number of closed cavities containing shale gas, allowing for inflow of gas from these cavities into the production wells. In the layers containing kerogens, from which shale oil may be extracted under increased temperatures in in-situ spaces, in order to extract shale oil a large number of drill-holes is drilled from the production wells positioned at an optimal distance from each other, and diameters of the drill-holes are increased to maximum values possible under given conditions, while lengths of the drill-holes and distances between the axes of the drill-holes are decreased to obtain maximum efficiency, and a plurality of emitters of high-power light energy are introduced into the drill-holes via the optical fiber cables. After in-situ temperatures are thus increased to 500-550 degrees Celsius, shale oil is formed out of kerogens, and the formed oil flows from the layers into the production well under the influence of simultaneous pressure increase.
Most mountain rocks and layers begin evaporating under the influence of high-power laser beams under the temperature of more than about 750 degrees Celsius, and in some cases, even under lower temperatures, such as, for example, carbonate rocks. As a result, large cracks, channels and cavities are formed in such rocks. Under temperatures of more than about 950 degrees Celsius, all minerals start evaporating with water, carbon-dioxide gas, sulfur dioxide and other gas emissions, and under temperatures of more than about 1450 degrees, silicon oxide mixed with other gas impurities starts evaporating from rocks, and under temperatures of more than about 1750 degrees, methane and ammonia begin evaporating from rocks and layers. With further temperature increase, the majority of rock material will turn into gases.
As illustrated in FIGS. 1A and 1B , the long drill-holes with small diameters 5 drilled along the plane of the layer 9 and the long drill-holes 6 drilled through the thickness of the layer 9 are positioned at optimal distance from each other within in-situ space, and this arrangement allows for the most complete and efficient extraction of oil and gas from the layer 9 , with the predetermined permeability of the layer and recoverable reserves of mineral resources contained within the layer. If certain properties and characteristics of the layer 9 change during the treatment of the layer, the positioning and characteristics of the long drill-holes with small diameters 5 and 6 may also be adjusted by increasing or decreasing the distance between the drill-holes and by changing their lengths and diameters, as well as by increasing in-situ temperature and pressure, to maintain the target level of oil and gas extraction. Because the production wells 1 and the long drill-holes with small diameters 5 and 6 , drilled by power and outstretch of the layer 9 , evenly cover large areas within the layer 9 , it is possible to extract even non-commercial oil and gas reserves that were not taken into account while calculating recoverable reserves as an object for potential extraction, due to cross-flows through the systems of cracks and channels in the areas of intensive extraction.
FIG. 2 illustrates a vertical cross-section of the rock mass with an exemplary embodiment of the laser-mechanical drilling system of the present invention positioned in a vertical production well for drilling of a well and subsequent enlargement of the well diameter by gradual removal or cutting off layers of given thickness along all the thickness of oil and gas layer.
The vertical production well 4 is drilled at the new development site from the surface towards the oil and gas layer 6 via the laser-mechanical drilling system of the invention. The drilling is implemented by using light energy emitters and the optical fiber cable 1 , which includes a plurality of optical fibers (light guides) that transmit light energy without losses from the high-power laser equipment positioned at the surface to the light energy emitters positioned within the wells. The emitters are positioned in internal lumen of the laser-mechanical drilling equipment 3 having hollow actuating rods and positioning devices or fixators 2 that prevent the optical fiber cable 1 from curling. The mountain rock layer 5 is destroyed and evaporated and the gas and oil layer 6 and its bottom 10 is treated with high-power high-temperature laser energy 14 emitted from a central emitter 13 positioned at a distal end of a central drilling crown 11 and from secondary extendible lateral emitters 12 , the central drilling crown 11 and lateral drilling crowns coupled to the expandable well-expanding device 8 are used to completely destroy the rock material to achieve the necessary diameter of the well 4 . A controller 20 is coupled to the central emitter 12 and the at least one lateral emitter 13 , wherein the controller controls at least one characteristic of the laser beam emitted by the emitters 12 and 13 . The characteristics controlled by the controller 20 include laser beam direction, laser beam intensity, laser beam temperature, and laser beam focus. During the drilling of the vertical production well 4 , the well walls are reinforced to prevent them from collapsing by either simultaneously melting the well wall material, if it is suitable for this purpose, via high-power light emission 14 from the lateral emitters 12 , or by depositing one or more layers on the well walls, wherein the layers are made of mixtures of substances prepared at the surface and remaining rock dust drilled from the bottom-hole of the well, or by completely evaporating the rock dust drilled from the bottom-hole of the well via the high-power laser emission 14 and then depositing layers of mixtures prepared at the surface onto the well walls 4 . In certain circumstances, it is necessary to deposit layers made with artificially prepared mixtures of substances on the well walls 4 in order to reinforce them because not all mountain rock material can be melted during the drilling of the well 4 and not under all conditions. For example, carbonate rocks and certain other types of rock material are very difficult or even impossible to melt due to fast destruction and evaporation of mixed-in weak minerals, such as calcite, dolomite, marlstone, chalk-stone and others, that quickly evaporate under high-power light influence and thus, cavities and cracks can be formed within the walls of the well. In such cases, the power of laser emission may be regulated via the controller 20 coupled to the lateral emitters 12 by refocusing of transparent protective lenses 22 and 24 , for example, sapphire lenses made of artificial crystals, that are positioned over the emitters 12 to reduce (by increasing divergence) or increase intensity of light emission based on changes in strength characteristics of the rock and layer material, or based on changes in the mode of operation, such as during depositing of various melted mixtures onto the well wall to reinforce them, or melting of the layers of suitable rock material, or complete evaporation of rock and layer material. In case of formation of water inflows or areas of weakened mountain rocks, for example carbonate rocks, with formation of cavities and cracks after the treatment with high-power laser beams, the well walls are reinforced by depositing a plurality of layers made from melted rock dust drilled out of the bottom-holes of the wells and left over after evaporation, wherein the rock dust is extracted out of the bottom-holes by compressed air and deposited onto circular welding devices 15 equipped with emitters of laser energy. The rock dust is combined with mixtures of quartz sand with other necessary substances, such as, for example, lead oxide, and materials for glasifying these materials within wells and depositing them on the well walls. In other embodiments, the rock dust drilled from the bottom-holes of the wells is completely evaporated and mixtures of substances prepared at the surface are supplied to the wells to be melted and deposited on the well walls for their reinforcement. All of the above mixtures are melted and deposited via the circular welding devices 15 on the well walls or on the melted rock and layer material within the wells with changing diameter and the emitters of high-power light energy located therein with the use of lateral laser energy emitters 12 positioned at a specified distance from the central crown of the laser-mechanical drilling system, with the capability of radial movement and full-circle rotation, either separately or together with the hollow actuating drilling rods.
Whenever needed, the method of the invention may be used to carry out continuous or major repairs of the well 4 by using the expandable well-expanding device 8 with the lateral crowns in order to achieve a desired diameter of the well via the laser-mechanical drilling system. The waste material created after the repairs, together with collapsed rock particles and pieces of destroyed layers deposited on the well walls, get into a bottom of the well 4 , which primarily functions to collect miscellaneous waste material from the well and in some cases, to facilitate advancement of the drilling equipment below the bottom of the layer 6 . After the well 4 is created, its walls are polished to a desired depth by depositing artificially created layers on the walls to create smooth wall surfaces and uniform diameter along the entire well 4 , except the region where a thick oil and gas layer 6 is opened. At this region of the oil and gas layer 6 opened by the vertical production well 4 , the diameter of the well 4 is gradually increased along the thickness of the layer 6 to a specified value via the laser-mechanical drilling system of the invention with the expandable well-expanding device 8 with the lateral crowns. In order to do that, the layers made with mixtures deposited onto the well walls for reinforcement during the drilling are cut off by gradually moving the drilling equipment up and down along the well. During the exploitation of the production well, its diameter is increased repeatedly and multiple subsequent layers 7 of specified thickness are cut off the well walls within the layer 6 by the laser-mechanical equipment of the present invention, together with asphalt, tar and paraffin deposits accumulated on the walls during the exploitation period, thereby improving the infiltration of oil and gas out of the layer into the well and also increasing the inflow area. The well diameter is increased to maximum value suitable under particular conditions for a particular layer type and taking into account capabilities of the laser-mechanical drilling system. At the same time, the area of inflow of oil and gas from the layer 6 to the well 4 is maximized, as well as the amount of oil and gas extracted out of the layer. After a prolonged time period of exploitation of the production well 4 , which leads to inevitable decrease in well's productivity, multiple long drill-holes with small diameters are drilled throughout the entire layer 6 thickness in directions towards other long drill-holes drilled from the adjacent production wells located within the same layer 6 to again improve oil and gas inflow into the well by significantly increasing the inflow area out of the layer, thus resulting in virtually complete extraction of oil and gas out of the layer and thereby reducing the time needed for effective exploitation of the layer.
Currently, the methods used to develop oil and gas and shale fields are not suitable for drilling many long drill-holes with small diameters from the production wells into the layers and rocks to evenly cover large areas within in-situ spaces in order to create conditions suitable for most efficient and complete extraction of oil and gas from the layers. Hydraulic fracturing technologies, which are currently utilized to extract oil and gas from the layers, are only capable of creating a few cracks (a single hydraulic fracturing cycle creates a single crack with an opening of few millimeters) that propagate in directions within the in-situ spaces that cannot be controlled, wherein those hydraulic fracturing cracks are quickly compressed by mountain rock pressure, despite pumping of expansion materials therein, such as quartz sand, small rocks, and other substances, which leads to significant reduction or elimination of oil and gas inflow out of the layers. This is especially true in cases wherein layer waters break into the production wells due to unexpected and occasional cracks forming through the water-bearing layers. For shale layers, large amounts of chemical components are typically added to liquids pumped into the wells during repeated hydraulic fracturing of the layers to improve efficiency thereof, and those substances and agents cause pollution of the environment around the formation layers. These known technologies cannot guarantee good efficiency and a high degree of oil and gas extraction from the production fields, and at the same time, cause significant harm to the environment.
The system and method of the present invention is ecologically clean compared to the known technologies that pollute and poison territories surrounding the field with agents and substances used during the oil and gas production process, as well as with miscellaneous production wastes and mud spills out of outdated wells that had not been worked out fully, as well as remaining oil and gas being vented into the atmosphere, such as methane that contributes into the greenhouse effect. The method of the present invention also allows for full and highly efficient extraction of oil and gas out of the production fields to gain valuable profit when implemented both at new undeveloped fields and fields that have been in operation for a long time. The method of the invention further allows for efficient elimination of underground disposals of harmful radioactive and chemical substances via evaporation of these substances underground via high-power laser beams. This method also allows for melting into the underground workings out of the ore bodies, lenses and veins, various metals contained therein, such as iron, copper, nickel, aluminum, silver, gold, platinum, and others. | A method of developing oil and gas fields includes creating a well by mechanically displacing rock material via a drilling device, increasing a well diameter by impacting the rock material via laser beams emitted from a central emitter, and reinforcing inner walls of the well by impacting wall material via laser beams emitted from a lateral emitter. A system includes a drilling device with a hollow lumen and a central drilling head, at least one fiber optic cable positioned within the lumen, a laser source coupled to a proximal end of the cable, a central emitter positioned inside the central drilling head and coupled to a distal end of the cable, at least one lateral emitter positioned on a side wall of the drilling device and coupled to the cable, and a controller coupled to the central and lateral emitters for controlling at least one laser beam characteristic. | 4 |
[0001] This invention was supported in part by funds from the U.S. government (NIEHS #ES06897) and the U.S. government may therefore have certain rights in the invention.
FIELD OF THE INVENTION
[0002] The present invention relates to a new class of fused-ring triazoles and methods for synthesis of these compounds. The present invention also relates to compositions comprising these fused-ring triazoles and methods for use of these compositions as anti-proliferative agents, anti-estrogenic agents, anti-microbial agents and/or anti-viral agents. These fused-ring triazoles have been found to be intensely fluorescent when excited at selected wavelengths. The fluorescent properties of these compounds are useful in tracking these compounds, for example in pharmacokinetic studies of these therapeutic agents. Their fluorescent properties also make them useful as fluorescent probes.
BACKGROUND OF THE INVENTION
[0003] The 1,2,4-triazole moiety is an important and versatile pharmacophore often found as a structural unit in diverse pharmaceutical classes. Antifungal imidazoles and indeed almost any important pharmaceutical, in which a five-membered nitrogen heterocyclic residue is incorporated, can be synthesized with a 1,2,4-triazole as a surrogate for that imidazole with retention of the model compound's original pharmacologic activity (Angibaud et al. Bioorg. Med. Chem. Lett. 2003 13:4361-4364). Biological pathways requiring histidine can be manipulated into accepting and incorporating the triazole analogue into the resulting protein (Ikeda et al. Protein Eng. 2003 16:699-706). Furthermore, the 1,2,4-triazole has been observed as a bioisostere for a phenyl ring in the PPARα agonists being explored as lipid-lowering drugs (Xu et al. J. Med. Chem. 2003 46:5121-5124).
[0004] A functionalized 1,2,4-triazole attached to a benzonitrile moiety is in clinical trials for breast cancer and is showing significant activity (Tominaga, T. and Suzuki, T. Anticancer Res. 2003 4:3533-3542). 1,2,4-Triazoles with alkylamino side chains were inhibitory against a host of malignant cell lines (Demirbas et al. Bioorg. Med. Chem. 2002 10:3717-3723). Dimers of 1,2,4-triazol-5-thiols were active against seven cancer types (Holla et al. Eur. J. Med. Chem. 2002 37:511-517). Both antitumor and anti-HIV activity were observed in triazoles fused to benzene sulfonamides (Pomarnacka E, Kozlarska-Kedra I, Farmaco 2003 58:423-429).
[0005] Fused ring systems in which the 1,2,4-triazole nucleus is the core of a larger heterocyclic pharmaceutical are showing considerable therapeutic promise. Catarzi reported that a triazole-quinoxaline class was potentially useful in neuroprotection (treatment and prevention of acute and chronic neurological disorders) (Catarzi et al. J. Med. Chem. 2004 47:262-272). Tourirte found modest inhibition of the replication of HIV by triazole-pyrimidines (Tourirte et al. Nucleosides Nucleotide Nucleic Acids. 2003 22:1985-1993).
[0006] Thus, the triazole nucleus is used widely in drug design and development.
SUMMARY OF THE INVENTION
[0007] A unique family of fused ring triazoles referred to herein as 3-R-7-(phenylmethylene)-s-triazolo[3,4-b][1,3,4]-thiadiazines has now been synthesized. This new class of fluorescent fused triazoles is useful as fluorescent probes and in the treatment of proliferative disorders and as anti-estrogenic, antimicrobial and antiviral agents.
[0008] Accordingly, an object of the present invention is to provide a compound of Formula II:
wherein R is selected from the group consisting of a furyl group, a thienyl group, a pyridyl group, an alkyl group, and an aryl or arylalkyl group. Preferably R is an aryl or arylalkyl group selected from the group consisting of 1-(2-phenyl)-ethyl, 3-methoxyphenyl, 4-trifluoromethylphenyl and 4-fluorophenyl, or a pyridyl group selected from the group consisting of 2-pyridyl, 3-pyridyl, and 4-pyridyl.
[0009] Another object of the present invention is to provide methods for synthesizing a compound of Formula II.
[0010] In one embodiment, the method of synthesis comprises a single step wherein α-bromocinnamaldehyde is added to a solution comprising a mercaptoaminotriazole and a tertiary amine, and a compound of Formula II precipitates therefrom.
[0011] In another embodiment, the method of synthesis comprises a two-step process wherein a bromocinnamyl imine is derived from the condensation of a mercaptoaminotriazole with an aldehyde, preferably α-bromocinnamaldehyde. The bromocinnamyl imine is then converted to a compound of Formula II by treatment at reflux with a tertiary amine.
[0012] Another object of the present invention is to provide a method for inhibiting cell proliferation which comprises administering to the cell a compound of Formula II.
[0013] Another object of the present invention is to provide a pharmaceutical composition comprising a compound of Formula II and a pharmaceutically acceptable vehicle.
[0014] Another object of the present invention is to provide a method for treating a proliferative disorder which comprises administering to a subject suffering from a proliferative disorder a pharmaceutical composition comprising a compound of Formula II and a pharmaceutically acceptable vehicle.
[0015] Another object of the present invention is to provide a method for inhibiting estrogen-mediated growth of cancer cells such as estrogen-dependent breast cancer cells which comprises administering to a subject suffering and estrogen-mediated cancer a pharmaceutical composition comprising a compound of Formula II and a pharmaceutically acceptable vehicle.
[0016] Another object of the present invention is to provide a method for treating a viral or microbial infection in a subject which comprises administering to a subject suffering from a microbial or viral infection a pharmaceutical composition comprising a compound of Formula II and a pharmaceutically acceptable vehicle.
[0017] Another object of the present invention is to provide a disinfectant or antiseptic agent comprising a compound of Formula II.
[0018] Another object of the present invention is to provide a fluorescent probe comprising a probe molecule fluorescently labeled with a compound of Formula II.
[0019] Yet another object of the present invention is to provide a method for fluorescently tagging a molecule of interest such as a selected protein or nucleic acid sequence using a fluorescent probe comprising a compound of Formula II.
DETAILED DESCRIPTION OF THE INVENTION
[0020] The present invention provides a novel class of fused ring triazole compounds represented by the following Formula II:
wherein R is selected from the group consisting of a furyl group, a thienyl group, a pyridyl group, an alkyl group, and an aryl or arylalkyl group. Preferably R is an aryl or arylalkyl group selected from the group consisting of 1-(2-phenyl)-ethyl, 3-methoxyphenyl, 4-trifluoromethylphenyl and 4-fluorophenyl, or a pyridyl group selected from the group consisting of 2-pyridyl, 3-pyridyl, and 4-pyridyl. This class of fused ring triazole compounds of the present invention is also referred to herein as 3-R-7-(phenylmethylene)-s-triazolo[3,4-b][1,3,4]-thiadiazines.
[0021] Also provided in the present invention are methods for synthesizing 3-R-7-(phenylmethylene)-s-triazolo [3,4-b][1,3,4]-thiadiazines of Formula II.
[0022] In one embodiment, these compounds are synthesized by a single-step process for preparation. The general scheme for this one-step preparation of a 3-R-7-(phenylmethylene)-s-triazolo[3,4-b][1,3,4]-thiadiazine is depicted in Scheme I:
[0023] As shown in Scheme I, in this one-step synthesis, a solution of a mercaptoaminotriazole of Formula I, wherein R is selected from the group consisting of 2-pyridyl, 3-pyridyl, and 4-pyridyl, is prepared by refluxing with a tertiary amine such as triethylamine or pyridine in a solvent such as anhydrous ethanol or dioxane. An aldehyde, preferably an α-halocinnamaldehyde such as iodo-, bromo- or chloro-cinnamaldehyde, is then added to the solution and the resulting mixture is refluxed for several hours until a precipitate of the 3-R-7-(phenylmethylene)-s-triazolo[3,4-b][1,3,4]-thiadiazine forms.
[0024] This one-step synthetic method is particularly useful for synthesis of compounds of the present invention wherein R contains a basic moiety such as the nitrogen of a pyridyl or quinolinyl functionality. Yields ranging from about 50 to about 75% are generally achieved using this method. This one step-synthesis can also be applied to any mercaptoaminotriazole of Formula I wherein R is selected from the group consisting of a furyl group, a thienyl group, an alkyl group, or an aryl or arylalkyl group such as 1-(2-phenyl)-ethyl, 3-methoxyphenyl, 4-trifluoromethylphenyl or 4-fluorophenyl as long as an equivalent amount of a tertiary amine, such as triethylamine, is also used.
[0025] In another embodiment, compounds of the present invention are synthesized by a two-step process. The general scheme for this two-step preparation of a 3-R-7-(phenylmethylene)-s-triazolo[3,4-b][1,3,4]-thiadiazine is depicted in Scheme II:
In step I, a bromocinnamyl imine is derived from the condensation of a mercaptoaminotriazole of Formula I with an aldehyde, preferably α-bromocinnamaldehyde, in accordance with procedures for preparation of 4-amino-3-mercapto-1,2,4-triazoles as set forth in WO 00/10564, which is herein incorporated by reference in its entirety. The resulting intermediate of bromocinnamyl imine (depicted in Formula III) has been isolated and characterized in >60% yields. These imines can be converted (step II) by treatment at reflux with an equivalent amount of a tertiary amine such as triethylamine or pyridine, in a solvent, preferably ethanol, to a 3-R-7-(phenylmethylene)-s-triazolo[3,4-b][1,3,4]-thiadiazine of Formula II with completion of the reaction defined by the time at which no detectable residue of Formula III, as determined by thin layer chromatography, remains.
[0026] Exemplary triazole compounds of the present invention synthesized in accordance with the one-step and/or two-step processes described herein include, but are in no way limited to,
[0027] Compound IIa, viz., 3-(4-pyridyl)-7-(phenylmethylene)-s-triazolo[3,4-b][1,3,4]-thiadiazine, wherein R is 4-pyridyl
[0028] Compound IIb, viz., 3-(2-pyridyl)-7-(phenylmethylene)-s-triazolo[3,4-b][1,3,4]-thiadiazine, wherein R is 2-pyridyl,
[0029] Compound IIc, viz., 3-(3-pyridyl)-7-(phenylmethylene)-s-triazolo[3,4-b][1,3,4]-thiadiazine, wherein R is 3-pyridyl,
[0030] Compound IId, viz., 3-(2-thienyl)-7-(phenylmethylene)-s-triazolo[3,4-b][1,3,4]-thiadiazine, wherein R is 2-thienyl,
[0031] Compound IIe, viz., 3-(2-furyl)-7-(phenylmethylene)-s-triazolo[3,4-b][1,3,4]-thiadiazine, wherein R is 2-furyl,
[0032] Compound IIf, viz., 3-(2-phenylethyl)-7-(phenylmethylene)-s-triazolo[3,4b][1,3,4]-thiadiazine, wherein R is 1-(2-phenyl)ethyl,
[0033] Compound IIg, viz., 3-(3-methoxyphenyl)-7-(phenylmethylene)-s-triazolo[3,4b][1,3,4]-thiadiazine, wherein R is 3-methoxyphenyl,
[0034] Compound IIh, viz., 3-(4-trifluoromethylphenyl)-7-(phenylmethylene)-s-triazolo[3,4b][1,3,4]-thiadiazine, wherein R is 4-trifluoromethylphenyl, and
[0035] Compound IIi, viz., 3-(4-fluoromethylphenyl)-7-(phenylmethylene)-s-triazolo[3,4b][1,3,4]-thiadiazine, wherein R is 4-fluorophenyl.
[0036] The antiproliferative activity of compounds of the present invention was demonstrated in PAM 212 tumor cells. Experiments were performed in accordance with the procedure described by Yurkow and Laskin (Cancer Chemother. Pharmacol. 1991 27:315-319). In these experiments, tumor cells were maintained in culture in growth medium consisting of Dulbecco's modified Eagle's medium (DMEM) supplemented with 10% fetal bovine. Tumor cells were plated at low density (5000 cells/well) in 6-well tissue culture dishes and allowed to adhere overnight. The medium was then replaced with phenol red-free DMEM supplemented with increasing concentrations of the compounds, with zero concentration of compound serving as the control. Six concentrations and a control were used for each inhibitor, and each concentration was tested in triplicate. After 5 days, cells were removed from the dishes and enumerated using a Coulter Counter (Coulter Electronics, Inc.). The controls and treated samples at each concentration were averaged. Data are presented as the percentage of control growth at each concentration of the compound, plus and minus the standard error. The IC 50 for growth inhibition was the concentration of each compound that inhibited growth by 50%. These are depicted in Table 1.
TABLE 1 Ability of Fused-Ring Triazoles to Inhibit Growth of Tumor Cells IC50 of fused ring triazole Cells type IIa IIb IId mouse PAM 212 keratinocytes 10 μM 18 μM 18 μM mouse B16 melanoma 9 μM 15 μM 23 μM human CX-1 colon cells 17 μM 30 μM 20 μM human HeLa cervical carcinoma 4 μM 9 μM 28 μM IC50 = Concentration of each compound inhibiting growth of cell line by 50%.
[0037] Accordingly, the compounds of the present invention are useful as anti-proliferative agents, particularly in the inhibition of tumor cell growth.
[0038] Further, triazole compounds are commonly used as anti-estrogens for example, to suppress estrogen mediated cancers such as estrogen-dependent breast cancer development in humans.
[0039] Thus, it is expected that pharmaceutical compositions comprising a compound of the present invention will be useful in the treatment of cancer as well as other proliferative disorders or diseases including but not limited to, macular degeneration, psoriasis, arteriosclerosis and restenosis and as anti-estrogenic agents.
[0040] Further, the inhibitory properties of these agents are expected to be useful against bacterial and viral infections as well, thus making these compounds also useful as anti-microbial and/or antiviral agents.
[0041] Compounds of the present invention are expected to be useful as antiproliferative, anti-estrogenic, antiviral and/or antimicrobial agents in all animals, including but not limited to, humans, dogs, cats, birds, horses, cows, sheep, swine (pigs and hogs), and other farm animals, as well as rodents and other animals seen in zoos. Thus, while the activities of these new compounds are believed to be particularly useful for inhibiting tumor growth and infectious diseases in humans, use of these compounds for veterinary purposes is also clearly within the scope of the instant invention.
[0042] Therefore, another aspect of the present invention relates to pharmaceutical compositions comprising a compound of Formula II. Pharmaceutical compositions of the invention may further include excipients, stabilizers, emulsifiers, therapeutic adjuvants, diluents and the like, referred to herein in general as pharmaceutically acceptable vehicles. Sustained-released and time-release formulations are also encompassed within the present invention.
[0043] Suitable solid or liquid formulations for use in the present invention are, for example, granules, powders, coated tablets, microcapsules, suppositories, syrups, elixirs, suspensions, emulsions, drops or injectable solutions. Commonly used additives in protracted release preparations are excipients, disintegrates, binders, coating agents, swelling agents, glidants or lubricants, flavors, sweeteners or solubilizers. More specifically, frequently used additives are, for example, magnesium stearate, magnesium carbonate, titanium dioxide, lactose, mannitol and other sugars, talc, lactalbumin, gelatin, starch, cellulose and its derivatives, animal and vegetable oils, polyethylene glycols and solvents. Common solvents include sterile water and monohydric or polyhydric alcohols such as glycerol. Acceptable carriers, agents, excipients, stabilizers, diluents and the like for therapeutic use are well known in the pharmaceutical field, and are described, for example, in Remington's Pharmaceutical Sciences, Mack Publishing Co., ed. A. R. Gennaro (1985). If appropriate, the compound may be administered in the form of a physiologically acceptable salt, for example, an acid-addition salt. The pharmaceutical compositions are preferably produced and administered in dosage units, each unit containing as an active component an effective dose of at least one compound of the present invention and/or at least one of its physiologically acceptable salts. The effective dose to treat diseases such as those discussed above typically ranges from about 1 to about 100 mg/kg of body weight per day.
[0044] The pharmaceutical compositions according to the invention are suitable for use as anti-proliferative, antimicrobial and/or antiviral agents in a subject, particularly a human patient or subject, and comprise an effective amount of a fused triazole compound according to the present invention and a pharmaceutically acceptable vehicle, carrier or diluent.
[0045] Such compositions may be administered by various routes selected in accordance with the condition to be treated. Exemplary routes of administration include, but are not limited, intravenously, orally, intramuscularly, parenterally, topically, bucally, via inhalation, and rectally.
[0046] For intravenous infusion or intravenous bolus injection, or parenteral or intramuscular injection, the active ingredient is dissolved in a pharmaceutically acceptable vehicle such as saline or phosphate buffered saline.
[0047] For oral treatment, administration of the active ingredient may be, for example, in the form of tablets, capsules, powders, syrups, or solutions. For tablet preparation, the usual tablet adjuvants such as cornstarch, potato starch, talcum, magnesium stearate, gelatin, lactose, gums, or the like may be employed, but any other pharmaceutical tableting adjuvants may also be used, provided only that they are compatible with the active ingredient. In general, an oral dosage regimen will include about 5 mg to about 50 mg, preferably from about 5 to about 10 mg, per kg of body weight. Such administration and selection of dosage and unit dosage will of course have to be determined according to established medical principles and under the supervision of the physician in charge of the therapy involved.
[0048] For topical applications, solutions or ointments may be prepared and employed. These may be formulated with any one of a number of pharmaceutically acceptable carriers, as is well known in the art. Topical formulations comprise an effective amount of the active ingredient per unit area. Preferably, the topical formulation is in the form of a one percent solution, suspension or ointment and is applied on the skin at about 0.1 mL per square centimeter. The formulations may contain a suitable carrier such as ethanol or any of the pharmaceutically acceptable carriers described supra.
[0049] The antiviral and/or antimicrobial activities of these compounds also render them useful as disinfectants or aseptic agents. The triazole compounds of the present invention, as disinfectants or antiseptic agents, are suitable for various uses including, but not limited to, water purifying agents, sanitizers and bactericides for use, for example, in room temperature methods for sterilizing a surface medical instruments or devices. Further, these compounds can be used to sterilize biological and medical fluids including, but not limited to blood, cerebrospinal fluid, and fluid replacements. The compounds can also be used to sterilize tissues, prosthetic implants or chemical compositions prior to administration, implantations or insertion during various medical procedures. For example, in one nonlimiting embodiment, the compound can be used to sterilize oral tissues prior to invasive dental procedures. In an alternative nonlimiting embodiment, the compound can be used to sterilize a chemical composition prior to administration into, for example, the vaginal canal to prevent the transmission of sexually transmitted diseases. Disinfectants or antiseptic agents of the present invention comprise a solution or suspension of a compound of Formula II. Other components of the solution or suspension may include those ingredients routinely incorporated into disinfectants and/or antiseptic agents and well known to those skilled in the art. Examples of additional components which can be included in the disinfectants or antiseptic agents include, but are in no way limited to alcohols, oxidizing agents such as hydrogen or benzoyl peroxide, halogens such as chlorides or iodides, heavy metals and quaternary ammonium compounds.
[0050] The triazole compounds of the present invention also exhibit a unique and intense fluorescent spectrum. Characteristics of their fluorescence spectra are shown in Table 2.
TABLE 2 Characteristics of Fluorescence Spectra of Representative Fused Ring Triazoles Compound Excitation peaks Emission peak IIa 224 nm, 286 nm 358 nm IIb 249 nm 320 nm
Excitation and emission spectra of a 10 micromolar solution of compounds IIa and IIb were determined using a Perkin-Elmer LS-5B Luminescence Spectrometer.
[0051] The fluorescent properties of these compounds are useful in tracking these compounds, for example in pharmacokinetic studies of these therapeutic agents. Their fluorescent properties also make them useful as fluorescent probes.
[0052] Accordingly, another aspect of the present invention relates to fluorescent probes comprising a compound of Formula II. Fluorescent probes are used extensively in cell and molecular biology and in clinical diagnosis to detect specific proteins and/or nucleic acid sequences such as DNA and RNA.
[0053] In one embodiment of the present invention, a fluorescent probe comprising a compound of Formula II is used to detect minute quantities of a selected protein or proteins or a nucleic acid sequence or sequences such as DNA and RNA in biological samples by covalently modifying the molecule of interest with the intensely fluorescent compound. Alternatively, a compound of Formula II can be attached or linked to a second agent, which directs binding of the probe to a selected molecule. Examples of second agents include, but are in no limited to, antibodies or other binding agent such as avidin, which can be used to detect selected molecules such as antigens. An additional example of a second agent is an agent that binds DNA, RNA or protein, for example, a dye that intercalates DNA and directs the fluorescent probe to a selected molecule such as a DNA, RNA or protein.
[0054] Fluorescence techniques are used increasingly in a variety of clinical assays.
[0055] For example, fluorescence techniques are used routinely in microscopy, whole animal imaging, fluorescence microplate readers and in flow cytometry in the detection of different types of cells of a tumor or in blood. The Fluorescence Activated Cell Sorter (FACS) was invented in the late 1960s by Bonner, Sweet, Hulett, Herzenberg, and others to do flow cytometry and cell sorting of viable cells and commercial machines were introduced by Becton Dickinson in the early 1970s. (Ehrenberg et al. Clin Chem. 2002 October;48(10):1819-27). Over the years, the number of measured FACS dimensions or parameters, as well as the speed of sorting, has been increased to where 12 fluorescent colors plus 2 scatter parameters can now be measured simultaneously. Flow cytometry via FACS thus has great utility as it allows for simultaneous staining and analysis, followed by sorting of cells from small samples of human blood cells. Analysis and sorting of multiple subpopulations of, for example, lymphocytes, by use of 8 to 12 colors can be performed. Alternatively, FACS and flow cytometry can be used in single cell sorting, for example, to clone and analyze hybridomas.
[0056] Fluorescence techniques are also used for chromosome analysis and/or molecular cytogenetics. The last 20 years have witnessed an astounding evolution of cytogenetic approaches to, for example cancer diagnosis and prognostication. Molecular techniques and, in particular, nonisotopically-labeled nucleic acid probes and fluorescence in situ hybridization (FISH)-based techniques have replaced the costly and potentially dangerous radioactive techniques used in research and the clinical detection of genetic alterations in tumor cells (Weier et al. Expert Rev Mol Diagn. 2002 March;2(2):109-19). Fluorescent DNA probes also enable the screening for very subtle chromosomal changes. Clinical laboratories now select from a growing number of FISH-based cytogenetic tests to support physician's diagnoses of the causes and the course of a disease. Depending on the specimen, state-of-the-art FISH techniques allow the localization and scoring of 10-24 different targets and overcome previous problems associated with target colocalization and detection system bandwidth. FISH-based analyses have been applied very successfully to the analysis of single cells and have demonstrated the existence of cell clones of different chromosomal make-up within human tumors. This information provides disease-specific information to the attending physician and should enable the design of patient-specific protocols for disease intervention.
[0057] Fluorescence techniques are also used in immunohistochemistry and western blotting for diagnosis, and in antigen and enzyme assays such as, for example, ELISA and other diagnostic immunoassays.
[0058] The unique fluorescent spectrum of the compounds, as exemplified in FIGS. 1 and 2, makes them useful alone in any of the above-described techniques or in combination with other fluorescent compounds allowing for multicolor analysis in any of the above-described techniques.
[0059] The following nonlimiting examples are provided to further illustrate the present invention.
EXAMPLES
Example 1
Preparation of Starting Materials
[0060] The mercaptoaminotriazoles (Formula I) employed herein were prepared as described in Reid and Heindel (Journal of Heterocyclic Chemistry 1976 13:925-926). Specifically, 4-amino-3-(2-pyridyl)-5-mercapto[4H]-1,2,4-triazole (Formula I wherein R is 2-pyridyl; mp 190-191° C.) and 4-amino-3-(3-pyridyl)-5-mercapto[4H]-1,2,4-triazole (Formula I wherein R is 3-pyridyl; mp=192-193° C.) were prepared and characterized in accordance with the procedure of Reid and Heindel (Journal of Heterocyclic Chemistry 1976 13:925-926). Melting points were obtained in capillaries in a MelTemp apparatus and are reported uncorrected. NMR analyses were performed in the solvents indicated on a Bruker 360 MHz NMR spectrometer. All solvents and reagents employed were of the highest commercially available purities.
Example 2
One-Step Synthesis of Compound IIa
[0061] To prepare Compound IIa by one-step preparation, 102 mg (0.53 mmol) of 4-amino-3-(4-pyridyl)-5-mercapto[4H]-1,2,4triazole were refluxed with 740 μL (0.53 mmol) of triethylamine in 25 mL of anhydrous ethanol until complete dissolution. To this solution was added α-bromocinnamaldehyde (197 mg, 0.93 mmol) and the mixture was refluxed for 5 hours. Over time the product precipitated out of solution and, after cooling down the reaction to room temperature, it was isolated by filtration and washed with ethanol. Yellow crystals were obtained after recrystallization from ethanol/DMSO. 92 mg, 57%, mp=245-246° C. Anal. Calcd. for C 16 H 11 N 5 S: C, 62.93%; H, 3.63%; N, 22.93%. Found: C, 62.86%; H, 3.42%; N, 22.86%. 1 H NMR (d 6 -DMSO) δ: 7.47-7.63 (m, 6H, Ph and H γ ); 7.99 (dd, J=1.5 Hz, J′=4.5 Hz, 2H, H b ); 8.23 (s, 1H, H α ); 8.77 (dd, J=1.5 Hz, J′=4.5 Hz, 2H, H a ).
Example 3
One-Step Synthesis of Compound IIb
[0062] To prepare Compound IIb by one-step preparation, 105 mg (0.54 mmol) of 4-amino-3-(2-pyridyl)-5-mercapto[4H]-1,2,4-triazole were refluxed with 760 μL (0.54 mmol) of triethylamine in 25 mL of anhydrous ethanol until complete dissolution. To this solution was added α-bromocinnamaldehyde (202 mg, 0.96 mmol) and the mixture was refluxed for 5 hours. Over time the product precipitated out of solution and, after cooling down the reaction to room temperature, it was isolated by filtration and washed with ethanol. Yellow crystals were obtained after recrystallization from ethanol/DMSO. 91 mg, 55%, mp=205-207° C. Anal. Calcd. for C 16 H 11 N 5 S: C, 62.93%; H, 3.63%; N, 22.93%. Found: C, 62.43%; H, 3.32%; N, 22.71%. 1 H NMR (d 6 -DMSO) δ: 7.47-7.64 (m, 7H, Ph, H c , H γ ); 7.93-7.96 (m, 1H, H d ); 7.99-8.04 (m, 1H, H b ); 8.17 (s, 1H, H α ); 8.76-8.78 (m, 1H, H a ).
Example 4
One-Step Synthesis of Compound IIc
[0063] To prepare Compound IIc by one-step preparation, 110 mg (0.57 mmol) of 4-amino-3-(3-pyridyl)-5-mercapto[4H]-1,2,4triazole were refluxed with 800 μL (0.57 mmol) of triethylamine in 25 mL of anhydrous ethanol until complete dissolution. To this solution was added α-bromocinnamaldehyde (212 mg, 1.00 mmol) and the mixture was refluxed for 5 hours. Overtime the product precipitated out of solution and, after cooling down the reaction to room temperature, it was isolated by filtration and washed with ethanol. Yellow crystals were obtained after recrystallization from ethanol/DMSO. 104 mg, 60%, mp=228-229° C. Anal. Calcd. for C 16 H 11 N 5 S+0.8H 2 O: C, 60.10%; H, 3.97%; N, 21.90%. Found: C, 60.01%; H, 3.61%; N, 21.40%. 1 H NMR (d 6 -DMSO) δ: 7.48-7.64 (m, 7H, Ph, H d , H γ ); 8.20 (s, 1H, H α ); 8.31-8.36 (m, 1H, H c ); 8.72-8.75 (m, 1H, H b ); 9.12 (s, 1H, H a ).
Example 5
Two-Step Synthesis of Compound IId
[0064] To prepare Compound IId by a two-step synthetic process one must first prepare (step I) the imine from the condensation of the mercaptoaminotriazole of Formula I [in this case the 5-(2-thienyl)-analog] and α-bromocinnamaldehyde. The methodology is set forth in WO 00/10564 which is herein incorporated by reference in its entirety. Thereafter, (step II), 100 mg (0.26 mmol) of this 4-imino-α-bromocinnamyl)-3-mercapto-5-(2-thienyl)-4H-1,2,4-triazole were refluxed with 83 μL (1.02 mmol) of pyridine in 35 mL of anhydrous ethanol until no more of the starting triazole could be detected by thin layer chromatography (hexanes 70%/ethyl acetate 30%). The reaction mixture was evaporated to dryness and the residue obtained purified by flash silica gel column chromatography (hexanes 70%/ethyl acetate 30%) leading to the isolation of a yellow solid as the final product. 32 mg, 40%, mp=180-183° C. Anal. Calcd. for C 15 H 10 N 4 S 2 +0.2H 2 O: C, 57.38%; H, 3.34%; N, 17.84%.
[0065] Found: C, 57.66%; H, 3.35%; N, 17.20%. 1 H NMR (d 4 -MeOH) δ: 7.22 (dd, J=3.7 Hz, J′=5.0 Hz, 1H, H b ); 7.38-7.64 (m, 6H, Ph and H γ ); 7.70 (dd, J=1.2 Hz, J′=5.0 Hz, 1H, H c ); 8.01 (dd, J=1.2 Hz, J′=3.7 Hz, 2H, H a ); 8.04 (s, 1H, H α ).
Example 6
One-Step Synthesis of Compound IId
[0066] To prepare compound IId by a one-step synthetic process, 117 mg (0.59 mmol) of 4-amino-3-(2-thienyl)-5-mercapto[4H]-1,2,4-triazole were refluxed with 83 μL (0.59 mmol) of triethylamine in 10 mL of anhydrous ethanol. To this solution was added α-bromocinnamaldehyde (218 mg, 1.03 mmol) and the mixture was refluxed until no more of the starting triazole could be detected by thin layer chromatography (hexanes 70%/ethyl acetate 30%). Over time the product precipitated out of solution and, after cooling down the reaction to room temperature, it was isolated by filtration and washed with ethanol. Yellow crystals were obtained, 129 mg (70%). Same physical characteristics as IId isolated through the two-step process.
Example 7
One-Step Synthesis of Compound IIe
[0067] To prepare compound IIe by a one-step synthetic process, 100 mg (0.55 mmol) of 4-amino-3-(2-furyl)-5-mercapto[4H]-1,2,4-triazole were refluxed with 76 μL (0.55 mmol) of triethylamine in 10 mL of anhydrous ethanol. To this solution was added α-bromocinnamaldehyde (203 mg, 0.96 mmol) and the mixture was reluxed until no more of the starting triazole could be detected by thin layer chromatography (hexanes 70%/ethyl acetate 30%). Over time the product precipitated out of solution and, after cooling down the reaction to room temperature, it was isolated by filtration and washed with ethanol. Yellow crystals were obtained, 125 mg (77%). 1 H NMR (d 6 -DMSO) δ: 6.74 (dd, J=3.5 Hz, J′=2.0 Hz, 1H, H b ); 7.23 (dd, J=1.0 Hz, J′=3.5 Hz, 1H, H c ); 7.46-7.62 (m, 6H, Ph and H γ ); 7.98 (dd, J=1.0 Hz, J′=2.0 Hz, 2H, H a ) 8.20 (d, J=0.5 Hz, 1H, H α ).
Example 8
One-Step Synthesis of Compound IIf
[0068] To prepare compound IIf by a one-step synthetic process, 103 mg (0.47 mmol) of 4-amino-3-{1-(2-phenyl)-ethyl}-5-mercapto[4H]-1,2,4-triazole were refluxed with 65 μL (0.47 mmol) of triethylamine in 10 mL of anhydrous ethanol. To this solution was added α-bromocinnamaldehyde (212 mg, 1.00 mmol) and the mixture was refluxed until no more of the starting triazole could be detected by thin layer chromatography (hexanes 70%/ethyl acetate 30%). Over time the product precipitated out of solution and, after cooling the reaction to room temperature, it was isolated by filtration and washed with ethanol. Pale yellow crystals were obtained, 98 mg (63%). Anal. Calcd. for C 19 H 16 N 4 S: N, 16.85%. Found: N, 16.64%. 1 H NMR (d 6 -DMSO) δ: 3.03 (t, J=7.8 Hz, H b ); 3.12 (t, J=7.8 Hz, H a ); 7.19-7.30 (m, 5H, Ph) 7.45-7.60 (m, 6H, Ph and H γ ); 8.10 (d, J=1.0 Hz, 1H, H α ).
Example 9
One-Step Synthesis of Compound IIg
[0069] To prepare compound IIg by a one-step synthetic process, 107 mg, (0.52 mmol) of 4-amino-3-(3-methoxyphenyl)-5-mercapto[4H]-1,2,4-triazole were refluxed with 72 μL (0.52 mmol) of triethylamine in 10 mL of anhydrous ethanol. To this solution was added α-bromocinnamaldehyde (167 mg, 0.79 mmol) and the mixture was refluxed until no more of the starting triazole could be detected by thin layer chromatography (chloroform 95%/methanol 5%). Over time the product precipitated out of solution and, after cooling the reaction to room temperature, it was isolated by filtration and washed with ethanol. tanned crystals were obtained after recrystallisation from acetone, 121 mg (70%), mp=202-203° C. Anal. Calcd. for C 15 H 10 N 4 S 2 +0.25H 2 O: C, 63.79%; H, 4.31%; N, 16.53%. Found: C, 63.84%; H, 4.22%; N, 16.41%. 1 H NMR (d 6 -DMSO) δ: 3.82 (s, 3H, CH 3 ); 7.11-7.15 (m, 1H, H b ); 7.47-7.62 (m, 9H, Ph and H a/b/c//γ ); 8.19 (s, 1H, H α ).
Example 10
One-Step Synthesis of Compound IIh
[0070] To prepare compound IIh by a one-step synthetic process, 124 mg, (0.48 mmol) of 4-amino-3-(4-trifluoromethylphenyl)-5-mercapto[4H]-1,2,4-triazole were refluxed with 66 μL (0.48 mmol) of triethylamine in 10 mL of anhydrous ethanol. To this solution was added α-bromocinnamaldehyde (150 mg, 0.71 mmol) and the mixture was refluxed until no more of the starting triazole could be detected by thin layer chromatography (chloroform 95%/methanol 5%). Over time the product precipitated out of solution and, after cooling the reaction to room temperature, it was isolated by filtration and washed with ethanol. Yellow crystals were obtained after recrystallisation from acetone, 125 mg (70%), mp=246-247° C. Anal. Calcd. for C 15 H 10 N 4 S 2 +0.5H 2 O: C, 56.69%; H, 3.17%; N, 14.69%. Found: C, 56.87%; H, 2.88%; N, 14.48%. 1 H NMR (d 6 -DMSO) δ: 7.47-7.64 (m, 6H, Ph and H γ ); 7.94 (d, J=8.4 Hz, 2H, H b ); 8.23 (s, 1H, H α ); 8.24 (d, J=8.4 Hz, 2H, H a ).
Example 11
One-Step Synthesis of Compound IIi
[0071] To prepare compound IIi by a one-step synthetic process, 152 mg (0.72 mmol) of 4-amino-3-(4-fluoromethylphenyl)-5-mercapto[4H]-1,2,4-triazole were refluxed with 100 μL (0.72 mmol) of triethylamine in 10 mL of anhydrous ethanol. To this solution was added α-bromocinnamaldehyde (267 mg, 1.27 mmol) and the mixture was refluxed until no more of the starting triazole could be detected by thin layer chromatography (chloroform 95%/methanol 5%). Over time the product precipitated out of solution and, after cooling the reaction to room temperature, it was isolated by filtration and washed with ethanol. Orange crystals were obtained after recrystallisation from acetone, 105 mg (45%), mp=254-255° C. 1 H NMR (d 6 -DMSO) δ: 7.40-7.64 (m, 8H, Ph and H b/γ ); 8.03-8.07 (m, 2H, H a ); 8.19 (s, 1H, H α ). | Fused-ring triazole compounds which inhibit proliferation of cells and exhibit a unique and intense fluorescence are provided. Also provided are methods for synthesizing these compounds and methods for using these compounds to inhibit cell proliferation and infection and to label and fluorescently detect selected molecules. | 2 |
This application is a divisional of application Ser. No. 07/309,016, filed Feb. 9, 1989 now abandoned which is a continuation of application Ser. No. 07/077,910, filed Jul. 27, 1987, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a method of making a water laid fibrous web such as a paper web or a web of plastics material and reinforcing fibres for consolidation or moulding into a fibre reinforced plastics sheet or article.
In paper webs, it is frequently necessary to incorporate particulate materials or powders such as pigments and fillers. In the case of webs of plastics material and reinforcing fibres one or more kinds of particulate plastics material may be included, together with materials such as pigments, fillers and antioxidants in the form of powders of substantially smaller particle size than the plastics material.
The process for making such water laid webs requires as a prerequisite the formation of an aqueous dispersion of the fibres and particulate materials from which the web is to be formed. Preferably, a foamed dispersion is used as described in the Applicants' co-pending European Application No. 85300031.3 (European Patent Publication No. 0 148 760), the subject matter of that Application being incorporated by reference herein. The dispersion so formed is then drained on a foraminous support such as the Fourdrinier wire of a paper machine, to form the web.
Two problems arise in the mechanism of more than one particulate material in an aqueous or foamed dispersion as referred to above.
First, the electrochemical conditions within such dispersions make it difficult to achieve a homogeneous mixture of the various components within the dispersion, and this is reflected as a lack of homogeneity in the web as laid down on the foraminous support.
Secondly, there will be a tendency for the particulate material to be lost during the wet laying process depending on the relative dimensions of the powder particles and the apertures in the foraminous element, for example the mesh size of a Fourdrinier wire.
When certain particles or fibres are dispersed in water, it is thought that an aqueous film forms around each individual particle or fibre and sets up an electro-chemical regime such that other particles are repelled. As a result, when fine powders are added individually, they do not agglomerate either with themselves or with other solid components of the dispersion. Thus, when the dispersion is laid down on the Fourdrinier wire, the fine particles pass through the wire with the water as drainage.
SUMMARY OF THE INVENTION
The invention is particularly concerned with a technique which will improve the homogeneity of the dispersion and resulting sheet, and which, where larger and smaller particles need to be incorporated in the sheet, will increase the retention of the smaller particles where the relative mesh size is such that they would otherwise be substantially lost in drainage through the foraminous element.
According to the present invention a method of making a fibrous web containing at least two particulate materials includes mixing the particulate materials together in a substantially dry condition, using the dry mix to form at least part of an aqueous dispersion of fibres, and draining the dispersion to form a web.
Thus, if a fibrous reinforced plastics material web is being made, the particulate materials can be a mixture of particulate thermoplastics. Alternatively a thermoplastic or a thermosetting polymer, can be mixed with a fine powder such as carbon black or titanium dioxide, the dry mix being dispersed in an aqueous dispersion of fibres prior to drainage to form a web. The fibres may, for example, be glass fibres.
The method of the invention is suitable for use with the process for forming a fibrous web set forth in the Applicants' co-pending European Application No. 85300031.3 (European Publication No. 0 148 760) the subject matter of that Application being incorporated by reference herein.
Again, the invention can be employed in the manufacture of a web in which the particulate material is a fibre, the dry mix being used to form an aqueous dispersion of fibres and drained to form a web.
The method can also be employed where two or more different fibres are to be incorporated in a web, with one or more of the fibres acting as the particulate material which is dry pre-mixed with the dry fine powder before an aqueous dispersion is formed.
It has been found that when mixed dry the homogeneity of the web is improved. Also, it has been found that dry mixing causes fine powder to adhere to substantially coarser particulate material such as thermoplastic, and that this adhesion persists when the dry mix becomes part of or forms the aqueous dispersion. Since the fine powder thus becomes part of a substantially larger agglomerated component of the dispersion, it is retained in the web.
It has also been found that the invention provides a successful method of incorporating a fine pigment powder in the web so as to effect a very uniform coloration of mouldings produced using the fibrous web produced by the process, although other fine powders for other purposes such as antioxidants can of course be employed alternatively or in addition to pigments.
It will be appreciated that the method can also be employed in the manufacture of paper to enhance the retention of powdered additives.
The fine powder and particulate materials can conveniently be pre-mixed in mixers are of the high shear type.
BRIEF DESCRIPTION OF THE DRAWING
The invention can be performed in various ways and one embodiment will now be described by way of example and with reference to the accompanying flow chart, which shows the benefits of the present invention by comparison with known technology.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The flow chart relates to the production of a foamed aqueous dispersion for use in the manufacture of a pigmented web of reinforcing fibre and particulate plastics material as described and claimed in European Patent Application 85300031.3 (Publication No. 0 148 760).
The technique shown may be used for the production of dispersions of two or more particulate plastics materials so as to achieve a homogeneous mixture of one or more particulate materials with much finer powders of, for example, pigments or antioxidants so as to achieve both homogeneity and retention of the powder during the wet web laying process.
However to illustrate the invention in a comprehensive manner the flow chart shows the technique of the invention as used for mixing two particulate polymers of relatively coarse particle size, for example, 100 to 500 microns, with a pigment having a particle size of, for example, 10 to 100 microns.
As shown in solid lines in the flow chart, the two particulate plastics materials and the pigment are first charged into a high shear powder blender 1, for example a Winkworth Ribbon Refiner Batch Mixer, a Gloucester Materials Handling High Shear Batch Blender or a Continuous Gerick E Blender (Powteck Type GAL 351). Microdiagram 2 shows that after blending the two particulate plastics materials 3a and 3b are evenly mixed and that they are both coated with the pigment 4.
The pigment coated particles 3a and 3b are transferred to a hydropulper 5 in which a foamed aqueous dispersion of glass fibres 6 has previously been formed. Because of the homogeneous mixing which has previously taken place in the mixer 1, the homogeneity of the dispersion of fibres and particles thus formed in the hydropulper 5 is assured. Furthermore, substantially all of the powdered pigment 4 continues to adhere to the larger polymeric particles 3a and 3b, as best seen in microdiagram 7.
The foamed aqueous dispersion formed in the hydropulper 5 is then used in the formation of a wet laid web in the process 8 which is carried out according to the process described in the aforementioned European Patent Application. The resulting web comprises well distributed glass fibres and polymeric particles, with the polymeric particles still retaining adherent pigments as best seen in microdiagram 9.
The formed web is then passed to drying, pressing and moulding stages 10 as required, which do not form part of this invention.
If the two particulate polymers 3a and 3b and the pigment 4 are added directly to the hydropulper 5 as indicated by the broken lines 11 and not premixed in a substantially dry state in the mixer 1, it is more difficult to achieve homogeneous mixing with the fibres 6 in the dispersion. Furthermore, the powdered pigment becomes dispersed as individual particles in the foamed dispersion, as best seen in microdiagram 12. As a result they tend to be lost in drainage during the wet laying process, so that few or none remain in the formed web, as shown in microdiagram 14.
It will be appreciated that the materials which can be premixed as described are not limited to particulate polymers or pigments. Wood or glass fibres, clays, and other fillers are understood as falling within the scope of the term "particulate materials" which can be so premixed.
Where plastics materials are to be included, they may comprise thermoplastics or thermosetting plastics particles of various kinds alone or as blends with other plastics for example as follows:
______________________________________Acrylonitrile-butadiene-styrene with PolyvincylchlorideAcrylonitrile-butadiene-styrene with PolypropylenePolyphenylene ether with PolypropylenePolyphenylene ether with PolyamidePolycarbonate with PolyalkyleneterephthalatePolycarbonate with PolyestercarbonatePolyvinylchloride with PhenolformaldehydePolypropylene with Lignin______________________________________
Where such polymers are incorporated alone or as blends, finely powdered antioxidants may be adhered to them by premixing as above described, together with, if desired, pigments such as carbon black or titanium dioxide or fillers such as calcium carbonate. Alternatively, or in addition, one of two particulate polymeric plastics to be included may be first ground to a smaller dimension and then adhered to the other plastic by premixing as above described.
As referred to earlier the particulate material can be the fibres themselves and thus the invention can be used in a paper making process by mixing the fine powder, again, for example a colouring pigment, with the fibres, for example, cellulose fibres in dry form and then using the mix to form an aqueous dispersion, laying this on a wire and forming a paper web in the usual manner.
The process can also be used if more than one kind of fibre is employed in a web, the fine powders being dry mixed with one or more of the fibres to be used prior to forming the aqueous dispersion. | A method of making a fibrous web containing at least two particulate materials and which includes mixing the dry particulate materials together in a substantially dry condition, using the dry mix to form at least part of an aqueous dispersion of fibres, and draining the dispersion to form a web. | 3 |
This invention was developed under contract with the US Air Force, titled “Demonstration of a Compact High Efficiency Magnetic Bearing Chiller”, contract F33615-98-C-2925, Jan. 22, 1999 through the present.
BACKGROUND AND SUMMARY OF THE INVENTION
The present invention relates to magnetic bearing systems and methods for controlling magnetic bearing systems. More specifically, this invention describes a system and a method for moving the rotor position setpoint away from the center point between two opposing bearings and closer to one of the bearings.
Magnetic bearings provide a host of advantages over traditional bearings. Chief among these are decreased frictional loss leading to increased efficiency and the possibility of increased rotational speeds and increased component life. However, the control of the magnetic bearings often proves problematic.
A typical magnetic bearing system, shown in FIG. 1, detects the position of the rotor shaft 19 using either Hall sensors or inductive sensors 16 . These sensors create an output voltage that is proportional to the magnetic flux, which is inversely proportional to the air gap width between the sensors and the rotor. The position signal is sent to a main controller, which compares the position to a pre-determined setpoint 13 and emits an output current proportional to the change in the bearing current that is necessary to bring the shalt back to the setpoint. The controller output current often passes through current amplifiers 18 that then emit the correctly scaled and conditioned bearing current. In state of the art bearings, the bearings operate in groups of at least one dual-magnet pair 20 and 21 . That means that as the current and therefore the force in one is increased, the current and force in the other is decreased by a similar amount. This methodology allows for twice the response of a non-dual-magnet pair. In order to enact the dual-magnet scheme, it is necessary to supply a bias current to the bearing pair. In this way, the current in each bearing can either be decreased or increased, whereas in a bearing without a bias current, no decrease is possible as the current is zero in the normal equilibrium state. It should be noted that some systems operate the bearings independently of each other in a non-dual magnet pair. In such a system, only the bearing that needs to exert the corrective force on the rotor position is activated.
In current magnetic bearing systems, the main dynamic controller typically operates using proportional-integral-derivative (PID), proportional-integral (PI), or proportional-derivative (PD) algorithms. There are many forms of the control algorithm equation, but all of them utilize the error signal, defined as the difference between the actual position and the position setpoint, along with combinations of the integral and derivative of the error signal. Each of these three components of the controller algorithm are multiplied by a separate gain that determines to what degree each term has control over the outputted correction signal. One form of the PID equation is given in Equation 1 with the transfer function given in Equation G ( t ) = K TG [ K P e ( t ) + K I ∫ e ( t ) t + K D t e ( t ) ] [ 1 ] G ( s ) = K TG [ K P + K I s + K D s ] [ 2 ]
Equation 2 is the Laplace transform of Equation 1. The Laplace transform associates one function with a simpler function of another variable. Often, this is used to switch between the time and frequency domains.
Additional filters such as low pass filters, notch filters, or lag-lead filters are sometimes employed to filter out high frequency noise and improve system stability.
Magnetic bearings are inherently unstable without dynamic control in place. One method of increasing the system stability is to decrease the bias current. However, by decreasing the bias current, the current in one of the dual-set bearings can approach zero under a lesser bearing load. Once the bearing current is at zero, the overall control of the magnetic bearings becomes highly non-linear because the system has effectively switched from utilizing a dual-magnet pair of bearings to utilizing only single independent bearings. Therefore, it would be preferable to use a method that decreases the bias current to increase system stability while maintaining both bearing currents above zero.
Additionally, different PID, PI, PD and filter constants are desirable for the dynamic controller for start-up and run situations. Start-up involves a large sudden transient as the bearing is levitated. Therefore, a set of parameters that can handle a large transient is needed. However, during operation, a different set of tuning parameters may be desirable in order to better track the steady-state disturbances in the system and thereby achieve better control over the bearings. These two sets of parameters may be very different, so a method of switching between two controller settings would be very beneficial.
In addition to the standard PD, PI, and PID control algorithms, over the past ten years, researchers have investigated several nonlinear control methods for magnetic suspension systems, including magnetic bearings. One technique is based on nonlinear feedback linearization, which gives excellent performance, but requires an accurate nonlinear design model as well as a central processing unit (CPU) capable of computing the nonlinear control algorithm. Variable structure control methods have also been investigated, but these methods are not suitable for use with current amplifiers because the control output is a high frequency switching signal. Many nonlinear controllers cannot be retrofit to commercial magnetic bearing systems, which are set up for PID-type control. Hence, a control system with improved stability based on linear models would be highly advantageous.
U.S. Pat. No. 6,023,115 uses a series of short duration voltage pulses to increase the force in radial electromagnets at several points during start-up as a means of preventing dragging in motors at their resonant frequencies. However, this does not provide steady-state position variation improvement and the added bias current may decrease the stability of the system.
U.S. Pat. No. 5,760,510 uses a CPU to determine the frequency spectrum of the position oscillations and then outputs a current to create a magnetic flux that counters each separate frequency component, but the position displacement is something that he seeks to eliminate.
U.S. Pat. No. 5,703,424 details a method of correcting for air gap fluctuations that occur in the natural operation of the system. The inventors do this partially by reducing the bias current. However, though he realizes the importance of reducing the bias current for increased stability, he does not provide for a means of reducing the bias current below the natural limit of the bearing system.
U.S. Pat. No. 5,471,106 uses the variable flux that results from the natural movement of the rotor during normal operation as an input in the determination of a current that will reject disturbances of varying frequencies, but the position displacement is again something the inventors seek to eliminate.
The above inventions all assume a central position for the rotor equidistant between two dual-magnet bearings, and they all vary the current as a means of producing the variable flux and hence the variable force on the rotor necessary to maintain that central position. However, a controller that varied the rotor position setpoint is a means of varying the flux and force would have several advantages, assuming the rotor was under a unidirectional load. First, since force is related directly to current and inversely to the air gap width, for a constant current a smaller air gap would produce a greater force. Thus, if a non-central position is used, a bearing magnet could produce a greater force than the force it was designed for. Secondly, given a constant force, a smaller air gap would require a smaller current. This would mean that smaller windings could be used in the bearing magnets. Third, as the current would increase in the opposing bearing, i.e. the bearing that would now see a larger air gap, the bias current could be lowered without allowing the opposing bearing current to dip to zero. A lower bias current would still further reduce the current in the first bearing while also increasing the stability of the system. Finally, the reduction in the current of both bearings caused by lowering the bias current would result in a decrease in the electrical power consumed by the bearings.
The variation of bias current and rotor set point in a dual-magnet bearing also has consequences for the controller. In particular, these variations may require an adaptive control process to re-optimize the gains or other linear PID, PI, or PD controller constants so as to maintain the optimal performance of the magnetic bearing system after the rotor has been moved from its central location. Hence, the advantages of varying the bias current and offset can only be fully realized by implementing an adaptive control.
Therefore, in light of the benefits of a variable position offset controller, as well as the aforementioned shortcomings in the prior art, this invention has the following objectives:
One object of this invention is to provide an improved method of magnetic bearing dynamic control.
A related object of this invention is to provide a means for increasing magnetic bearing stability by decreasing the bias current while simultaneously providing a means of maintaining both bearing current levels above zero.
Another object of this invention is to provide a means of increasing the force output possible for a given bearing size by varying the rotor position setpoint away from a centered position.
A fourth object of this invention is to provide a means of lowering the maximum currents in the bearing windings by offsetting the position of the shaft from the central position of a dual magnet bearing.
Another object of this invention is to provide a means of decreasing the electrical power consumption of a magnetic bearing by varying the rotor position setpoint away from a centered position.
A further object of this invention is to provide a means of enabling the reduction of the bias current by offsetting the position of the shaft from the central position of a dual magnet bearing.
Another object of this invention is to provide the design of hardware that will automatically vary the rotor position setpoint as a function of bearing current, rotor speed, or any other aerodynamic, thermodynamic, or hydrodynamic process variable.
Yet another object of this invention is to teach a magnetic bearing adaptive control method that will optimize the linear control parameters as a function of bearing current, rotor speed, or any other aerodynamic, thermodynamic, or hydrodynamic process variable.
The benefits of this are fourfold, assuming the force on the rotor is unidirectional, meaning that the force is always in the same direction, though not necessarily with the same magnitude. First, the bearings will be more stable. Secondly, the bearings will be able to exert more force on the rotor. Thirdly, the bearings will require less current, thereby allowing for the reduction of the winding size. Finally, the power consumption of the bearing will be decreased. However, the movement of the shaft in one direction or the other necessitates adaptive control, or the alteration of the dynamic control algorithm to maintain optimal performance by accounting for different system stability requirements.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects, advantages and novel features of the present invention will become apparent from the following detailed description when considered in conjunction with the accompanying drawings herein.
FIG. 1 is an overall schematic of a state of the art magnetic bearing system.
FIG. 2 shows the root locus of a typical axial magnetic bearing system. The curves show the locations of all possible closed-loop poles, generated by varying the loop gain of the system. That is, the root locus curves show the closed-loop poles as a function of control system loop gain. Note that the root locus is a function of the open-loop poles and zeroes, which are indicated by “x” and “o” marks. The real axis “x” marks roughly located at ±417 rad/s are attributed to the bearing poles. The complex-conjugate pair of “x” marks (located here at roughly −354±j354 are due to the low pass filter poles. Other “x” and “o” marks on the real axis are attributed to the PID controller and lead filter. Some curves of root locus tend toward the left-half plane of the plot, but the curves from the complex-conjugate poles move toward the right-half plane. As such, there is a “window” of loop gain values for which all of the closed-loop poles are in the left-half plane, yielding a stable system. The gain window is created by the bearing poles, located here at roughly ±417 rad/s and the low pass filter poles.
FIG. 3 contains data showing the current in the dual-magnet bearings as a function of air gap width. At 125 μm, the bias current could be reduced almost 2.5 A without ever zeroing out the overall bearing current. This would also reduce the other bearing's current to roughly 3 A.
FIG. 4 is a schematic of one possible embodiment of the present invention.
FIG. 5 shows two plots of rotor position versus time. The two plots were taken within minutes of each other under essentially identical system operating conditions. The top plot shows a rotor position oscillation of 40 μm. The bottom plot, with improved gain constants, shows a rotor oscillation of less than 20 μm. The PID gain settings of the lower plot do not allow for stable levitation and delevitation, however, illustrating the need for adaptive control.
FIG. 6 is a schematic drawing of an embodiment of the present invention including an axial magnetic bearing.
FIG. 7 is a schematic drawing of an embodiment of the present invention including a conical magnetic bearing.
DETAILED DESCRIPTION OF THE INVENTION
A typical magnetic bearing system is shown in FIG. 1 . The rotor shaft 19 position is detected using either Hall sensors or inductive sensors 16 which create an output voltage proportional to the magnetic flux which is inversely proportional to the air gap between the sensors and the rotor. In state of the art bearings, the bearings operate as a dual-magnet pair 20 and 21 . That means that as the current and therefore the force in one is increased, the current and force in the other is decreased by a similar amount. This methodology allows for twice the response of a non-dual-magnet pair.
According to the laws of electromagnetics, the force exerted on a magnetic body by a current-carrying coil is directly proportional to the square of the current in the coil and inversely proportional to the square of the distance between the two, as given in Equation 3. F magnetic ∝ i coil 2 d gap 2 [ 3 ]
Equation 3 holds for all magnetic levitation systems, including axial, radial, and conical magnetic bearings. The proportionality constant depends on the geometry and construction of the system. For example, a state of the art axial magnetic bearing would have a force equation given by Equation 4. F = μ 0 AN 2 i 2 4 d g 2 [ 4 ]
where μ 0 is the permeability of free space in a vacuum, A is the pole face area, N is the number of turns in the bearing winding, i is the current in the bearing, and d g is the air gap width. In a dual-magnet bearing, the two bearing halves act against each other so the two forces must be vectorally summed to calculate the total force on the rotor. Additionally, any equation describing the force on an off-center rotor must take into account the different air gaps widths between the rotor and each of the dual-magnet bearing halves. This is easily done in a few steps by one skilled in the art (see Example 4, Equation 9).
Through a stability analysis of a typical axial magnetic bearing system, the inherent open-loop poles of an axial bearing can be shown to be; X poles = ± μ 0 A m d g 3 Ni bias [ 5 ]
where m is the mass of the rotor and i bias is the bias current. The pole in the positive half plane causes an inherent instability within the system. By closing the loop and increasing the gain in the controller, this closed-loop pole can be brought back into the negative half plane. This is easier to do if i bias is smaller, meaning the pole starts closer to the origin, as a lower gain will cause the system to remain stable. Again, Equation 5 assumes a centered rotor, but a similar equation for an off-centered rotor is easily derived.
The pole locations denoted by Equation 5 apply to a dual-magnet bearing with the rotor or shaft equidistant from each magnet. For the case where there is offset from a central location, the air gaps on either side of a rotor will be different and the resulting poles for the system will also vary. Using tuning methods familiar to those skilled in the art, the optimal linear controller settings, i.e., gains and other constants, can be calculated.
Typically a magnetic bearing system will include a linear controller (e.g., PID, PD, or PI) and filters (e.g., lowpass, lead, notch). The stability of a system is then determined by the poles and zeros of the transfer functions describing these devices. The transfer function for a PID controller is given by Equation 2, and the transfer function for a lowpass and lead filter, respectively, are shown below: G ( s ) = [ ( s ω n ) 2 + ( 2 ζ ω n ) s + 1 ] - 1 [ 6 ] G ( s ) = [ ( 1 2 π f z ) s + 1 ] / [ ( 1 2 π f p ) s + 1 ] [ 7 ]
where ω n is the natural frequency of a second order lowpass filter, ζ is the lowpass filter damping factor, f z is the lead filter zero frequency, and f p is the lead filter pole frequency.
A root locus of a typical axial magnetic bearing system is shown in FIG. 2 . The natural poles of the bearings themselves are shown on the real axis. When the loop is closed and the system loop gain is increased, the closed-loop pole that starts at the bearing pole in the positive half plane moves towards the left. When the closed-loop pole crosses the imaginary axis, the system stabilizes. Obviously, if the closed-loop pole starts closer to the imaginary axis, it will take a lower gain to stabilize the system.
At the same time, the low pass filter that is necessary to eliminate high frequency noise in the signal often creates a pair of complex-conjugate poles, one in the second quadrant and one in the third quadrant. When the control loop is closed and the loop gain increased, two closed-loop poles move from the low-pass filter poles towards the positive half plane. At some gain, the two closed-loop poles enter the positive half plane and the system becomes unstable. Thus, these two pairs of poles, the bearing poles and low pass filter poles, define a window of stable loop gain values. The gain must be large enough to move the positive closed-loop pole into the negative half plane but small enough to keep the complex-conjugate poles from crossing to the positive half plane. By moving the bearing poles closer to the origin, this window is enlarged, and the system becomes more stable.
Referring again to Equation 5, μ 0 is a universal constant and A, m, and N are all constants of the system. That leaves only d g and i bias that can be varied. Therefore, by lowering i bias , the poles can be brought closer to the imaginary axis, and the stability window is increased. It should be mentioned that decreasing the air gap will act to move the poles back out away from the origin, but the bias current is the dominant effect, as the air gap differential is on the order of a couple hundred μm while the bias current reduction is potentially as much as several amps.
When an external force is applied to the shaft, the current in one of the bearings increases while the current in the other decreases by the same amount. By moving the rotor closer to the bearing that sees the current increase, less current is necessary to produce the same amount of counter-force, as seen by Equation 3. As a result, the current in the opposing bearing decreases by less as well. Hence, the same force will cause less of a deviation in the bearing current. This allows for a lower bearing bias current without the danger of hitting the zero current region, which would result in non-linear control. Additionally, by lowering the bias current, and therefore the currents in both magnetic bearings, the total power consumption of the bearing system is decreased.
EXAMPLE 1
The usefulness of this invention is shown in FIG. 3, which depicts a graph of the dual-magnet bearing currents with respect to the air gap width under a unidirectional steady-state load. At 125 μm, the bias current could be reduced almost 2.5 A without ever zeroing out the overall bearing current. This would also reduce the opposite bearing's current to roughly 3 A.
EXAMPLE 2
The variation of rotor position setpoint in a magnetic bearing can improve the stability of the system. For purposes of discussion and comparison, the width of the window is described in decibel (dB) units, where: dB = 20 * log 10 [ highest_stable _gain lowest_stable _gain ] [ 8 ]
The data in example one was taken with a bias current of 4.0 Amps. This corresponds to a bearing pole placement of ±303.05 and a stability window of approximately 8 dB. After the air gap is moved 125 μm, we are able to reduce the bias current by 2 Amps, and this corresponds to a pole placement of ±220.52, including the correction for the new air gap width. The new stability window is approximately 18 dB. Therefore, the stability window is increased by 10 dB when the rotor is off center.
One of the presently preferred embodiment of the present invention is shown in FIG. 5. A RPM sensor 10 measures the speed of the rotor. The rotor speed is related to the amount of force seen by the bearings, and it is often measured as a series of pulses that is then fed into a frequency to voltage (FV) converter 11 . The output 14 of the FV converter is then proportional to the rotational speed of the rotor. This voltage is then fed into a voltage divider 12 . The voltage divider can be easily configured by anyone skilled in the art to output a voltage 13 proportional to the FV converter output and scaled properly to be used as the rotor position setpoint input voltage of the magnetic bearing controller 15 for a desired range of the setpoint.
Another preferred embodiment of the present invention would utilize a current sensor on the bearings in place of the RPM sensor 10 and a current to voltage converter in place of the FV converter 11 . In such an embodiment, the smaller of the two bearing currents would be held above a certain value by moving the shaft back and forth.
A third preferred embodiment would be one that utilizes an aerodynamic, thermodynamic, hydrodynamic, or other system process variable as the means of determining the desired rotor position offset. One example of this would be the direct measure of a pressure at the inlet piping of a magnetic bearing centrifugal compressor system.
A fourth preferred embodiment would be one that uses a processor or data acquisition board to accept the RPM sensor 10 input or the current input, calculates a new setpoint through software, and outputs the proper rotor position setpoint voltage 13 to the controller 15 .
It should also be noted that a processor could also be used to reduce the bias current in the windings at the same time that the shaft position is changed.
EXAMPLE 3
To summarize the entire scope of the invention, a complete example is now presented. Assume a magnetic bearing centrifugal compressor system with a pole face area of 2×10 −3 m 2 , 100 turns of wire per magnet, a nominal air gap width of 500 μm, and a maximum bearing current of 12 A. According to Equation 4, the maximum force exerted per bearing is 3620.16 N, or 813.85 lb f . A process which requires 900 lb f from one bearing at a shaft speed of 20,000 RPM will require then a new air gap of 475.47 μm. A typical voltage to position sensitivity for a controller and position sensor is 0.0197V/μm. Therefore, a total voltage of 0.483V is necessary to provide this offset at 20,000 RPM. This means that the FV converter and accompanying voltage divider must have a total combined FV gain of 24.16×10 −6 V/Hz.
EXAMPLE 4
Now assume that the system of Example 4 is to be redesigned to reduce the currents in the winding. With the above offset and specified force, the current will be mixed out at 12 A in the bearing providing the force. Assuming the bias current is 6 A, then the current in the opposing bearing is zeroed out. If the maximum bearing current is reduced from 12 A to 10.1 A, then the bias current can be reduced from 6 A to 5 A. As mentioned previously, it is undesirable to have one of the bearing currents zeroed out. Therefore, using a current of 10.1 A in one bearing and a bias current of 5 A will result in a current of 0.1 A in the opposing bearing. Equation 4 can be modified to account for both of the dual-set bearings the non-zero rotor position setpoint. F dual_bearing = μ 0 AN 2 4 ( i 1 2 d g 2 - i 2 2 ( 1000 × 10 - 6 - d g ) 2 ) [ 9 ]
where i 1 and i 2 are the currents in the closer and farther bearings, respectively. The factor of 1000×10 −6 is the total width of both halves of the air gap (500 μm times 2), and d g is again the air gap between the rotor and the bearing magnet that is exerting the principle force on the rotor. Substituting all values into the equation and solving for the air gap width, d g , results in a new value of 400 μm for the air gap width. This also leads to an increase in the stability window as shown in Example 2. Therefore, by adjusting the rotor position setpoint a mere 100 μm, from an air gap width of 500 μm to 400 μm, more power is possible with lower current and greater stability. To implement this design, assuming the same rotor speed and position to voltage sensitivity of Example 4, the FV converter and accompanying voltage divider must have a total combined FV gain of 98.50×10 −6 V/Hz.
EXAMPLE 5
Consider a 100,000 RPM centrifugal compressor used in an oxygen generation system. A typical axial force requirement for this application is around 50 lb f . This is accomplished with 75 turns per magnet, a maximum magnet current of 5 A, a pole face of 1.258×10 −3 m 2 , and an air gap of 500 μm. If the output of the oxygen generator is to be increased, the rotor must spin faster At 110,000 RPM, the force requirement increases to 54 lb f . To accomplish this, the air gap must be decreased to 481.47 μm. If the maximum current is then decreased to 4.75 A, and the bias current reduced to 1.9 A, the air gap must be further decreased to 450 μm. The stability window is then enlarged accordingly.
A further result is that the optimal run settings may have changed as well because the transfer function of the bearings have changed, resulting in poles placed differently from those given by Equation 5. The result is that adaptive control may be necessary to keep the system stable or at optimal running conditions.
Adaptive control may be required to re-optimize a linear controller after the rotor position setpoint has been changed. Adaptive control is a method known to those skilled in the art which can adjust control parameters automatically in such a way as to compensate for variations in the characteristics of the process it controls. In practice, this is a variation of linear control variables (e.g., gains and time and/or time constants) and filters. The optimal operational settings are likely not to be the optimal start-up settings.
EXAMPLE 6
Adaptive control as a result of offset is best illustrated by a third example shown in FIG. 4 . The top plot in FIG. 4 shows a time plot of the position of an axial magnetic bearing in a centrifugal compressor spinning at 21,000 RPMs under a steady-state disturbance using a set of start-up settings. In this case, the axial position oscillation is approximately 40 μm off center. The bottom plot in shows the same disturbance using some example run settings. In this case, the oscillation has been improved to less than 20 μm. It should be noted that it is impossible to levitate the bearings stably using the run settings. Therefore, it is desirable for the bearings to start and run under different settings. The exact same theory would apply to radial or conical bearings as well.
There are two preferred embodiments for enacting an adaptive control technique. The first is to utilize a controller that iterates from the original settings to the final settings. This means that it changes each parameter that needs to be changed by very small increments in sequence until the final settings are reached. Each step of each iteration must be in a stable linear control region, or the system will cease to function correctly. A second technique is to simply shift between two setting registers so that all settings are changed simultaneously.
While the invention has been described in connection with currently preferred embodiments, procedures, and examples, it is to be understood that such detailed description was not intended to limit the invention on the described embodiments, procedures, and examples. Instead, it is the intent of the present invention to cover all alternatives, modifications, and equivalent which may be included within the spirit and scope of the invention as defined by the claims hereto. | A method for controlling magnetic bearings is disclosed. More specifically, this method moves the rotor position setpoint away from the center point between two opposing bearings and closer to one of the bearings. Assuming the force on the rotor is unidirectional, the bearings will be more stable and will be able to exert more force on the rotor. The bearings require less current, thereby allowing for the reduction of the winding size, and the power consumption of the bearing is decreased. The movement of the shaft in one direction or the other necessitates adaptive control, or the alteration of the dynamic control algorithm to maintain optimal performance by accounting for different system stability requirements. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a system for monitoring slip the angle of a vehicle, such as an automotive vehicle. More specifically, the invention relates to a system which can project vehicular slip angle having simple construction and a simplified process.
2. Description of the Background Art
In modern control systems for controlling vehicular activity of an automotive vehicle, such as a suspension control system, an anti-akid brake control system, a power train control and so forth, the slip angle at a road wheel is one of the parameters for performing precise control operation. In order to monitor the wheel slip angle, Japanese Patent First (unexamined) Publication No. 62-299430 discloses a vehicular attitude control system for a four-wheel drive type vehicle, which controls wheel slip angle within a desired range. The disclosed system includes a longitudinal acceleration sensor for monitoring longitudinal acceleration exerted on the vehicular body and a lateral acceleration sensor for monitoring lateral acceleration exerted on the vehicle body. Wheel slippage data is derived by dividing the lateral acceleration value by the longitudinal acceleration value. The arithmetic operation is performed when a judgement is made that the vehicle is traveling on a curved road or corner. Such a judgement, in the proposed system, is made by monitoring steering angular displacement to detect a steering angle greater than a predetermined value. The disclosure further proposes to detect the vehicular condition of passing through the curved road or corner by comparing the longitudinal acceleration and the lateral acceleration.
The disclosed system intends to control the drifting magnitude of the four-wheel drive type vehicle for tight cornering and preventing spinning of the vehicle due to excess slip angle on the wheel. In this aspect, the disclosed system is successful for providing slip angle data for a control system which controls means for generating a yawing force for drifting.
However, when the disclosed system is applied for proving slip angle data for a purpose other than drift control, the accuracy level of detection of the occurrence of the lateral slip of the wheel simply monitored on the basis of the steering angle, cannot be satisfactorily high for a control operation requiring higher a precision level of detection of the slip angle. Namely, since the magnitude of lateral acceleration is variable depending upon the vehicle speed even at the same steering angular displacement, slip angle can be varied depending upon not only the steering angular position but also vehicular speed. When the vehicle speed is high, a relatively large wheel slip angle can be created even by a small magnitude steering angular displacement.
On the other hand, in the latter case, when the vehicle is driven at a substantially constant speed, the longitudinal acceleration on the vehicle body is maintained substantially zero. Therefore, any magnitude of lateral acceleration may cause the judgement that the vehicle is turning. Furthermore, when the vehicle is in deceleration (acceleration being negative), lateral acceleration held at zero becomes greater than the longitudinal acceleration to trigger slip angle derivation. On the other hand, while the vehicle is in a decelerating or acceleration state, the longitudinal acceleration can be greater than the lateral acceleration so that the system should ignote it so as to not perform derivation of the wheel slip angle despite the fact that the vehicle is turning.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide a system for monitoring slip angle on a vehicle.
In order to accomplish aforementioned and other objects, a slip angle monitoring system, according to the present invention, directly compares an absolute value of lateral acceleration with an experimently derived given value which serves as a slip criterion to derive slip angle on a vehicle. Slip angle is set at zero while the absolute value of the lateral acceleration is smaller than or equal to the given value. On the other hand, when the absolute value is greater than the given value, the slip angle is derived by dividing the lateral acceleration by the longitudinal acceleration or by taking the minus one power of the tangent of the quotient obtained by dividing the lateral acceleration by the longitudinal acceleration (i.e., the cotangent of the quotient).
Preferably, the slip angle may be corrected on the basis of wheel acceleration in order to incorporate a wheel acceleration dependent component in the resultant value.
In the a practical construction, the given value may be variable depending upon a vehicle speed or the longitudinal acceleration. According to one aspect of the invention, a system for monitoring the slip angle of a vehicle comprises:
a longitudinal acceleration monitoring unit for monitoring longitudinal acceleration exerted on the vehicle and producing a longitudinal acceleration indicative signal;
a lateral acceleration monitoring unit for monitoring lateral acceleration exerted on the vehicle and producing a lateral acceleration indicative signal;
a wheel speed sensor for monitoring rotation speed of a vehicular wheel to produce a wheel speed indicative signal; and
an arithmetic circuit for receiving the longitudinal acceleration indicative signal, the lateral acceleration indicative signal and the wheel speed indicative signal, the arithmetic circuit deriving a basic slip angle on the basis of values of the longitudinal acceleration indicative signal and the lateral acceleration indicative signal, and correcting the basic slip angle with a correction factor derived on the basis of the wheel speed indicative signal.
According to another aspect of the invention, a system for monitoring the slip angle of a vehicle comprises:
a longitudinal acceleration monitoring unit for monitoring a longitudinal acceleration exerted on the vehicle and producing a longitudinal acceleration indicative signal;
a lateral acceleration monitoring means for monitoring a lateral acceleration exerted on the vehicle and producing a lateral acceleration indicative signal; and
an arithmetic circuit for receiving the longitudinal acceleration indicative signal, the arithmetic circuit comparing the lateral acceleration indicative signal value with a predetermined lateral acceleration criterion to derive the slip angle data, setting the slip angle at zero when the lateral acceleration indicative signal value, is smaller than or equal to the criterion and calculates the slip angle on the basis of values of the longitudinal acceleration indicative signal and the lateral acceleration indicative signal value when the lateral acceleration indicative signal is greater than the criterion value.
According to a further aspect of the invention, a system for monitoring slip angle of a vehicle comprises:
a longitudinal acceleration monitoring unit for monitoring longitudinal acceleration exerted on the vehicle and producing a longitudinal acceleration indicative signal;
a lateral acceleration monitoring unit for monitoring lateral acceleration exerted on the vehicle and producing a lateral acceleration indicative signal;
a wheel acceleration monitoring unit for monitoring wheel acceleration and producing a wheel acceleration indicative data;
an arithmetic circuit for receiving the longitudinal acceleration indicative signal, the arithmetic circuit comparing the lateral acceleration indicative signal value with a predetermined lateral acceleration criterion to derive the slip angle data, setting the slip angle at zero when the lateral acceleration indicative signal value is smaller than or equal to the criterion and calculating a basic slip angle on the basis of values of the longitudinal acceleration indicative signal and the lateral acceleration indicative signal value when the lateral acceleration indicative signal is greater than the criterion value, and correcting the basic slip angle with a correction value derived on the basis of the wheel acceleration indicative data.
The arithmetic circuit may derive the correction factor by differentiating the wheel speed indicative signal. Practically, the correction factor is a wheel acceleration data to be added to the longitudinal acceleration indicative data.
The arithmetic circuit derives the basic slip angle by dividing the longitudinal acceleration indicative signal by the lateral acceleration indicative data.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description of the invention given herebelow and from the accompanying drawings of the preferred embodiments of the invention, which, however, should not be taken to limit the invention to the specific embodiment, but are for explanation and understanding only.
In the drawings:
FIG. 1 is an illustration showing the first embodiment of a slip angle monitoring system according to the present invention, which is applied to an automotive vehicle;
FIG. 2 is an illustration showing slip angle in relation to the vehicle activity including vehicle traveling direction and accelerations exerted on a vehicle body;
FIG. 3 is a block diagram of the preferred embodiment of a slip angle monitoring system of FIG. 1;
FIG. 4 is an illustration showing the second embodiment of a slip angle monitoring system according to the present invention, which is applied to an automotive vehicle;
FIG. 5 is an illustration showing slip angle in relation to the vehicle activity including vehicle traveling direction and accelerations exerted on a vehicle body; and
FIG. 6 is a block diagram of the second embodiment of a slip angle monitoring system of FIG. 1;
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, particularly to FIG. 1, the first embodiment of a slip angle monitoring system, according to the invention, has a longitudinal acceleration sensor 2 and a lateral acceleration sensor 3. These longitudinal and lateral acceleration sensors 2 and 3 may be arranged on appropriate positions on the vehicle body 1. The longitudinal acceleration sensor 2 monitors a longitudinal acceleration exerted on a vehicle body and produces a longitudinal acceleration indicative signal X". The direction of the longitudinal acceleration coincides with the direction of the PG,8 longitudinal axis of the vehicle body. The lateral acceleration sensor 3 monitors a lateral acceleration exerted on the vehicle body and produces a lateral acceleration indicative signal Y". The direction of the lateral acceleration Y" is transverse to the longitudinal axis of the vehicle body.
The longitudinal and lateral acceleration sensors 2 and 3 are connected to an arithmetic circuit 4 which arithmetically derives slip angle data. Assuming that the vehicle travels along a path represented by an arrow A, the center O of the vehicle body 1 passes a center of the path as indicated by the arrow A. During curving, a longitudinal acceleration as indicated by a vector X" and a lateral acceleration as indicated by a vector Y" are exerted on the vehicle body 1. A composite acceleration as indicator by a vector Z is the acceleration actually exerted on the vehicle body. On the other hand, vehicular speed vector V is in a tangential direction of to the curved path A. As seen, the composite acceleration vector Z points in a direction transverse to the vehicular speed vector V.
When the lateral acceleration Y" is zero, the composite acceleration Z also becomes zero. This means that the vehicular speed vector V matches the vehicular longitudinal axis and thus the vehicle is traveling on a straight path. When the lateral acceleration Y" is substantially small but not zero, the composite acceleration vector Z is offset from the vehicular speed vector V in a substantially small magnitude in an angular direction. As long as the angular shift of the composite acceleration vector Z with respect to the vehicular speed vector V is maintained substantially small, such an angular shift may not affect the cornering force of the vehicle. The angular shift range θ 0 may be variable depending upon the vehicular cornering characteristics. Therefore, the angular shift range θ 0 is experimentarily derived according to the cornering characteristics of the vehicle to which the preferred embodiment of the slip angle monitoring system is applied, and a desired precision level in monitoring the slip angle.
In a practical process in deriving the slip angle θ 1 , the absolute value |Y"| of the lateral acceleration indicative signal value is compared with the reference value θ 0 . If the lateral value |Y"| is smaller than or equal to the reference value θ 0 , then, the judgement is made that the vehicle is traveling on a substantially straight road. On the other hand, if the absolute value |Y"| of the lateral acceleration is greater than the reference value θ 0 , the judgement is made that the vehicle is traveling on a curved road or turning a corner. Then, the slip angle θ 1 is arithmetically calculated on the basis of the longitudinal acceleration indicative signal value X" and the lateral acceleration indicative signal value Y". Namely, the slip angle θ 1 can be calculated from one of the following equations:
θ.sub.1 =X"/Y" (1)
θ.sub.1 =tan.sup.-1 (X"/Y") (2)
FIG. 3 shows a block diagram of the first embodiment of the slip angle monitoring system, according to the present invention. As seen from FIG. 3, the arithmetic circuit 4 has a divider 101 receiving the longitudinal and lateral acceleration indicative signals X" and Y" from the longitudinal and acceleration sensors. The divider 101 implements a dividing operation to divide the longitudinal acceleration indicative data X" by the lateral acceleration indicative data Y". The slip angle thus derived is fed to a circuit 102 for implementing calculation according to equation (2).
FIG. 4 shows the second embodiment of the slip angle monitoring system according to the present invention. In this embodiment, a wheel speed sensor 5 is provided in addition to the system of FIG. 1. The wheel speed sensor 5 monitors rotation speed of a vehicular wheel to produce a wheel speed indicative signal. The wheel speed indicative signal of the wheel speed sensor 5 is fed to the arithmetic circuit 4.
The arithmetic circuit 4 performs an arithmetic operation to derive wheel acceleration indicative data Vx" on the basis of the wheel speed indicative signal. The wheel acceleration indicative data Vx" is practically derived by differentiation of the wheel speed indicative signal. With the wheel acceleration indicative data Vx", a wheel acceleration dependent correction value is derived for correcting the slip angle derived on the basis of the longitudinal acceleration indicative signal value X" and the lateral acceleration indicative signal value Y" according to the equations of (1) and (2).
In practice, a corrected slip angle θ 2 is derived by the following equations:
θ.sub.1 =(X"+Vx")/Y" (3)
and
θ.sub.1 =tan.sup.-1 {(X"+Vx")/Y"} (4)
FIG. 5 shows the influence of wheel acceleration Vx" on the slip angle derived on the basis of the longitudinal acceleration and the lateral acceleration. Namely, in the example of FIG. 5, the vehicle travels along a curved path which curves toward right with respect to the vehicular longitudinal axis. At the position shown, the vehicle speed vector V is offset in angle from the longitudinal axis of the vehicle body at an angle θ. This can be precisely derived by incorporating wheel acceleration component Vx" an additional component for determining the actual longitudinal acceleration X 1 "=(X"+Vx") which is created by the centrifugal force during cornering. Assuming the lateral acceleration is Y" or Y 1 ", the composite acceleration is Z with an angle θ 1 . This can be compared with the composite acceleration derived on the basis of the longitudinal acceleration indicative signal value X" and the lateral acceleration indicative signal data Y" and can be appreciated that the slip angle thus derived taking the wheel acceleration dependent component, can provide higher accuracy than that of the former embodiment.
FIG. 6 shows a block diagram implementing the second embodiment of the slip angle monitoring system according to the present invention. As can be seen from FIG. 6, the arithmetic circuit 4 of the embodiment shown of the slip angle monitoring system includes a discrimination circuit 201 which receives the lateral acceleration indicative signal Y". The discrimination circuit 201 derives an absolute value |Y"| of the lateral acceleration indicative signal value and compares the absolute value with the given value θ 0 . The discrimination circuit 201 produces a discriminator signal indicating that the absolute value of the lateral acceleration indicative signal is smaller than or equal to the given value θ 0 to a circuit 202 which outputs a zero level slip angle indicative signal. The discriminator circuit 201 on the other hand outputs the discriminator signal representative of the absolute value of the lateral acceleration indicative signal being greater than given value θ 0 to a circuit 203. The circuit 203 performs an arithmetic operation according to the equation (3) or (4) as set forth above.
While the present invention has been disclosed in terms of the preferred embodiments in order to facilitate better understanding of the invention, it should be appreciated that the invention can be embodied in various ways without departing from the principle of the invention. Therefore, the invention should be understood to include all possible embodiments and modifications to the shown embodiments which can be embodied without departing from the principle of the invention set out in the appended claims. | A slip angle monitoring system directly compares an absolute value of lateral acceleration with an experimentarily derived given value which serves as a slip criterion to determine slip angle of a vehicle. Slip angle is set at zero while the absolute value of the lateral acceleration is smaller than or equal to the given value. On the other hand, when the absolute value is greater than the given value, the slip angle is derived by dividing the lateral acceleration by the longitudinal acceleration or by taking the minus one power of the tangent of the quotient obtained by dividing the lateral acceleration by the longitudinal acceleration, that is, the cotangent of the quotient. | 1 |
PRIORITY
The present application is a continuation of application No. 13/425,882, filed Mar. 21, 2012, which claims the benefit of U.S. Provisional Application No. 61/467,242, filed Mar. 24, 2011, the disclosures of each of which are hereby incorporated by reference herein in their entireties.
BACKGROUND
Field
The embodiments disclosed herein relate to a system and method for controlling emission of Volatile Organic Compounds and, more specifically, to an improved system and method for increasing volumetric throughput through an internal combustion engine used to control Volatile Organic Compounds.
Description of the Related Art
The direct release of Volatile Organic Compounds (VOC's) into the atmosphere has been for some time now recognized as a primary contributing factor in affecting ozone concentrations in the lower atmosphere. The EPA has established standards for safe levels of ozone, and local air quality districts have implemented regulations and mandated control measures pertaining to the release of hydrocarbon vapors into the atmosphere, from operations such as soil remediation, storage tank inerting, and storage vessel loading and unloading; that have been identified as sources of hydrocarbon emissions responsible for impacting ozone levels.
The process of treating these vapors, through any of a variety of methods, is typically referred to as “degassing”; which is either the collection or on-site destruction of these vapors as an environmentally responsible alternative to their otherwise direct release into the atmosphere.
The internal combustion engine, as well as open-flare incinerator units, have been employed for several decades as a means of on-site destruction of these VOC's by elemental combustion. The combustion process does itself give rise to the undesirable production of carbon monoxide and nitrogen oxides; however this has been accepted as a reasonable consequence for the nearly 99% efficiency in the destruction of hydrocarbon based VOCs. These consequential emissions are accepted, but tolerated only to a regulated extent, and are also a factor to be considered in engines and incinerators employed in vapor destruction applications. The maximum permissible limits of consequential hydrocarbon, carbon monoxide and nitrogen oxide emissions are regulated to different standards within different air quality regions.
The many different VOC's typically subject to treatment represent a wide range of hydrocarbons between C1 through C10 along with their corresponding alcohols and ketones. Each of these individual compounds is characterized by having unique upper and lower flammability limits, expressed as a range of concentration in atmospheric air within which a source of ignition results in combustion of the mixture. This data is well established and widely published; along with the stoichiometric mixture ratio for each of these compounds, defined as the theoretically ideal mixture at which combustion will be complete without a remaining excess of either air or fuel. Generally, combustion is most complete with a slight excess of air, approximately 15%, being slightly leaner than the theoretical stoichiometric mixture concentration.
The internal combustion engine, as well as open-flare incinerator units, have been employed for several decades as a means of on-site destruction of these Volatile Organic Compounds by elemental combustion; but each with slightly different performance characteristics. In the case of the open-flare incinerator unit; the VOCs to be processed are typically introduced at a vapor concentration equivalent to or less than the lower explosion limit and passed over a continuously maintained flame source responsible for combustion of the subject VOCs. Open-flare incinerator units are able to support combustion of the introduced VOCs at concentrations less than the lower explosion limit by virtue that the flame front has already been established by a continuously maintained pilot flame. The disadvantage of the open-flare incinerator unit is that the inlet concentration is limited by the ability of the unit to dissipate the amount of heat generated by the combustion of VOCs, based upon the heat content of the VOCs undergoing treatment. A further disadvantage of open-flare incinerator type units is that greenhouse gasses (CO2) are continuously generated by the pilot flame without relation to the mass quantity of VOCs being processed.
In the case of the internal combustion engine employed in vapor destruction applications, the resultant heat produced from combustion of the VOCs is very effectively handled by the engine cooling system, affording VOC concentrations in the upper range approaching the upper explosion limit. The internal combustion engine is also self-sustaining in that the fuel source is entirely that of the subject VOC itself and does not require any addition of fossil fuel until the concentration of subject VOC falls below the lower explosion limit of the subject VOC undergoing treatment.
It is important to note that the aforementioned values of lower and upper explosion limits as defined for subject VOC's undergoing treatment was established in a laboratory setting and under the thermodynamic principles of a constant pressure (Cp) type process. Actual conditions of combustion within the internal combustion engine, whether spark ignited or compression ignited, more closely resemble combustion characteristic of a “constant volume” (Cv) type process and typically must therefore be adjusted. This adjustment is on the order of approximately 15% above the lower explosion limit (herein defined as the lean limit), and approximately 15% below the upper explosion limit (herein defined as the rich limit).
Because the many VOCs typically subject to treatment are too numerous to elaborate herein, gasoline vapor has been selected as the model for purposes of discussion. In selecting gasoline vapor; it is herein defined as having an upper explosion limit of 7.5%/vol ; with a lower explosion limit of 1.5%/vol ; and a stoichiometric value of 4.5%/vol. Adjusting these values for practical combustion ranges within the internal combustion engine operating under the thermodynamic principals of a constant volume combustion process ; the rich limit is defined as 6.5%, the lean limit as 2%, and the stoichiometric ratio as 4.5%. There are many factors which could influence these specific values; but these values are selected for the purpose of discussion herein.
The internal combustion engine employed in vapor destruction applications has traditionally been that of the “lean-burn” type ; wherein the process vapor is introduced at a concentration value less than stoichiometric and more closely approximating that of the lean-limit for the subject VOC. At this lean mixture, the resultant emissions with regard to hydrocarbons and carbon monoxide, tend to be at their lowest value, and remain low up to the lean-limit where after combustion is no longer possible. Oxides of nitrogen emissions tend to increase dramatically on the immediate lean side of stoichiometric, but then fall in value as the mixture becomes increasingly lean up to the lean limit. These engines are typically fitted with “reduction/oxidation” type catalytic convertors as a final polish to the exhaust stream prior to emitting into the atmosphere.
Although lean-burn operation is a sought after objective for modern engines employed in power producing applications, such as motor vehicle and industrial power applications wherein fuel efficiency and minimal exhaust emissions are of primary concern; this is not the ideal configuration for such engines employed in vapor destruction applications wherein maximum fuel consumption in terms of vapor processing volumetric throughput are of primary interest.
SUMMARY
A lean-burn engine employed in processing gasoline vapor equates to a vapor processing rate of 2% of the total volumetric throughput of the engine. In the case of the engine with a total displacement volume of 500 cfm, this equates to a VOC processed volume of: [500(0.02)], or 10 cfm. The same engine operating in rich-burn mode, processing vapor at 6% by volume equates to a VOC processed volume of: [500(0.06)], or 30 cfm. This is a 3-fold increase being a linear function of the proportionate increase in vapor concentration up to the rich-limit, where after combustion is no longer possible.
Although the internal combustion engine has the inherent ability to cope with and dissipate the heat energy associated with combustion of VOCs at the upper extreme of their rich-limit, it is important to note that hydrocarbon and carbon monoxide emissions increase substantially when operating on the rich side of stoichiometric, along with a corresponding decrease in excess air within the final exhaust stream. Because most engines employed in vapor destruction applications are equipped with a catalytic convertor, requiring a certain excess of atmospheric air as part of the exhaust stream for proper catalytic convertor function, these engines must typically operate on the lean side of stoichiometric as a necessity for catalytic convertor function.
The internal combustion engine, as part of prior art employed in vapor destruction applications, has been limited in realizing its full potential in terms of volumetric throughput of processed vapors; due to the natural increase in hydrocarbon and carbon monoxide emissions associated with rich-burn operation, and also that of requiring an excess of air in the final exhaust stream essential to support proper catalytic convertor operation.
Accordingly, one embodiment comprises a system for controlling emissions of VOC's by combustion of said VOC's in an internal combustion engine. The system can include an inlet conduit for connection to a source of VOC's, an internal combustion engine that is connected to the inlet conduit; exhaust path that receives exhaust from the internal combustion engine and an air source of supplemental air. A manifold comprises a first conduit that receives the exhaust from the exhaust path and a second conduit that receives supplemental air from the air source. The manifold is configured to transfer heat from the exhaust in the first conduit to the supplemental air in the second conduit. An abatement device is in fluid communication with the first conduit downstream of the manifold. A fourth conduit is in communication with the first conduit upstream of the abatement device.
In another embodiment, a method of controlling emissions of VOC's comprises transporting VOC's to an engine and transporting exhaust from the engine into a manifold. Supplemental air is transported into the manifold and heat is transferred from the exhaust to the supplemental air within the manifold. The supplemental air is mixed with the exhaust and at least a portion of the supplemental air and exhaust mixture is transported into a pollution abatement device.
Other embodiments and arrangements are described below.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic illustration a degassing system according to one embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
As described herein, one embodiment can include a method of employing secondary “thermal oxidation” for increased volumetric throughput and reduced hydrocarbon and carbon monoxide emissions from internal combustion engines employed in “degassing” operations. As described herein, “degassing” operations is intended to be a broad term that can be generally defined as the destruction of Volatile Organic Compounds, by elemental combustion, of hydrocarbon vapors emanating from soil remediation, in situ process streams, pipelines and storage vessels; as an environmentally responsible alternative to the otherwise direct release of these vapors into the atmosphere. In other embodiments, the degassing operations can also be applied to other compounds and/or from sources other than those listed above.
One advantage of certain embodiments is that an internal combustion engine, as employed in certain embodiments, can operate at richer than stoichiometric mixtures for greater vapor processing capability without consequential increase in the production of hydrocarbon and carbon monoxide emissions typically associated with rich-burn engines; and while also reducing oxides of nitrogen emissions inherent to internal combustion engines capable of operating on the rich side of stoichiometric air/fuel ratios.
One advantage of the certain embodiments is that they allows the internal combustion engine as typically employed in vapor destruction applications to operate at the upper range of the flammability limit for the VOC being processed, without the corresponding increase in hydrocarbon and carbon monoxide emissions normally associated with operation in this upper range, and provides a method to an exhaust stream containing sufficient excess air to support proper catalytic convertor operation.
Certain embodiments allow the internal combustion engine to operate at greater than stoichiometric mixture ratios for the particular VOC being processed, by providing an intermediate stage of combustion immediately following combustion within the engine, that allows combustion to proceed under lean-burn constant-pressure conditions in an environment of excess air that not only supports more complete combustion but also provides sufficient excess air in the final exhaust stream essential to support proper catalytic convertor operation.
In one arrangement, the exhaust stream immediately following exhaust from combustion within the engine can be passed (e.g., via a conduit) into a heated manifold wherein air is injected (e.g., via a conduit) from an outside source such to effectively reduce the relative concentration and assimilate combustion under lean-burn and constant-pressure conditions with sufficient excess air necessary to support subsequent introduction to the catalytic convertor for a final polish before finally being emitted to the atmosphere.
In such arrangements, a several-fold increase in the volumetric throughput of processed vapors within the fixed displacement of the engine itself, without increase in exhaust emissions typically associated with operation in rich-burn mode, and provides also sufficient excess air in the final exhaust stream necessary to support proper catalytic convertor operation.
FIG. 1 is a schematic illustration of one embodiment of a degassing system. In the illustrated embodiment, the subject VOC is introduced into the system at point ( 1 ). In the case of soil remediation or in situ process streams (for example), the vapor concentration at point ( 1 ) may remain very constant or substantially constant at some value ranging between 0% to 100%/volume over an indefinite period of time. In the case of processing a fixed volume of VOC vapors, such as from storage vessels, the concentration at point ( 1 ) can commence at a value of 100%/volume concentration and can eventually fall to 0%/volume at the conclusion of the “degassing” event. Accordingly, the VOC concentration measured at point ( 1 ) can be a variable that may change over time.
In the illustrated embodiment, when the vapor concentration as measured at point ( 1 ) is substantially equal to or greater than the upper explosion limit (or some calculated or predetermined reference value), or more accurately the predetermined “rich-limit” for the subject VOC ; dilution air can be introduced at point ( 2 ) such that the vapor concentration as measured at point ( 3 ) is equal to the predetermined “rich-limit”. When the vapor concentration as measured at point ( 1 ) falls below the upper explosion limit, or the predetermined “rich-limit”, dilution air is no longer required. When the vapor concentration as measured at point ( 1 ) falls substantially below the lower explosion limit (or some calculated or predetermined reference value), or the predetermined “lean-limit”; a supplemental fuel (such as methane or propane or other) can be introduced at point ( 4 ) such that the combustible mixture as measured at point ( 5 ) is equal to or substantially equal to the “lean-limit” necessary to sustain combustion within the engine. When the subject vapor concentration as measured at point ( 1 ) falls within the range of the “rich” and “lean” limit ; neither dilution air nor supplemental fuel are necessary to form a combustible mixture.
Accordingly, in one embodiment, the VOC vapors being processed, can be introduced at a concentration ranging from 100%/vol to 0%/vol and combustion is still supported within the engine employed in vapor destruction processes, and can thereby process the subject VOC vapors to 0% in vapor destruction “degassing” operations.
An advantage of the internal combustion engine employed in vapor destruction applications is its inherent ability to cope with the combustion heat generated from operation in the upper range of the flammability limit. In the case of the engine processing gasoline vapor, this equates to a concentration value of approximately 6% versus the approximate 2% normally associated with engines operating in lean-burn mode of operation.
When the vapors to be processed are introduced into the engine at the lean-limit (e,g, 2% for gasoline); the volumetric throughput for an internal combustion engine with a displacement volume of 500 cfm becomes:
[(0.02) 500]=10 cfm processed vapors (in lean-burn mode)
When this same engine is operated in rich-burn mode, wherein the vapors to be processed are introduced at their “rich-limit” (e.g. 6% for gasoline); the volumetric throughput for the same engine with a displacement volume of 500 cfm becomes:
[(0.06) 500]=30 cfm processed vapors (in rich-burn mode)
Although the numbers are only relative, it represents a 3-fold increase in volumetric throughput for the same engine when operated in this rich-burn mode.
One associated benefit with operation in rich-burn mode, is that oxides of nitrogen emissions tend to be at their lowest values due to reduced combustion temperatures and the increased heat capacity of the system. The primary disadvantage however; is that hydrocarbon and carbon monoxide emissions tend to increase substantially due to the absence of sufficient excess air to facilitate complete combustion, and the absence of sufficient excess air in the final exhaust stream essential to proper catalytic convertor operation. A certain excess of nitrogen is essential to the reduction phase of the catalyst, and a certain excess of atmospheric oxygen is essential to the oxidation phase of the catalyst.
The embodiments describe herein can allow the engine to operate in rich-burn mode for maximum volumetric throughput of processed vapors, while still providing sufficient excess air in the exhaust stream to facilitate complete combustion and with sufficient excess air in the final exhaust stream necessary for proper catalyst function.
With continued reference to FIG. 1 , a conduit transfers the VOC vapors and any dilution air and/or supplemental fuel to the engine 6 . As the engine 6 operates an exhaust stream is generated and transferred to a conduit. Atmospheric air can be introduced into the exhaust stream as it leaves the combustion chamber at point ( 7 ) in the conduit before the exhaust stream passes into the thermal oxidizer exhaust manifold ( 8 ). The atmospheric air can be supplied by source ( 10 ), which can be either an exhaust driven turbocharger, roots blower, or other source such as an external air compressor. The conventional turbocharger, properly selected for the application, is herein suggested as a proven and preferred method due to its compact size but more importantly the ability to closely regulate its volumetric output with a minimum of complex controls.
In the illustrated arrangement, the introduced air from source ( 10 ) can be passed through an annular space ( 9 ) surrounding the thermal oxidizer exhaust manifold ( 8 ) in such a way that the natural heat of the exhaust gas passing through the manifold is transferred to the introduced air. This serves not only to provide cooling to the manifold from the hot exhaust gas passing within, but also imparts this heat to the introduced air stream such to maintain an elevated temperature (e.g., approximately 1200 F in one arrangement) at the point wherein this air is injected to the exhaust stream as it leaves the combustion chamber at point ( 7 ). If the introduced air is not maintained at this elevated temperature, then gas phase termination of active specie in the exhaust gas could occur; resulting in excessive hydrocarbon and carbon monoxide emissions. The manifold may or may not be fitted with insulation (not shown) to aid in retaining the natural heat within the manifold and imparting this heat to the introduced air rather than the surrounding environment. The mixture of exhaust gases and heated supplemental air can then be transferred via a conduit 12 to the catalytic convertor 13 . A conduit ( 11 ) is upstream of the catalytic converter ( 13 ) and/or the manifold ( 8 ).
In order to determine the amount of supplemental air necessary to be introduced in converting from lean-burn to rich-burn mode of operation; in one embodiment, the vapor concentration associated with operation under lean mode of operation is determined and the amount of normal engine air based upon the fixed displacement volume of the engine is determined.
For example, in the arrangement of the engine with a displacement volume of 500 cfm, operated in lean-burn mode having a vapor concentration of 2%:
engine air=(98%) 500=490 cfm
VOC volume=(2%) 500=10 cfm
The amount of supplemental air required for conversion to rich-burn (6% concentration) therefore becomes:
[(Crich/Clean)−1] (engine air)=supplemental air
or in this case:
[(0.06/0.02)−1](490)=supplemental air=980 cfm
The amount of excess air now present in the exhaust stream by the addition of supplemental air is such to return the total mixture to the equivalent of operation in lean-burn mode, as:
30/(490+980)=2%/volume=(original lean-burn conditions)
It is interesting to note also that although the total heat capacity of the system within the thermal oxidizer manifold has increased by the addition of supplemental air, the heat produced within the system has increased commensurately; such that exhaust gas temperature remains relatively unchanged from that of operation in lean-burn mode. In certain arrangements, this can be an important factor in maintaining proper catalyst temperature.
The total volume quantity of exhaust gas passing through the catalyst, has now been increased several fold by the introduction of supplemental air; which may have a significant impact upon proper catalyst operation. Not only is there an increased concern for excessive back pressure produced in the exhaust system, but also an increase in gas density and a corresponding decrease in residence time within the catalyst, that could be detrimental to proper catalyst operation. This potential condition for the particular catalyst employed can be considerable, and the addition of a supplemental catalyst in parallel, or an appropriate retrofit can be part of a particular application.
According to certain of the embodiments described above, a method is provided by which the volumetric vapor processing capability can be increased by several fold within the internal combustion engine having a fixed displacement volume, when the vapor concentration to be processed (as measured at point 1 ) is greater than the upper explosion limit or the predetermined rich-limit for the particular VOC undergoing treatment. Although this can afford a several fold increase in the vapor processing capability of the system when the VOC concentration is greater than the predetermined rich-limit; such embodiments provide no improvement in the volumetric throughput of the system when the inlet concentration measured at point ( 1 ) falls below the lower lean-limit. The continued introduction of supplemental air at this point may actually be detrimental to the performance of VOC destruction in that excessive amounts of supplemental air are not needed and may be detrimental to the chemistry of proper catalyst operation in addition to reduced exhaust gas temperatures resulting in excessive cooling and reduced performance of the catalyst.
For this reason, it is suggested in certain embodiments, that the introduction of supplemental air be terminated when the subject VOC concentration as measured at point ( 1 ) falls below the predetermined lean-limit for the particular VOC undergoing treatment.
As described above, in the illustrated embodiments a reciprocating internal combustion engines is used. However, it is contemplated that other types of engines and/or internal combustion engines could be utilized in modified embodiments.
As used herein the term “conduit” is intended to be a broad term that includes, pipes, ducts and channels. In addition, a conduit need not be a separate device or element but can define portions of a longer conduit. That is, a first and second conduit can be portions or sub-sections of a larger conduit.
Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In addition, while a number of variations of the invention have been shown and described in detail, other modifications, which are within the scope of this invention, will be readily apparent to those of skill in the art based upon this disclosure. It is also contemplated that various combinations or subcombinations of the specific features and aspects of the embodiments can be made and still fall within the scope of the invention. Accordingly, it should be understood that various features and aspects of the disclosed embodiments can be combined with or substituted for one another in order to form varying modes of the disclosed invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims. | A method and device for controlling emissions of VOC's comprises transporting VOC's to an engine and transporting the exhaust from the engine into a manifold. Supplemental air is transporting into the manifold and heat is transferred from the exhaust to the supplemental air within the manifold. The supplemental air is mixed with the exhaust and the mixture is transferred to a pollution abatement device. | 5 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit under 35 U.S.C. §371 to international application No. PCT/TN2005/000004, filed on May 6, 2005.
FIELD OF INVENTION
This invention relates to a manufacturing process for executing plane, curvilinear, polyhedral and spherical structures which may be decomposed into a finite number of triangles and more particularly, the present invention relates to a manufacturing process and triangular structures which can be arranged together to form, for example, domes from truncated cone icosahedrons, and chapel-shaped greenhouses.
BACKGROUND OF THE INVENTION
Implementation of geodesic domes is conventionally carried out through a series of different shaped triangular structural elements, which can be arranged in a specified pattern based on the frequency of the different shaped triangular structures that are chosen and linked at their tops (i.e., apexes) by knots. Such knots are various connector devices designed according to the manufacturing and securing methods chosen for the triangular structures. U.S. Pat. No. 4,009,543, issued Mar. 1, 1997 reveals an example thereof.
The fact of using prefabricated monobloc triangular structures in a plastic material and for which the interior of sides is empty is also described to construct domes, the assembly of which may be implemented by a screw-and-nut system, as illustratively disclosed in U.S. Pat. No. 5,732,518, issued Mar. 31, 1998.
Monobloc triangular structures, the plastic material of which is heat hardening resin, have also been described as being formed over a metal section, and one of the sides of which is revealed can be a curve to form a cylinder, as illustratively disclosed in Danish patent DE2117332A1, published Oct. 12, 1972.
The fact of covering the metal section with a thermoplastic polymer is also currently described in Patent WO 2005/054740 A1 published Jun. 16, 2005. Spherical structures have been described as being achievable from triangular structures which however are not monobloc and the sides of which remain rectilinear, as illustratively described in British patent GB1109139A, published Apr. 10, 1968.
The execution of chapel-shaped greenhouses is also conventionally carried out using a series of triangles, groins, shafts. A thermal protection for greenhouses constructed according to a geodesic dome has been described in Canadian patent 1211285, Sep. 16, 1986. Nevertheless, nothing prevents from proceeding by using monobloc triangular structures, as for domes, in order to construct green-houses with chapel shape.
Execution of submarine bells for use in submarine works is also conventionally carried out using metallic structures with cylindrical or spherical shape generally manufactured according to such processes so as to make an only one structure. Execution of such structures in form of parts that can be assembled under water so as to obtain a cylindrical shape is nevertheless described in application publication no. WO880218, published Apr. 21, 1988. Adjunction to submarine bells of movable parts making doors or windows allowing panoramic sight through transparent materials is also described in U.S. Pat. No. 4,094,160, issued Jun. 13, 1978.
Manufacture of submarine bells for tourist use proceeds generally from execution of the sphere segment made in one block in transparent plastic material. For such tourist use, which means for pressure levels not exceeding three (3) absolute atmospheres, nothing, however, prevents from proceeding by using assembled triangular structures, as for domes, since such assembling ensures water tightness for the final structure of the bell.
The execution mode for geodesic domes and chapel-shaped greenhouses does not, however, offer-even by having the same known characteristics in combination of the state of the art, as described in the above mentioned patents, i.e. without the adjunction of other characteristics sought simultaneously:
An integral water-tightness for the structure; The double water-tight partition allowing the circulation of a heat conducting fluid or the creation of a relative vacuum and therefore a more efficient thermal insulations; An easiness during the fitting process with, to the extreme extent, the absence of complicated and costly preparation for ground or yard work and foundations, even on an uneven land; and A series manufacture of a limited number of identical elements which may serve in constructing final structures of various dimensions.
These four characteristics being sought are particularly interesting when it is being intended on economic and energetic levels to use greenhouses in arid and hostile environments, and domes for housing purposes in hostile environments and submarine bells for tourist use.
SUMMARY OF THE INVENTION
The process according to the present invention overcomes at least the aforementioned disadvantages or shortcomings in the prior art. In fact, it consists, according to a first characteristic, in manufacturing on a series basis and then assembling a finite number of two or more types of triangular structures with rectangular, isosceles or equilateral form having the following characteristics:
Monobloc triangular structure made of a section covered in a plastic material. The plastic material may, moreover, be a heat-hardening resin or a thermoplastic polymer, a paste which has plastic properties during the manufacturing process, such as a plaster—or cement—based paste. As for this case, a person of ordinary skill in the art can adapt the mould and select the mostly adequate moulding process depending on the material being used; Having a top or outer thickness, i.e., length, greater than a bottom or inner surface thickness (length) to form an angled outer surface, and an inner shouldering allowing for inclusion of a double wall, where a side panel is positioned on each side of the inner shoulder; Having a groove for inserting seal members to provide a watertight seal with adjacent structures; Having certain angular faces allowing assembling in dihedron of groups of triangles; and/or Showing at their tops (i.e., apexes) such indentations which complement, through a cylindrical piece embedded during the assembling process, both the fixation of final structures to the ground and the water-tight tackling of the covering surfaces of the triangular structures.
According to an embodiment and referring to FIG. 1 , the triangular shape structural elements can be formed from steel sections, such as rectangular tubes that are cut and welded according to a specific template. The rectangular tube sections are positioned at predetermined distances between the inner walls of a female mould. The walls may already be pre-covered with polyester resin layered with fiberglass. After closing the three parts of the mould, polyurethane foam is injected. The use of the mould ensures the series manufacturing of triangular structures perfectly identical, including the angles necessary to assembling.
During the coating process for the inner walls of the mould using polyester resin layered with fiberglass, parallel grooves may be formed on the three outer faces (i.e., outer surfaces) into the triangle thickness. These grooves can receive a seal member that is used to form at least a watertight seal with an adjacent triangular structure. A watertight environment is ensured by the fact that during the assembling process, each triangular structure provides and receives a watertight seal with of the adjacent triangular structure. Each outer face of a triangular structure is then served by at least two watertight seals despite the even or odd (i.e., alternating) position within the assembling sequence of the different shaped triangular elements. The outer and inner sides from both sides of the sealing members between two adjacent triangular structures can accordingly be fully insulated.
During the coating process of the inner walls of the mould using the polyester resin layered with fiberglass, an indentation at the level of each top of a triangular structure can be formed. Such indentations are shaped in a circular arch, such that when multiple monobloc structures are positioned adjacently side-by-side, a complete cylindrical channel is formed by the joined apexes of the multiple monobloc structures. The housings of seal members are successive within the indentations. In each of such indentations, a groove may be provided in the middle point of other indentations in order to receive a seal member to perfect the watertight ability of the cylindrical piece embedded in the channel mentioned above during the assembling process. This cylindrical piece can serve as a particular knot (i.e., connector) device to secure the whole final structure in a form of dome or chapel-shape to the ground (i.e., Earth), using cables and/or steel tubes as anchors. Such cylindrical connector can also serve as support for levers provided to chuck the covered surfaces of the triangular structures, as described below in further detail with respect to FIG. 7 .
Each monobloc triangular structure can include, by reason of the form of the section, a shouldering formed over the inner faces of its thickness. The sides of the shouldering can include one or more grooves, which can be formed during the coating process for the inner walls of the mould by the polyester resin layered with fiberglass. The grooves can house a seal member to provide a watertight seal with a cover or side panel. Optionally, the sides of the shouldering and the watertight seals can be fitted with covering surfaces (e.g., side panels) to form a double wall, which are chucked to the sides of the shouldering. Such covering surfaces can be fabricated from glass material, polycarbonates, Plexiglas or any other material, even non hard material, such as a plastic film. The covering surfaces can be chucked against the watertight seals using hard metallic frames, which are secured to levers using adjustable tightening screws.
In an embodiment, there can be provided along the thickness of each side of the triangular structure during the shaping process of the section, three hollowing-outs (i.e., channels), as follows:
A central channel ensures communication of the confined space present in the double wall of two adjacent triangular structures. A heat-conducting fluid, such as water may then circulate from one triangular structure to another and then through the whole final structure in a direction which can be induced by means of a pump. To that fluid, a pigment can be added to color it and/or make it more or less opaque. Thus, an excess of heat may be diminished or, to the contrary, heat transmitted by the envelope, and then made watertight, may be brought along, to the hermetically closed space formed by the inner volume on the dome-shaped or chapel-shaped final structure. Also, by air aspiration, a relative vacuum within the thickness may be created, thereby increasing the insulation of the structure's inner space from the outer environment.
The other two channels located from both sides of the central channel can serve to introduce threaded, slightly curved and/or straight rods depending on the dihedron being present. Such rods can secure, using such nuts and wedges which perfectly embed into the channels the sides of two adjacent structures.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages and features of the present invention will become apparent from the detailed description of a preferred embodiment of the invention with reference to the accompanying drawings, in which:
FIG. 1 depicts a cross-sectional view of a mould with a triangular structure of the present invention being formed therein;
FIG. 2 depicts a right, outer surface perspective view of the triangular structure of the present invention manufactured using the mould of FIG. 1 ;
FIG. 3 depicts a cross-section view of the assembly in a dihedron of two adjacent triangular structures which include angled edges that interface to form a dihedron angle;
FIG. 4 depicts a cross-section view in dihedron of two triangular structures connected together at their apexes with a cylindrical connector, and opposing side panels positioned over the outer and inner areas of the triangular structure which are secured by radially extending levers and rigid chucking frames;
FIG. 5 depicts an assembling method of configuring equilateral and isosceles shaped triangular structures of the present invention to form a truncated cone icosahedrons in a manner suitable to double its volume;
FIG. 6 depicts an assembling method of configuring equilateral and right angle triangles in groups to form larger hexagon and rectangular shaped elements, which collectively form a greenhouse in a manner suitable to double its volume; and
FIG. 7 depicts a top perspective view of adjacent triangles of the present invention having side panels secured thereover.
To facilitate understanding of the invention, identical reference numerals have been used, when appropriate, to designate the same or similar elements that are common to the figures. Further, unless stated otherwise, the drawings shown and discussed in the figures are not drawn to scale, but are shown for illustrative purposes only.
DETAILED DESCRIPTION OF THE INVENTION
By reference to those drawings, and particularly FIGS. 1 and 2 , each triangular structural element ( 200 ) is preferably fabricated using a mould ( 100 ). In one embodiment, the process includes coating, with polyester resin layered with fiberglass or with other coating plastic material ( 1 ), the inner faces ( 102 ) of a mould ( 100 ) so as to include all its inner matrix. An elongated section ( 3 ), which was previously cut and welded in a template according to the type of triangle (e.g., equilateral, isosceles, right angle) and the height levels chosen, is placed at the bottom of the mould ( 100 ). Such section ( 3 ) is maintained at a definite distance from the mould walls ( 102 ) using the edges provided in the mould walls and penetrating the section. After closing the parts of the mould, an annular cavity ( 208 ) is formed between the section ( 3 ) and the inner surface of the coating material ( 1 ). A polyurethane foam ( 4 ) is injected into the cavity ( 208 ) to form the three leg members ( 5 a ), ( 5 b ) and ( 5 c ) (collectively leg members ( 5 )) of the triangular structure ( 200 ).
Referring to FIGS. 2 and 3 , the triangular structure ( 200 ) obtained after hardening of the polyester resin ( 1 ) and the polyurethane foam ( 4 ) is:
A monobloc structure ( 200 ), having an outer surface ( 202 ), inner surface ( 204 ) and opposing side surfaces ( 206 ). The interior part of leg members ( 5 ) is empty due to the use of the section ( 3 ), thereby forming an annular cavity ( 208 ). The polyurethane foam ( 4 ) fills the annular cavity ( 208 ) to provide insulation. A structure, the tops (i.e., apexes) ( 6 ) of which include no external joints, due to the plastic coating ( 1 ). A triangular structure ( 200 ), the tops of which include indentations ( 7 ) in form of a well-defined circular arch. On the face (i.e., outer surface) of each leg member ( 5 ) of a given structure includes grooves ( 8 ). The raised shouldering ( 9 ) formed on inner faces ( 204 ) of each leg member ( 5 ) of a triangular structure ( 200 ) includes a groove ( 10 ) on both its side edges ( 404 ), the groove ( 10 ) sized to receive a watertight seal member ( 28 ) (see FIG. 4 ). A structure including at least one leg member ( 5 ) having opposing sides with different thickness ( 11 ), e.g., heights, to form an angled (sloping) outer surface ( 40 ) extending between the opposing sides. A structure which shows on each of its faces at least three ports ( 12 ) corresponding to channels ( 14 ) designed into the section ( 3 ).
In the embodiment according to FIG. 3 , two triangular structures ( 200 1 ) and ( 200 2 ) are assembled according to a definite (i.e., predetermined) angle and make a dihedron ( 13 ) which contributes during the assembling process of the whole triangular structures to the construction of a dome having the form of truncated icosahedrons or of a chapel-shaped greenhouse. The dihedron angle ( 13 ) is formed by aligning the angled outer surface ( 40 ) of adjacent triangular elements together. Both channels (e.g., upper and lower channels) ( 14 ) then formed, in the two structures, by a rectangular tube section are positioned face-to-face so as to form a port ( 12 ) in the thickness of the polyester resin layered with glass fiber ( 1 ). A threaded and slightly curved rod ( 15 ) is introduced during the assembling process through the two channels ( 14 ) and secures the structures ( 200 1 ) and ( 200 2 ) by means of nuts and wedges ( 16 ), which tightly embed within the section ( 3 ). The seal members ( 17 ) are placed into grooves ( 8 ) during the assembling process so as between the sides of two adjacent triangular structures ( 200 1 ) and ( 200 2 ); there exist already two parallel seal members both which close around one of the two triangular structures.
In the embodiment according to FIG. 4 , the knot or connector device ( 406 ) at the top (i.e., apex) of a set of triangular structures assembled, is a cylinder ( 18 ) which is embedded in the hollow (i.e., aperture) formed by the indentations ( 7 ) joined together. Such cylinder ( 18 ) closes hermetically at the two edges by two lids ( 19 ) which hug the dihedral angle ( 13 ). Such cylinder ( 18 ) includes in its middle point a seal member ( 402 ), which is placed during the assembling process between two parallel seal members ( 8 ) carried by the triangular structures, into a groove ( 20 ) which is provided to it within the indentations ( 7 ) of each triangular structure. The two cylinder lids ( 19 ) are crossed by a threaded rod ( 21 ) which contains in its outer part:
A device ( 22 ) on which securing-to-ground cables and/or tubes are fixed; Referring to FIG. 7 , two opposing levers ( 23 ), each of which makes a bissectrix on one of the two covered surfaces. Each lever ( 23 ), through an adjustable tightening screw ( 25 ) and three arms ( 27 ), secures a rigid frame ( 26 ) extending along the perimeter over the seal members ( 28 ) inserted in the grooves ( 10 ) formed in the opposing sidewalls ( 404 ) of the raised shoulder ( 9 ). Each arm ( 27 ) has a distal end extending to the frame ( 26 ) and positioned between two apexes of the triangular structure, and the opposing proximate ends of the arms ( 27 ) joined together and attached to the tightening screw ( 25 ) above the barycentre of the triangle formed by the covering surface ( 24 ). One end of the lever ( 23 ) is attached to the tightening screw ( 25 ) and the opposing end of the lever ( 23 ) is attached to the connector device ( 406 ). The rigid frames ( 26 ) thereby chuck the covering surfaces ( 24 ) against the seal members ( 28 ) provided in each side ( 404 ) of the inner shouldering ( 9 ) of the triangular structure ( 200 ).
In the illustrative embodiment shown in FIG. 5 , the assembly of six equilateral triangular structures can be used to form a hexagon ( 29 ) and five isosceles triangular structures can be used to form a pentagon ( 30 ), which collectively contributes to manufacturing a final structure of a dome ( 500 ) that is constructed in the form of truncated icosahedrons. However, the assembly of four equilateral triangular structures ( 31 ) to form a triangular structure with double dimension allows to form a hexagon of double size; this can be achieved by handling the order and the angle modifying the thickness of one of the sides of the elementary triangular structures during the moulding process. By this process, also applied to pentagon, we can achieve a doubling of the overall volume of the constructed dome.
In the illustrative embodiment shown in FIG. 6 , the assembly of six equilateral triangular structures can be used to form a hexagon ( 29 ). A plurality of right triangular structures ( 32 ) can be added in order to transform the hexagon ( 29 ) into a square shaped structure ( 33 ), which can further be used to form a portion of a final structure such as a chapel-shaped greenhouse ( 600 ). However, the assembly of two squares ( 33 ) into one rectangle can also be achieved by handling the order and the angle modifying the thickness of one side of the elementary triangular structures during the moulding process, which can double the height of the final structure and thereby allow constructing a chapel-shaped greenhouse twice as large in size.
Further embodiments of the triangular elements can include:
Equilateral, isosceles and right triangular structures elaborated during the moulding process without an over thickness ( 11 ) i.e., without a beveled an angled edge along of one of their sides (e.g., leg 5 a of FIG. 2 ) and accordingly without any dihedral angle ( 13 ) may, when assembled, form perfectly plane structures with double wall. These triangular structures without an angled edge can serve, subsequently, as walls, slabs and other additive elements in construction of geodesic domes and chapel-shaped greenhouses. Triangular structures showing a curvature in space dimensions may be moulded when each of the three sides of a structure is itself moulded in a curved shape in the direction of the structure's overall curvature. Such structures contribute, when assembled, to obtaining an entirely spherical form.
As non-limitative example, the process uses series monobloc pre-fabricated triangular structures which will have the shape of equilateral, isosceles and right triangle. In the case of a triangular structure having the shape of an equilateral triangle, the dimensions illustratively can be about 0.80 meter in length per leg, 0.10 to 0.06 meters in thickness and make a double wall of 0.4 meters in depth.
The process according to the present invention is particularly suitable for manufacturing domes in series (proceeding from truncated icosahedrons), chapel-shaped greenhouses, and submarine bells.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. | Triangular elements for forming geodesic structures each have three elongated leg members arranged end-to-end to form three apexes. At least one of the apexes is formed with a curved-shaped indentation which extends along an outer surface and perpendicular to the opposing side surfaces. The legs of each triangular element also include one or more outer grooves extending longitudinally along the outer surface. Each outer groove is sized to receive a seal member. An inwardly raised shoulder extends longitudinally along the inner surface. An inner groove is formed along a side edge of the raised shoulder and each inner groove is sized to receive a seal member. Panels are positioned over the opposing sides to form double-walled triangular element. Channels extend through the outer surface and raised shoulder of the inner surface. The triangular elements are arranged to form a geodesic structure and fasteners extend through the channels to secure adjacent triangular elements. | 8 |
FIELD OF THE INVENTION
The present invention is related to a cooling device for a transmission in a washing machine.
A conventional washing machine comprises an external cabinet, a tub mounted within the external cabinet for containing washing and rinse water, a basket rotatively mounted in the tub, and an agitator mounted within the basket with oscillatory rotation in both directions i.e. clockwise and counter-clockwise. Rotational force of a motor positioned below the tub is transmitted to the transmission via a pulley and a belt arrangement. The agitator or tub is rotated by transmission shafts under the selective control of the transmission. The conventional transmission includes a planetary gear train and a housing enclosing the planetary gear train. With the rotational reduction of the planetary gear train, the rotational force of the pulley is transmitted to the agitator at a reduced rotational speed. Heat generated during the rotation of the transmission radiates through the housing. A typical conventional transmission is shown in Japanese Utility Model Laid-Open No. 1989-66289. The external surface area of the housing of this transmission is not sufficient in that the surface area cannot satisfactorily radiate the heat produced by the frictional engagement of the planetary gear train during a reduction of rotational output. Further, the transmission can not achieve adequate radiation from natural convection alone. Because of these effects, the life of the planetary gear train, made of an organic resin, is shortened. Furthermore, the operational efficiency of the washing machine is decreased due to the thermal expansion of the planetary gear train.
SUMMARY OF THE INVENTION
An object of the present invention is to provide a cooling device which can sufficiently radiate heat generated by gearing of a washing machine transmission by the increasing the surface area of the transmission available for heat radiation generated during use.
Another object of the present invention is to provide a cooling device which forceably convects the heat radiated by the transmission thereby extending the life of the transmission, and increasing the operating efficiency of the washing machine.
In accordance with the present invention, the cooling device for transmission comprises passive cooling members and an active cooling member. The passive cooling members provide a housing for the transmission which transmits rotational force of the motor to the basket and the agitator respectively, and reduces heat generated by operation of the reduction member mounted therein. Further, the passive cooling members consist of an upper and a lower cup, with each of the cups having a plurality of openings formed therein for enable air communication therethrough. The reduction member consists of a case drum and a gear case in which a planetary gear train is included. The case drum includes a plurality of opening formed therein to enable air communication therethrough. The active cooling member is mounted on a pulley which transmits rotational force from the motor to the transmission, and communicates with the passive cooling members by forcing cooling air to the passive cooling member.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of the transmission with a cooling device according to the present invention; and
FIG. 2 is an exposed view illustrating the cooling device according to the present invention.
DETAILED DESCRIPTION
Referring to FIG. 1, a basket 2 for washing and rinsing (partially shown) contains an agitator 4 for agitating in both a clockwise and counter-clockwise directions is installed in the basket 2. Pulley 15 transmits rotational force of the motor (not shown) to the transmission 1. The pulley 15 is connected with the transmission 1 through a first driving shaft 7 and a second driving shaft 8. The transmission 1 is connected with the agitator 4 by a first driven shaft 5 and is connected with the basket 2 by a second driven shaft 3.
The transmission 1 comprises passive cooling members 13,14 which function as a housing for the transmission 1 and also radiate the heat generated therein, and a reduction member 200 transmits the rotational force of the pulley 15 to the agitator 4 and the basket 2, respectively. As shown in FIG. 2, the reduction member 200 comprises a case drum 6 with a ring gear 12, usually made of an organic resin, operatively positioned on an internal surface thereof and the second driving shaft 8. An upper circular portion of the second driving shaft 8 connects securely with a lower portion of the case drum 6, and a lower protrusive portion of the second driving shaft 8 connects rotatably in a bushing with the first driving shaft 7. A plurality of openings 23 are formed in a circular portion of the case drum 6 which adjoins the upper circular line of the ring gear 12. Inside the case drum 6 planetary gears 11, which mesh with the ring gear 12, are positioned. The planetary gear system consists of four pinions 11A, top plate 9A and bottom plate 9B, and four pins 11B engaging the pinions 11A with the top and the bottom plates 9A, 9b. The pinions 11A are usually made of a organic resin material. To work the planetary gears 11, a sun gear 10 is provided at the top end of the first driving shaft 7 and the external teeth of the sun gear 10 are molded of a resin. A driven gear 9 is provided at the bottom end of the first driven shaft 5 so that the driven gear 9 is driven by the planetary motion of the planetary gears 11 and the external teeth of the driven gear are molded of a resin. The first driven shaft 5 is assembled rotatively in a bushing with the second driven shaft 3. A top end of the second driven shaft 3 is bolted to the basket 2. The middle portion of the second driven shaft 3 is support by a bearing 3A, and the bottom portion thereof is assembled tightly in an upper protrusive portion of the case drum 6. The passive cooling member 13, 14 consists of a lower cup 13 which is formed as a downward extended cylinder having a step shown in FIG. 2, and an upper cup 14 which is formed as an upward extended cylinder and assembled with the lower cup 13. A lower hub 14B of the upper cup 14 has a plurality of openings 21 formed along a circular portion of the lower hub 14B. A middle hub 13A of the lower cup 13 is formed so that the column portion of the gear case 8 is supported by a bearing 8A placed in the middle hub 13A. A lower hub 13B of the lower cup 13 has a plurality of openings 22 formed along a circular portion of the lower hub 13B. A flange 13C of the lower cup 13 and a flange 14C of the upper cup 14 are formed integrally with the lower hub 13B, 14B, respectively. The flanges 13C, 14C are formed as an approximated square and assembled with a crossmember (not shown). It is desirable to have a large surface for enhancing maximum radiation from the upper cup 14 and the lower cup 13. The active cooling device 20, e.g. a plurality of blades for forcing the movement of air, is formed on an upper surface of the pulley 15. The active cooling device 20 rotates as pulley 15 is rotated, so the air neighboring the active cooling device 20 is forced toward the transmission 1.
As a result of the above structure, the pulley 15 is oscillated by the motor, and the rotational force of the pulley 15 is transmitted to the first driving shaft 7 via a selective connection of a coupling 16. The sun gear 10 of the first driving shaft 7 rotates the planetary gears 11, and the planetary gears 11 rotate the first driven shaft 5 via the driven gear 9. At this time, heat is generated from the operation of the planetary gear train 10, 11, 12. The heat flows to the cooler exterior surface of the passive cooling members 13, 14 through the reduction member 200. This transferred heat then radiates from the surface of the passive cooling members 13, 14. Furthermore, the heat from the surface of the passive cooling member 13, 14 is forcibly moved by the air generated by the active cooling device 20 on the pulley 15. The air is fed into the cooling device 1 through the plurality of openings 22. The air is forced into and out of the reduction device 200 through the plurality of openings 23 of the case drum 6. The heated air of the reduction member 200 is forced out through the plurality of openings 21 of the upper cup 13.
Therefore, the heat of the reduction member 200 is removed in a more efficient manner, and thus prevents the planet gear train from wear causing excessive heat. | A washing machine includes a tub in which a basket and agitator are mounted. A transmission produces rotation of the basket and oscillation of the agitator. A shaft transmits rotary motion to the transmission from a motor via a pulley mounted on the shaft. The transmission includes a housing having heat conducting openings. Blades are mounted on the pulley for forcing air through the openings during rotation of the shaft. | 3 |
BACKGROUND OF THE INVENTION
I. Field of the Invention
The present invention relates generally to securing devices. More particularly, the present invention concerns a securing device for fixing a rod in position. Even more particularly, the present invention provides a securing device for securing an automotive hatchback in an open position.
II. Prior Art
Vehicles having a hatchback-type door have become increasingly popular as the consumer trend towards sportier, more fuel-efficient vehicles continues. Typically, two liftgate supports, one disposed on each side of the hatchback-type door, secure the hatchback in the raised position. After several years of usage or during freezing temperatures, these liftgate supports eventually malfunction, creating a safety hazard to anyone loading or unloading items from the back of the vehicle.
Heretofore, the art has proposed means for preventing the liftgates and other vehicular components from collapsing. For example, U.S. Pat. No. 2,671,355 issued to Hawkins discloses a holding device to retain a vehicle hood or trunk in a raised position. The device includes two members engaged in a telescoping relationship. The holding device includes a first tubular member that slidably receives a rod together with a coiled spring urged locking dog. The locking dog engages the rod with respect to the tubular member, so as to retain the hood or the trunk raised by a pre-determined amount.
In U.S. Pat. No. 4,415,194 there is disclosed a vehicular hatchback-type door closure system which is designed to prevent the downward pivotal rotation of the hatchback-type door. A pair of telescoping struts are positioned such that the studs that secure the strut to the hatchback-type door come into a wedging engagement with the struts to limit the clockwise rotation of the hatchback-type door.
U.S. Pat. No. 5,024,303 issued to Kosloff discloses a hatchback locking device to retain a hatchback-type door of a vehicle in an open position. The locking device comprises a two piece body member where the two pieces are hingedly connected so they may be fit around the liftgate support and then be fastened. The body member is secured to a housing cylinder by two sided tape proximate to where the elongated piston rod is received by the housing cylinder. The two-piece member is expensive to produce and, once attached with tape, is difficult to remove from the housing cylinder.
U.S. Pat. No. Des. 296,866 issued to Behring discloses a lockable sleeve that slips onto the elongated piston rod of the liftgate support to secure the liftgate door in the raised position. The lockable sleeve must then be removed from the liftgate support to lower the hatchback-type door. The sleeve is cumbersome to use and store and can easily damage the liftgate support or the hatchback-type door.
In addition, the Polyon Manufacturing Company has developed a spring-loaded brace for after-market installation that automatically retains a liftgate support of a hatchback-type door in an open position. The brace is expensive and detracts from the appearance of the vehicle when the hatchback-type door is opened.
It is to be appreciated that the prior art devices are cumbersome to install; difficult to manipulate as well as being expensive to manufacture.
What is needed is a securing device that overcomes all of the disadvantages as an after-market lock that is fitted onto one of the liftgate supports, the securing device being universally adapted to virtually any type of cylinder rod.
SUMMARY OF THE INVENTION
The present invention provides a device for housing and securing an elongated rod, the device comprising:
(a) first and second interdigitating opposedly arranged body portions, each of the first and second body portions having an outer surface and an inner surface, each of the first and second body portions having a pedestal and a foot, the foot of the first body portion seating rearwardly of the pedestal of the second body portion and the pedestal of the second body portion seating rearwardly of the foot of the first body portion upon interdigitation, the interdigitated first and second body portions cooperating to define a body member having a central aperture formed therethrough in which the elongated rod is slidably positionable relative to the body member;
(b) at least one locking member for locking the first and second body portions together and securing the body member to the rod thereby precluding the slidable movement of the elongated rod relative to the body member.
Each of the two body portions has a threaded channel formed therein so that when the two body portions are interdigitated, the resulting body member has two channels drawn from its outer surface to its inner surface.
A locking member, such as a screw, fits into either of the two channels and functions to secure the two body portions together, while allowing the elongated rod to slidably move through the central aperture when not engaged therewith.
When fitted further, the threaded screw secures the elongated rod in position by pressing it against the inner surface of the body member. The housing and securing device is now in a fully locked position. In the fully locked position, the body member restricts the movement of the elongated rod into the hydraulic or pneumatic cylinder of a hatchback door mechanism. The elongated rod does not move relative to the body member and the body member cannot fit into the hydraulic or pneumatic cylinder. Therefore, the hatchback-type door is held in an open position until the locking member is withdrawn to the semi-locked position.
The present invention will be more clearly understood with reference to the accompanying drawings. Throughout the various figures, like reference numerals refer to like parts in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view depicting a preferred embodiment of the housing and securing device;
FIG. 2 is a perspective view depicting housing and securing device hereof in an unassembled state;
FIG. 3 is a top view of the housing and securing device hereof in a semi-locked configuration;
FIG. 4 is a top view of the preferred embodiment of the housing and securing device hereof in a fully locked configuration; and
FIG. 5 is an environmental view of the preferred embodiment of the housing and securing device hereof as implemented in a liftgate support system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, a preferred embodiment of the housing and securing device of the present invention is depicted, generally, at 10. The housing and securing device 10 includes a body member 12 and a locking member 14. The body member 12 is, generally toroidal in shape and has a first aperture 16 which is designed to slidably encircle an elongated rod 18, such as a piston or rod. The body member may be formed of a variety of materials including various hard plastics or metals.
As shown in FIG. 2, two body portions 20, 20', which are substantially identical and opposedly arrayed, interdigitate to form the body member 12, the two body portions 20, 20' are substantially identical, thus reducing the number of machining steps necessary to produce the locking device 10. For clarity, the description will only reference one of the substantially identical body portions 20, 20'.
The body portion 20, has an outer surface 22, an inner surface 24, and a helically threaded channel 26, drawn between its outer surface 22, and inner surface 24, respectively.
The inner surface 24, of the body portion 20, has a first interdigitating member or foot 28, and a second interdigitating member or pedestal 30.
As shown, the two body portions are opposedly arranged so that the first interdigitating member, or foot 28 of each body portion 20, interdigitates with the second interdigitating member 30, of the other body portion 20, to form the body member 12.
The first intedigitating member 28, of the body portion 20, includes a flange 32.
When the two opposedly arranged body portions 20, 20' are interlocked, the flange 32, defines a portion of the edge of the first aperture 16 formed through the body member 12. The flange 32, has a semi-circular notch 33, cut into it. The semi-circular notch 33, of the flange communicates and is coaxial with the helically threaded channel 26, of the opposedly arranged body portion 20.
More particularly, and as shown in the drawing, the pedestal 30 extends inwardly from the periphery or perimeter of the surface 22. A u-shaped core or recess is provided rearwardly of the pedestal 30, as shown. The recess has a width slightly larger than that of the opposed foot 28' of the other body member so that it nests therein.
Each foot 28 or 28' is disposed or formed interiorly of the respective body portion, as shown.
Each body portion has a shoulder 35,35' formed above the interior opening above the associated channel 26, or 26'. The opposed foot 28 or 28' seats in the opposed shoulder upon interdigitation with its associated notch, cooperating to "round off" the interior opening, as shown. The interior portion of each foot nests in an opposed recess 31 or 31'. Likewise, the interior portion of each pedestal nests in the cut-out provided rearwardly of each foot, as shown.
A locking member 14 such as a helically threaded fastener or screw 34 may be projected or threaded through a channel 26 to lock the two body portions together as well as to secure the device 10 to the rod 18.
The helically threaded fastener has a threaded portion 36, a bearing surface 38 and a finger portion 40. The threaded portion 38 of the locking member 14 is helically threaded so as to be received by either of the helically threaded channels 26 of the two substantially identical body portions 20, 20'. Additionally, the bearing surface 38 of the locking member 14 is preferably made of a soft metal or plastic to prevent damage to the elongated rod 18. The finger portion 40 is designed to allow a person to easily grasp and turn the fastener 34.
As shown in FIG. 3, when the body portions 20, 20' are interdigitated and the helically threaded fastener 34 is inserted into one of the helically threaded channels 26, 26' so that the bearing surface 38 of the helically threaded fastener 34 is just short of protruding into the first aperture 16 of the body member 12, the two portions are secured together although the rod is not secured, since the fastener has a length greater than either channel. This is the semi-locked configuration.
In this configuration, a small section 40 of the helically threaded portion 36 of the helically threaded fastener 34 engages the semi-circular notch 33, 33' of the flange 32, 32' on the first interdigitating member 28 or 28' of the opposedly arranged body portion 20, 20'. The elongated rod 18 may still slidably move within the aperture 16 of the body member 12 in this configuration.
As shown in FIG. 4, when the bearing surface 38 of the helically threaded fastener 34 protrudes into the first aperture 16 of the body member 12 and bears against the elongated rod 18, the two body portions 20, 20' are locked together and the elongated rod 18 is held in place relative to the body member 12.
Referring now to FIG. 5, the present invention is particularly adapted for use in preventing unwanted slippage of a vehicular hatch-back support such as that depicted at 42. The liftgate support 42 is secured to a hatchback-type door 44 of a passenger vehicle 46 in the well-known manner.
The liftgate support includes a housing cylinder 48 and an elongated piston rod 50. The elongated piston rod 50 is slidably positionable relative to the housing cylinder 48 along the longitudinal axis of the elongated piston rod 50. One end of the housing cylinder 48 is attachable to the vehicle 46 and one end of the elongated piston rod 50 is attachable to the hatchback-type door 44. One end 52 of the elongated piston rod 50 is received within the housing cylinder 48. The locking device 10 rests upon the housing cylinder 48.
The locking device 10 is positioned about the elongated piston rod 50 by placing each of the opposedly arranged body portions 20, 20' about the elongated piston rod. The two body portions are then interdigitated along the longitudinal axis of the elongated piston rod 50 to form the body member 12. The helically threaded fastener 34 is then threaded into either of the helically threaded channels 26, 26' and rotated clockwise until it achieves the configuration of FIG. 4, where the locking device 10 slidably retains the elongated piston rod 50.
To fully lock the piston rod 50 in the open position, the helically threaded fastener 34 is turned clockwise until it reaches the position depicted in FIG. 5.
In this configuration, the elongated piston rod 50 will not slide through the aperture 16 formed in the body member 12. The body member abuts the far end of the housing cylinder 48. Therefore, the elongated piston rod 50 may not slide into the housing cylinder 48. Accordingly, the hatchback-type door 44 is held in an open position.
When the helically threaded fastener 34 is subsequently turned counter-clockwise so that it conforms to the configuration depicted in FIG. 3, the body member 12 remains locked about the elongated piston rod 50 which is once again slidable within the aperture 16 formed through the body member 12. In this way, the hatchback-type door may be closed or opened.
The present invention provides an extremely cost effective way for retaining a hatchback-type door in an open position when the liftgate support has failed to function properly.
Additionally, the present invention may be utilized in a variety of other contexts including as a screen door stopper, a boom extension, and a tip-up for fishing, etc.
As will be realized, the invention is capable of other and different embodiments and its several details are capable of modifications in various obvious respects, all without departing from the invention. | A locking device for use with a conventional liftgate support to retain a hatchback-type door of a vehicle in an open position. The locking device of the present invention is for use with a liftgate support to retain a hatchback-type door in an open position even in cold weather or after the liftgate support has worn out. The locking device is defined by a pair of opposed interdigitating body portions which encircle the rod. A threaded member locks the two portions together and secures the device to the rod. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a recording/reproducing apparatus which records data on a recording medium having a large capacity and has an area for managing the data recorded on the recording medium.
[0003] The present invention also relates to a recording/reproducing apparatus which records data in units having different sizes, and a recording/reproducing method and a recording medium therefor.
[0004] 2. Description of the Related Art
[0005] Recording/reproducing apparatuses for CDs (Compact Discs) and DVDs (Digital Versatile Discs) using optical disks as their recording media are widely used and are expected to increase in their recording capacity.
[0006] FIG. 5 shows a data structure used in the user data area in a DVD. In the figure, parities are added to user data in two different directions. Reference numeral 51 denotes the user data, specifically, one recorded data block made up of 16 sectors, from sector 0 to sector 15 . Reference numeral 52 denotes the PI parity added in the row direction, while reference numeral 53 denotes the PO parity added in the column direction. Since the parities are added in the row and column directions as shown in the figure, decreasing the number of the sectors (currently 16 sectors) or decreasing the number of pieces of the user data to be employed without changing the number of parities requires a significant change in the recorded data block structure. Further, if the method for adding the parities is changed, it is necessary to carry out different decoding operations for the ordinary parity and the parity for the altered data block structure in the reproduction, which complicates the configuration of the decode circuit and deteriorates the error correction capability. Therefore, practically, the data must be recorded in minimum record block units of 32K bytes even when information to be recorded is small. Thus, a small data unit is difficult to record in the data structure of the conventional DVD.
[0007] In the field of DVDs, recordable/reproduceable optical disks such as DVD-RAMs, on which data can be recorded a plurality of times, and DVD-Rs, on which data can be recorded only once, have been developed together with their recording/reproducing apparatuses.
[0008] In data recording on a disk, information for which data is recorded is recorded in a specific management area and then read out to carry out the control.
[0009] FIG. 6 shows areas on a DVD-R disk. The area consisting of a PCA (Power Calibration Area) and an RMA (Recording Management Area) indicated by reference numerals 31 and 32 , respectively, is an R-information area, which is the management area for the recorded data. Reference numeral 33 denotes a read-in area, 34 denotes a user data recording area, and 35 denotes a readout area. Generally, the read-in area and the user data area are separated such that their border exists between 02FFFFh and 030000h in terms of ECC block (correcting block) addresses. Further, the size of the RMA area is determined such that the RMA area can record a predetermined number of ECC blocks.
SUMMARY OF THE INVENTION
[0010] As shown in FIG. 6 , the management area has a capacity of a predetermined number of blocks to record management information.
[0011] With this arrangement, if a large minimum data unit for recorded data is used to record a small data amount of management information, the recording time is long, and furthermore when a WO (write once) is used as the recording medium, the number of recording operations which can be performed is restricted depending on the size of the recorded data in the management area. Since data is recorded in units of 32K bytes in a DVD, a 32K-byte area is allocated even to data whose size is less than 32K bytes. Thus, a 32K-byte recording area is consumed each time data is recorded. Therefore, when data is frequently recorded, unless there is storage space left in the management information recording area, it is not possible to record user data even if there is enough storage space left in the user data area. This problem becomes more serious when the user data area is increased by use of a technique providing higher density, etc.
[0012] The present invention has been devised in view of the above problem. It is, therefore, an object of the present invention to suitably record information in a limited management area so as to efficiently use the user data area-when recording data.
[0013] The above problem can be alleviated by recording data in a management area in units smaller than ordinary units for recorded data.
[0014] Specifically, according to the present invention, a method for recording data on a recording medium comprises the steps of: combining predetermined n (n is an integer) number of pieces of data; adding error correcting code to the data; adding addresses to the data; arranging the data in a distributed manner; and, when management information is recorded in a management area, combining and recording predetermined m (m is an integer and smaller than n) number of pieces of data.
[0015] When reproducing data, the present invention combines data in different units each corresponding to an area in the above recording medium from which the (data) signals were reproduced.
[0016] Furthermore, when a plurality of record block sizes are used, the present invention records codes indicating the record block sizes onto the recording medium. By detecting each code, it is possible to carry out reproduction processing corresponding to each record block size.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a diagram showing a method for forming a record block from a larger record block and recording the formed record block according to an embodiment of the present invention;
[0018] FIG. 2 is a diagram showing a data structure of a data unit of data to be recorded on a recording medium according to the embodiment;
[0019] FIG. 3 is a diagram showing a data arrangement in which each 2K bytes of data is put together into one logical block using the record block shown in FIG. 2 ;
[0020] FIG. 4 is a diagram showing a structure of data obtained as a result of adding error correcting code to the 2K-byte logical blocks 1 to 4 included in the record block shown in FIG. 3 ;
[0021] FIG. 5 is a diagram showing the data structure of user data in a DVD;
[0022] FIG. 6 is a diagram showing a configuration of areas on a DVD-R disk;
[0023] FIG. 7 is a diagram showing a 16K-byte recorded data structure formed from the 8K-byte recorded data structure shown in FIG. 1 ;
[0024] FIG. 8 is a diagram showing a 32K-byte recorded data structure formed from the 16K-byte recorded data structure shown in FIG. 7 ;
[0025] FIG. 9 is a diagram showing an example of how areas on a disk are actually assigned to data according to the embodiment of the present invention;
[0026] FIG. 10 is a diagram showing a configuration of a recording apparatus according to the present invention;
[0027] FIG. 11 is a diagram showing a configuration of a reproducing apparatus according to the present invention;
[0028] FIG. 12 is a diagram showing CPR_MAI in the data area in a DVD;
[0029] FIG. 13 is a diagram showing a data structure used to record data in units of 4K bytes according to the present invention;
[0030] FIG. 14 is a sync and subcode arrangement used to record data in units of 4K bytes according to the present invention;
[0031] FIG. 15 is a diagram showing an example in which errors are included in portions of a sync and a subcode when a 4K-byte data structure according to the present invention is reproduced, indicating data positions at which the errors may be present;
[0032] FIG. 16 is another diagram indicating data positions at which errors may be present when the 4K-byte data structure according to the present invention is reproduced; and
[0033] FIG. 17 is a diagram showing a method for processing data to be recorded according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] Symbols (reference numerals) mainly used in the figures indicate the following: 101 denotes signal input; 102 addition of parity; 103 addition of subcode; 104 interleave; 105 modulation; 106 a disk; 107 system control; 109 a semiconductor circuit for processing recording signals; 110 output; 111 a process of putting data together in predetermined units; 112 error correction; 113 address detection; 114 deinterleave; 115 demodulation; and 119 a semiconductor circuit for processing reproducing signals.
[0035] A preferred embodiment of the present invention will be described below with reference to the accompanying drawings. FIGS. 2 and 3 show data structures used to record user data according to the present invention. FIG. 1 shows an example in which the size of a record block is changed according to the present invention. FIG. 4 shows a data arrangement obtained as a result of rearranging the data structure shown in FIG. 3 to actually record the data.
[0036] FIG. 2 shows a data structure of a record unit of data to be recorded on a recording medium according to the present invention. The following description assumes that the recording medium is an optical disk.
[0037] The record block comprises: in each column, 496 bytes; and in each row, a sync (synchronization signal) of one byte, data of 38 bytes, and 3 sets of a burst error detecting subcode of one byte and data of 38 bytes; totaling 77,736 bytes. The arrow indicates the direction in which data is recorded on a disk. The LDC (Long Distance Code) portions constitute user data and are obtained as a result of adding 32 parities to 216 pieces of data, using an RS (Reed Solomon) code. In the figure, the code runs sequentially as a single column indicated by the shaded portion. However, the code may be divided and arranged by means of interleaving.
[0038] FIG. 3 shows a data arrangement in which each 2K bytes of data is put together into one logical block using the record block shown in FIG. 2 . Thus, 32 2K-byte logical blocks can be arranged using the 64K-byte record block. In addition to the above example, the logical blocks may be arranged such that each 2 blocks are aligned in a row.
[0039] FIG. 4 shows the structure of data obtained as a result of adding error correcting code to the 2K-byte logical blocks 1 to 4 shown in FIG. 3 . As shown in the figure, the error correcting code RS ( 248 , 216 , 31 ) is vertically (in the column direction) added to the data. Thus, the figure shows a case in which the error correcting code is added to the vertically aligned logical blocks 1 to 4 . However, the error correcting code may be added to the logical blocks 1 , 16 , 2 , and 17 with the same effect. Thus, the present invention is not limited to a specific combination of logical blocks; any combination may be employed by means of regular interleaving.
[0040] FIG. 1 shows a method for forming and recording a record block smaller than that shown above.
[0041] As shown in FIG. 2 , the record block a comprises: in each column, 496 bytes; and in each row, a sync of one byte, data of 38 bytes, and 3 sets of a burst error detecting subcode of one byte and data of 38 bytes; totaling 77, 736 bytes. The arrow indicates the direction in which the data is recorded on a disk. The record block b 1 comprises: in each column, 62 bytes; and in each row, a sync of one byte, data of 38 bytes, and 3 sets of a burst error detecting subcode of one byte and data of 38 bytes, as in the case of the record block a; totaling 9, 672 bytes. The direction in which data is recorded on a disk is the same as that for the record block a.
[0042] Data of 2048 bytes and an error check code of 4 bytes collectively form a recorded data unit, and the data of the record block a is made up of 32 recorded data units. As for the record block b 1 , data of 2048*4 bytes and an error check code of 4*4 bytes collectively form its minimum recorded data unit. The minimum recorded data unit is rearranged, as indicated by the record block b 2 in the figure, to form a structure (arrangement) similar to that of the record block a which includes RS code (error correcting code), making it possible to use the same method as that employed for the record block a for carrying out RAM control to temporarily store data for signal processing or performing error correction processing. That is, error correcting code and then a subcode are added to the structure of the record block b 2 . When recording the data, the data is recorded as the record block b 1 (using the structure of the record block b 1 ). Since the subcode is a code string of 62 bytes, it may be added as a single column or arranged by means of interleaving.
[0043] Incidentally, data of 2048 bytes are roughly 2K bytes. Accordingly, the record block b 1 has a data structure for recording 8K bytes of data which includes 62 record block units each arranged in a row. However, the record block b 1 is not limited to this specific data structure, that is, this specific number of bytes, 8K bytes. The record block b 1 (that is, its data structure) may be of any size if it can be easily divided and rearranged to form the data structure of the record block a.
[0044] On the other hand, a data structure made up of small blocks such as those described above may make it impossible to interleave the data, deteriorating the error correction capability. To solve this problem, the same data may be recorded a plurality of times or error correcting parities may be added.
[0045] FIG. 7 shows a 16K-byte recorded data structure formed from the 8K-byte recorded data structure shown in FIG. 1 . A 32K-byte recorded data structure also can be easily obtained from the 16K-byte recorded data structure using a similar method. FIG. 8 shows an area in the user data area of a DVD in which copy control information is recorded. In the figure, the area CGMS (Copy Generation Management System) records information on user data, and therefore is not required as management information data. Accordingly, management information may be recorded in this area by coding the size of data to be recorded into a few types of code and recording the code. For example, when 2 bits are assigned to the area CGM, the flag “00” may be used to indicate an 8K byte recorded data. The area for recording such information is not limited to the area CGMS. Any area can be used to record such information if it is used for user data and not included in the management area.
[0046] FIG. 8 shows a data structure larger than that shown above. As shown in FIG. 8 , the record block d comprises 32K bytes of data, which is half of the 64K-byte record block a in size. Since DVDs record data in units of 32K bytes, a record block of this data size can easily be made compatible with a DVD system. With this record block, data to be recorded is added with parities and subcodes and then interleaved such that the data is distributed to enhance the burst error detecting capability. The subcodes may be added after the interleave instead of before the interleave. With the record block a, data is interleaved by adding parities to the data and then, for example, rearranging it. With this arrangement using an interleaving technique, when a burst error has occurred, two apparent burst errors half as long as the actual burst error are detected. Therefore, even in the case where data cannot be serially reproduced due to the burst error, the data may be corrected by use of the added parities if the apparent burst errors are within a distance of error correction by use of interleaving. To obtain such effect, the data is interleaved and then the subcodes added to the interleaved data are also interleaved to enhance the error correction capability.
[0047] Since the record block d includes data smaller than that of the record block a, the same interleaving technique as that for the record block a cannot be applied to the record block d. Accordingly, the subcodes are interleaved within 248 bytes. By using such a method, it is possible to form and record a record block of 32K bytes. In each of the above descriptions, data is put together in units of a number of bytes close to the nth power of 2 (n is an integer). This is not restrictive. To round a fraction, redundant data may be added to produce a number easy to use when combining data.
[0048] FIG. 9 shows an example of how data to be recorded according to the present invention is actually recorded on a disk. The recording disk has arranged thereon a management information area, a read-in area, a user data area, and a readout area, and data is recorded in a predetermined format in each area. Data is recorded in predetermined record blocks having 64K bytes in the user data area. As for the management information area, data is recorded in record blocks having a block size smaller than 64K bytes, namely 4K bytes, 8K bytes, 16K bytes, or 32K bytes. By recording data as described above, it is possible to efficiently record management information in a limited area. It should be noted that even though the management area is provided inside the read-in area in FIG. 9 , this relationship may be reversed.
[0049] Furthermore, if it is known beforehand that there is not enough management area, it may be arranged such that a definition can be established to extend it. For example, the border between the read-in area and the user data area shown in FIG. 5 may not be fixed (even though it is fixed between 02FFFFh and 030000h in terms of ECC block addresses in the figure), and may be changed. In such a case, the position of the changed border can be recorded in the first portion of a specific area such as the management information area to extend the management area if it is known beforehand that a management area of large size is required.
[0050] FIG. 10 shows a configuration of a recording apparatus according to the present invention. Reference numeral 101 denotes a signal input section for inputting data to be recorded; 102 an “addition of parity” section for adding error correcting code; 103 an “addition of subcode” section for adding information such as addresses in a distributed manner; 104 an interleave section for rearranging data; 105 a modulation section for recording data; and 106 a disk on which the data is recorded. Reference numeral 107 denotes a system control circuit for controlling the system, while 109 denotes a semiconductor circuit for processing recording signals. Though not shown, a recording means is provided to record data on a recording medium. The term “a recording means” here denotes, for example, an optical head. A recording means may further include a recording optical system and a laser for recording. The term “a combining means” here indicates a means for putting together data to be recorded on a recording medium in predetermined units so that parities can be added to the data. For example, the process (section) 100 for combining data into predetermined units shown in FIG. 10 is a combining means. It should be noted that if there are a plurality of different data units (that is, each data unit consists of a different number of bytes, etc.) in which data is put together, a different circuit may be used for each data unit, or alternatively a single circuit may be used which is capable of changing the number (of bytes) constituting the data unit. Further, an error correcting code adding means is a means for adding parities to data to be recorded on a recording medium. For example, the “addition of parity” section 102 shown in FIG. 10 is an error correcting code adding means. An error correction code adding means may include a mechanism for storing data in a RAM, etc. and writing/reading the data. It should be noted that if there are a plurality of different data units (that is, each data unit consists of a different number of bytes, etc.) in which data is put together, a different circuit may be used for each data unit as an error correcting code adding means, or alternatively a single circuit may be used for all different data units as an error correcting code adding means by switching among different data units or among different data string units (each having a different number of bytes, etc.).
[0051] The system is controlled such that when data to be recorded is management information and small, each piece of data entered from the signal input section is set to be small and is not subjected to ordinary interleave processing but directly subjected to modulation and recorded on a disk by use of changeover switches after it is added with parities and subcodes. In the figure, the addition of subcode 103 is carried out before the interleave. However, it may be carried out after the interleave, depending on the data to be recorded. Furthermore, even in the above case in which data is not subjected to the ordinary interleave processing by use of the changeover switches, the data may be subjected to simple interleave processing which is suitable for small data to be recorded. The above processing operations may be switched by a changeover signal from the system control 107 or automatically switched by means of address detection performed inside the semiconductor circuit 109 .
[0052] FIG. 11 shows a configuration of a reproducing circuit (apparatus). A reproduced signal from a disk 106 is demodulated by a demodulation section (circuit) 115 and is subjected to address detection by an address detection section 113 . Reference numeral 114 denotes a deinterleave section for rearranging data. The data is subjected to error correction by an error correction section 112 , and output from a terminal 111 after the data is put together in predetermined units. Reference numeral 119 denotes a semiconductor circuit for processing reproducing signals. The term “a demodulating means” here denotes a means for demodulating data in a recording medium. For example, the demodulation circuit 115 in FIG. 11 is a demodulating means. The term “a reproduction combining means” here indicates a means for combining data reproduced from a recording medium in predetermined units corresponding to units in which the data was recorded, in order to carry out error correction. This means corresponds to the process (address detection section) 113 , shown in FIG. 11 , for detecting the address of data and combining the data in predetermined units. It should be noted that if there are a plurality of different data units (that is, each data unit consists of a different number of bytes, etc.) in which data is put together, a different circuit may be used for each data unit, or alternatively a single circuit may be used which is capable of changing the number (of bytes) constituting the error correction data unit based on the address value. Further, an error correcting means is a means for correcting an error in data reproduced from a recording medium. For example, the error correction section 112 shown in FIG. 11 is an error correcting means. An error correcting means may include a mechanism for storing data in a RAM, etc. and writing/reading the data. It should be noted that if there are a plurality of different data units (that is, each data unit consists of a different number of bytes, etc.) in which data is put together, a different circuit may be used for each data unit as an error correcting means, or alternatively a single circuit may be used for all different data units as an error correcting means by switching among different data units or among different data string units (each having a different number of bytes, etc.).
[0053] The system is controlled such that when data to be reproduced is management information and small, the unit of data to be reproduced from a recording medium and error-corrected is set to be small and subjected to error correction. When management information data of small size is read out, the location of the data is checked by means of address detection. By controlling changeover switches, the data is not subjected to the ordinary interleave processing before it is; stored. Then, the data is error-corrected in predetermined record blocks and output.
[0054] FIG. 12 shows the structure of CPR_MAI (Copyright Management Information) 403 in the data area in a DVD. Of available 48 bits, only 4 bits are currently used. Reference numeral b 47 denotes CPM (Copyrighted Material) which indicates whether this sector includes a copyrighted material; b 46 denotes CP_SEC which indicates whether this sector has a specific data structure for a copyright protection system; and b 45 and b 44 denote CGMS (Copy Generation Management System) which records copy restriction information. Information on control of data copying must be recorded in the data area. However, copy information such as CGMS need not be recorded in the management area. Accordingly, the following arrangement can be made. The size of a record block in the management area may be coded into a code of 2 bits which is then recorded in the CGMS 2-bit area, making it possible to obtain the size of the record block.
[0055] FIG. 13 shows a data structure used to record data in units of 4K bytes. In the figure, reference numerals A to H each denote a data unit having 19 bytes in each row and 31 bytes in each column. A record block e 2 comprises: two subcode strings each having 62 bytes including parities; and 19 code strings each having 248 bytes arranged in a column. These data units (the record block e 2 ) are rearranged into a record block e 1 having a data structure comprising 31 bytes in each column and 156 bytes in each row. By using such a data structure, it is possible to record data having a size of 4K bytes. Incidentally, if the subcode strings s 1 and s 2 in the record block e 2 are divided and rearranged as they are, the positions of the syncs after the rearrangement do not match the arrangement of the user data in the record block e 1 .
[0056] To solve this problem, as shown in FIG. 14 , the syncs are inserted into specific portions in the structure of the code strings s 1 and s 2 , and data, such as address information, and parities added to the data are put in the other portions. By using such a data structure of the subcodes, it is possible to match the positions of the syncs with the arrangement of the user data.
[0057] FIG. 15 shows an example in which errors are included in portions of a sync and a subcode when the 4K-byte data structure illustrated in FIGS. 13 and 14 is reproduced. In the figure, a sync N.G. and a subcode N.G. are indicated as error examples. Specifically, when a sync is not properly detected or erroneous data is included in error correcting code for subcode, the subsequent string must be processed since the string may be erroneous. When a sync detection N.G. or a subcode N.G. occurs, as described above, the error portions included in the data units A to H can be estimated from the position of the sync N.G. or the subcode N.G. as indicated by the shaded portions in the figure. By correcting errors in data based on this information, it is possible to properly decode the data. In such a case, the data may be recorded a plurality of times.
[0058] FIG. 16 shows another example (different from the example of FIG. 15 ) in which the case where a sync is not properly detected or erroneous data is included in error correcting code for subcode occurs a plurality of times serially, and the data between the errors is processed since the data may be erroneous. Use of such an algorithm increases the reliability of information on the positions of errors in data, making it possible to correct the data by discarding the erroneous portions.
[0059] FIG. 17 is a flowchart showing a method for processing the data to be recorded described so far, changing the structure of the data. First of all, when data is recorded, it is determined whether the target area is the management area at step 171 , and if it is the user data area, the data is processed in units of 64K bytes. Syncs and subcodes are added at step 173 , and the data is interleaved to produce a record data structure at step 174 . If the target area is determined to be the management area at step 171 , on the other hand, the size of the data to be recorded is determined at step 175 . In this case, if the size of the data to be recorded requires that the data be recorded in record units of 64K bytes, a 64K-byte record block is used to record the data as in the case of the user data area. The sizes which require that data be recorded in record units of 64K bytes include sizes a little smaller than 64K bytes (for example, 60K bytes or so) and sizes larger than 64K bytes.
[0060] If the size of the data to be recorded is determined to be small at step 175 , an appropriate record block size is selected based on the size of the data to be recorded at step 179 . As described above, a record block can be configured such that its size is set to be one of various sizes smaller than 64K bytes, such as 32K bytes (illustrated in FIG. 8 ), 16K bytes (illustrated in FIG. 7 ), 8K bytes (illustrated in FIG. 1 ), and 4K bytes (illustrated in FIG. 13 ). Accordingly, by selecting an appropriate record block size based on the size of data to be recorded, it is possible to reduce an amount of data recorded in the management area.
[0061] Then, an identification code is added at step 180 . The identification code indicates the size of a record block. The addition of syncs and subcodes and the conversion of the data arrangement are carried out based on the size of the record block indicated by this identification code. Specifically, at step 181 , the data to be recorded and the identification code are added with syncs and subcodes for small sizes. At step 182 , the data is rearranged based on the size to produce data to be recorded. By carrying out such processing, it is possible to record even data of small size in a disk management area.
[0062] According to the present invention described above, when data is recorded on a recording medium, even data of small size to be recorded can be subjected to recording signal processing in much the same way as ordinary data (of ordinary size) to be recorded, making it possible to record data in a management information area in small units. Accordingly, it is possible to reduce the time required for recording management information, and efficiently use the management information area. | If a large minimum data unit for recorded data is used to record a small data amount of management information, the recording time is long, and furthermore when a WO (write once) is used as the recording medium, the number of recording operations is restricted. To solve the above problems, the present invention records data in a management area in units smaller than ordinary units for recorded data to suitably record information in a limited management area and thereby efficiently use the user data area. At that time, the present invention simplifies interleave processing usually applied to ordinary recorded data, and performs the simplified interleave processing on a data structure (for data of small size) of the present invention so as to ensure the signal processing compatibility between the ordinary data and data having the data structure according to the present invention. | 6 |
This application is a continuation-in-part of U.S. Pat. application Ser. No. 629,702 filed Nov. 6, 1975.
BACKGROUND OF THE INVENTION
This invention relates to motor cycle carriers.
The invention to which this problem is generally directed is the cost of manufacture of carriers suitable for carrying parcels and such-like on motorcycles.
The problem is not so much one of the cost of manufacture of a carrier as such, but rather that associated with having to make for the end user a carrier suitable for one particular model of one particular type of motor cycle.
The problems here are enormous.
Those who are familiar with this art will understand that there many hundreds of differing models of motor cycles of the dozens of differing makers and that it has been conventional practice to tailor-make each carrier so that this will fit appropriately on one particular model of one particular manufacturer.
The cost here is firstly that a specific jig must be made and then some number of carriers must be manufactured which are then supplied to the various stores who must then take stock of each of the carriers for a large number of the models and makers. There is some hope that any particular retailer will be holding particular stock in one model of one maker.
It will be well appreciated firstly that retailers will be most reluctant to stock large numbers of carriers simply because of the capital investment involved. Secondly where these carriers are of the fixed side support type, the space requirements involved are great. Finally, the problem that any of the carriers may not be popular and there is an investment involved in stock which can easily become very dead.
There is the further problem, that for the manufacture of such carriers, it can hardly be justified to provide mass production techniques such as moulding, where the sales of that particular carrier are going to be limited. While separate fabrication of each carrier is relatively expensive, substantial capital cost otherwise necessary for mass production is not required and hence this has been generally considered to be the only feasible way for manufacture of such carriers.
The problems of the cost of carriers, the cost of inventorying carriers presently made, and the difficulties of supply will therefore be obvious enough. There are of course further difficulties when one attempts to overcome this problem, in that any carrier that must be designed has firstly to be able to be made strong enough to support substantial loads and yet at the same time be of good appearance when secured to a motor cycle, and perhaps almost as important, to enable the carrier to be used on the bike for a long period of time without mechanical deterioration.
SUMMARY OF THE INVENTION
The general object of this invention is to propose a concept by which the costs of making motor cycle carriers particularly for a variety of makes and models be cheaper than has hitherto been possible.
There is the further object to provide a mechanical arrangement that is very suitable for application, provides adequate strength, and can enable a good looking design to be achieved.
There is the further object that there be provided a system of support for a carrier which will assist in the long lasting of the mechanical parts of a carrier.
It is a further object to provide a concept whereby a major portion of a carrier can be made according to substantive mass production techniques and that only minor portions of the carrier need to be especially shaped or fabricated to make the carrier suitable for any type of model or make.
Clearly the invention will be better understood when reference is made to preferred embodiments and therefor reference is now made to drawings in which
IN THE DRAWINGS
FIG. 1 is a perspective view showing a parcel carrier according to a first preferred embodiment in position on a motor cycle.
FIG. 2 is a cross-sectional view of a side of a parcel carrier according to a second embodiment
FIG. 3 is a perspective view slightly from behind and above of the second preferred embodiment, in this case however the stabilizing arms being removed, and
FIG. 4 is a view of the same embodiment as is shown in FIG. 3 except in this case the view is from below and the extension arms have been exploded.
DESCRIPTION OF THE INVENTION
The invention in one form could be said to reside in a motor cycle parcel carrier of a type including a parcel support frame arranged to be held rearward of a motor cycle seat and above a rear wheel of a motor cycle, and side supports to provide sole support for the parcel support frame, each side support adapted to be located one to each side of the rear wheel of a motor cycle each side support being adapted to be held, at two spaced apart locations, by direct securement to the structure of the motor cycle, the parcel carrier being characterized according to this invention in that each of the side supports is comprised of separate portions, including a side strut having an upper portion interlocking with and therefore removably secured to the said parcel support frame, a stabilizing arm having a rearward portion interlocking with a lower portion of the side strut, and forward end of the stabilizing arm being so shaped as to be adapted to be secured to an upper end of a shock absorber of the motor cycle, and a bracket secured in a removable manner at an outer end to the lower forward portion of the side strut and extending inwardly from the secured outer end to an inner which is adapted by reason of its shape to be secured directly to the structure of the motor cycle.
The discovery associated with this invention is that, by having firstly a bracket and secondly a stabilizing arm which connect the motor cycle to the carrier or at least a major portion of the carrier, the carrier in each case can be made according to very standard techniques and can be universally used over a large number of motor cycle makes and models, and the bracket and stabilizing arm in each case can be specifically tailored to the particular make or model.
The important feature then is that the bracket and stabilizing arm are a very small proportion of the whole of the cost, can easily be fabricated by pressing or easy manufacturing techniques so that a person in a retail store need only hold a very small number of parcel support frames and side struts and they may hold the very much cheaper brackets and stabilizing arms appropriate for a much larger variety of motor cycles which however will cost only a very small proportion of the otherwise full cost.
The invention can also be said to reside in the combination of a motor cycle parcel carrier when secured to a motor cycle, for instance when there is a parcel support carrier located above a rear wheel of the motor cycle and rearward of the seat of the motor cycle, the parcel support frame being solely supported by two side supports, one to each side of the motor cycle, the side support in each case having an upper end secured to the parcel support frame and having at a lower end a portion extending forwardly, said portion comprising a stabilizing arm which is secured at a forward end to the motor cycle by a bolt engaging the frame of the motor cycle which also engages and holds the upper end of a shock absorber extending and functioning between the main frame of the motor cycle and the rear wheel assembly of the motor cycle, and a rearward end which interlocks with, in separable manner, a lower portion of the side support strut, and a bracket secured, in removable manner, at an outer end, to a lower portion of the side support strut and at an inner end, in removable manner, to the frame of the motor cycle.
It is a preferred feature that the stabilizing arm interlocks with the lower portion of the side support by sliding means arranged to allow relative freedom of movement in a forward to rearward orientation between the stabilizing arm and the side support strut, but to lock the side strut against any rotational freedom of movement where this is about any transverse horizontal axis relative to the stabilizing arm.
It has been discovered that there is value in leaving some relative movement potential between some of the members of the carrier when held on the motor cycle especially where this relates to preferred embodiments and it has been found that this has the advantage of reducing stresses on critically stressed portions of the carrier as will be described in particular during the particular description of the preferred embodiment.
It has been a further preferred feature that each side support strut includes at a lower end an extension arm interlocking at a rear end of the arm with this side upright arm, these two constituting the side support strut, and the outer end of the bracket being secured at a forward end of the extension arm.
It is especially preferred that the extension arm is a member of tubular shape where interlocking with the side upright arm is achieved by a forward pointing spigot forming part of the side upright arm engages with a close fit, the rearwardly otherwise open end of the extension arm.
The extension arm of course includes the means to support the bracket which extends inwardly, and by providing a separate member which is an extension arm the distance forwardly or rearwardly of the inwardly directed bracket can be varied and hence the relative position of the parcel support frame relative to the seat of the motor cycle.
This then provides that there is even greater universality for any given frame design while still not adding considerably to the cost of the specific portions which must be especially uniquely fabricated for each model or make.
It is to be noted that the extension arm can be of two or three specific sizes only so perhaps two or three such lengths of extension arm can be manufactured which does allow this once again to be made according to mass production techniques.
It is of course a preferred feature that each side support is removably secured to the parcel support frame.
It is particularly preferred that each side support include a rearwardly pointing pin engaging within a correspondingly shaped and located socket in the parcel support frame, and at a location forward of the pin and socket joint, a bolt passes through an aperture in the side support and threadably engages the parcel support frame holding thereby the side support to the parcel support frame.
The special advantage of this last feature is that there need only be one bolt to each side which needs to be tightened and this will hold the parcel carrier together in a relatively secure manner with minimal undue strain.
Furthermore it allows for a very simple frame arrangement for the parcel support frame and allows this article to be manufactured once again according to the economic mass production techniques without difficulty.
Referring now in detail to the drawings and referring in particular to FIGS. 2, 3 and 4 there is shown a parcel carrier 1 which includes a parcel support frame 2, side supports 3, the side supports 3 being adapted to provide sole support for the parcel support frame 2 and there being one side support attached to each side of the parcel support frame 2.
Each side support includes a side upright arm 4, an extension arm 5, a stabilizing arm 6 and an inwardly extending bracket 7.
The assembly of the side upright arm and the extension arm shall be referred for the sake of simplicity as the side strut 8.
The parcel support frame is cast from aluminium and includes two longitudinal struts 9 and at a forward end a transverse strut 10 and at a rearward end a transverse strut 11 with curved ends 12.
Each side upright arm 4 is moulded from cast aluminium in the shape generally as shown in the drawing, the upper end of which is adapted to interlock with the parcel support frame and accordingly there is a rearwardly pointing pin 13 and a forwardly open socket 14 within the frame end in each case a portion 12 of transverse strut 11 whereby the pin 13 will nest securely within the socket 14.
The forward end of the side upright arm 4 includes a transverse aperture 15 and a bolt 16 passes through this and threadably engages a threaded aperture (not shown) within the front transverse strut 10.
It will be seen in this way that there is a very simple interlocking method which can be held in very tight securement by one bolt in the case of each side support.
Furthermore this system of interlocking allows for easy casting of the respective members.
At the lower end of the side upright arm 4 is an extension arm 5 which is of a square cross-section tube held in place by a forward pointing spigot 17 forming part of the side upright arm 4 engaging within, with a close fit, the rearwardly otherwise open end of the extension arm 5.
The stabilising arm is being held by the extension arm 5 locked in position with respect to the spigot 17 by a bolt 18 passing through correspondingly positioned apertures 19 and 20.
At a forward end of the extension arm 5 there is secured a downwardly extending bolt 21 which engages and holds an outer end 22 of bracket 7.
The bracket 7 extends inwardly and upwardly and terminates with an aperture in its end, the aperture being referred to as 23, this bracket 17 shaped so as to provide an appropriate fitting location for a selected model and make of motor cycle.
In the same way the extension arm 5 is of such a length this length being selected to be appropriate to a particular model or make of motor cycle.
The stabilizing arm 6 interlocks with the extension arm 5 by reason of its shape being formed of a tubular metal member the diameter of which corresponds to the internal distance apart of the sides of the tubular shape of the extension arm 5 so that there is a sliding fit of the rearward end of the stabilizing arm 6 this being referred to as 24.
The length of the rearward end of the stabilizing arm within the extension arm is sufficient as is especially shown in FIG. 2 to provide sliding freedom which of course then allows for relative freedom of movement in a fore to aft rearward orientation between the stabilizing arm and the side support 3, but this arrangement will ensure that the assembly will be locked against any rotational freedom of movement where this is about any transverse horizontal axis relative to the stabilizing arm 6.
The forward end 27 of the stabilizing arm 6 is adapted to be secured by a bolt by reason of there being an aperture 28 to an upper end of a motor cycle shock absorber fixing assembly.
Referring now to FIG. 1 there is shown an assembly of a motor cycle carrier actually secured in position rearward and above a rear wheel of a motor cycle 30.
In this case, it will be seen that the parcel support frame 2 and the side upright arm 4 are the same as is shown in the examples of FIGS. 2, 3 and 4 but in this case an extension arm 31 is fitted in the manner as is shown in FIGS. 2, 3 and 4. In this case of somewhat greater length than that previously seen and in the same way, there is an inwardly extending bracket 32 of somewhat smaller size than the inwardly extending bracket 7 and further more there is a forwardly extending stabilizing arm 33 which has its forward end held by bolt 34 to an upper assembly of a shock absorber 35 which is actively functional between a rear swinging wheel assembly of the motor cycle and its frame.
It will now be seen that what has been provided is a system whereby with very small cost, a widely varying range of models and makes of motorcycles can be fitted with components for making a parcel carrier which has the major components which can be manufactured according to well known massed production techniques such as moulding.
The side upright arms 4 can also be made from moulded plastic.
There is special advantage in the fact that the stabilizing arm 33 is retained with only a sliding fit within the forwardly open end. This ensures that where there is vibrational reaction caused between the inertia of the parcel carrier and the motor cycle engine, the forces will be spread over the contact area between the stabilizing arm 33 and the internal areas of the conduit of the extension arm 31.
It is conventional in prior carriers to find that there can be some weakness in the vicinity of such arms and by leaving the freedom to slide between the stabilizing arm and the extension arm has had substantive advantage in reducing such pressure concentrations and hence fracture for this reason.
It is to be noted that it has been found best to make the stabilizing arm and the extension arm in each case from metal. | A motorcycle carrier having the main components of which suitable for a large number of different makes and models of motorcycles. A parcel support frame and side supports cooperate with a stabilizing arm and inwardly extending bracket so that the carrier can be tailor-made for each variety of motorcycle. The various parts interlock to reduce concentration of forces on parts of the frame enabling efficient and most economical manufacture and assembly. | 1 |
FIELD OF THE INVENTION
This invention relates to sealant strips.
More particularly, this invention relates to sealant strips which are useful, for example, as sealant strips between opposed pairs of substrate surfaces such as a pair of glass sheets or panes to form an insulated glass assembly. In another aspect of this invention, the invention relates to the method of forming a sealant strip and to a method of forming an insulated glass body using the sealant strip.
BACKGROUND OF THE INVENTION
Inasmuch as the present invention has particular application to the field of insulating glass, particular reference will be made thereto.
Insulating glass is normally formed of two or more sheets of glass joined together about their periphery by means of a sealant strip between these sheets. Conventional sealant strips are typically formed of a body of e.g. solid butyl rubber which may or may not include a metal reinforcement within the body. In other cases, sealant strips may also be formed of an extruded foam material of a synthetic nature and which typically must include a moisture and air impermeable thin backing of e.g. Mylar™ applied by adhesive to two or three sides of the strip.
In the teachings of the prior art, several steps are required to form an insulated glass assembly. Generally, prior art arrangements involve placing a removable spacer between opposed substrates, injecting a sealant therebetween, allowing the sealant to cure and finally removing the spacer means. In application where permanent spacers are used, an adhesive must be applied thereto to secure the same between the sheets, the spacer is then placed therebetween and a sealant injected into the periphery formed between the edges of the glass and the spacer. In addition, desiccants are often included in the sealant material, which has been found to have limitations in effective moisture absorbing between the sheets.
It is apparent that the prior art practices are labour intensive, messy and provide many opportunities for ineffective construction of insulated glass assemblies.
SUMMARY OF THE INVENTION
The present invention provides an effective sealant strip for use in fabricating insulated glass assemblies which traverses the limitations of the prior art practices by providing an energy saving and easily fabricated insulated glass assembly.
One object of this invention is to provide a sealant strip for application between a pair of opposed substrates comprising:
an elongated base member having a plurality of surfaces including at least one surface adapted to receive a retaining means;
an insulating body associated with a surface of the base member other than at least one surface, the body having spaced apart substrate engaging surfaces adapted for placement in juxtaposition with a substrate surface; and
retaining means associated with at least one surface of the base member for retaining back-fill whereby the backfill anchors the strip between the opposed substrates.
Another object of this invention is to provide an insulated glass assembly comprising:
a pair of opposed glass surfaces, the surfaces having a sealant strip at least partially extending inwardly from the exterior thereof between the glass surfaces, the sealant strip and elongated base member having a plurality of surfaces including at least one surface adapted to receive a retaining means, the sealant strip further including an insulating body associated with the surface of the base member other than at least one surface, the body having spaced apart substrate engaging surfaces adapted for placement in juxtaposition with a substrate surface; and
retaining means associated with at least one surface of the base member for retaining back-fill whereby the backfill anchors the strip between the surfaces.
A still further object of this invention is to provide a method of forming a sealant strip comprising:
providing a base member having an insulating body associated therewith;
mounting the base member and the insulating body between a pair of opposed substrate surfaces; and
anchoring the insulating body and the base member with a back-fill between the substrate surfaces to thereby seal the same.
The base member and insulated body may be coextruded or be fastened together by suitable means e.g. chemical or thermal bonding.
In an alternate form, the base member may include a plurality of projecting elements to retain the back-fill material.
Further, the cooperating elements of the base member and back-fill material may be reversed, i.e. the projecting element may be a channel which engages a projecting element of the back-fill material.
In greater detail in the present invention, the insulating body may be formed of any suitable solid or foamed cellular structure which may in turn, be of any suitable thermoplastic or thermal setting polymeric material. Typical of such materials are, as representative examples, polyurethanes, polyolefins such as polyethylene, polypropylene, copolymers thereof and the like; polysilicones, polyvinylchlorides, etc. These materials may be used in a solid or foamed form; in the case of solid materials, materials such as various butyl polymers, ethylene polymers, polyamides and the like may be employed. In the case where it is desired to have high insulating properties for the insulating body, polysilicones or polyurethanes are particularly desirable. Generally, these latter products will be employed in the form of a foam structure, the density of which may vary considerably.
The insulating body will also be chosen, depending on the particular use of the product of the present invention and the type of assembly to be formed, to have certain other characteristics such as gas impermeability, moisture impermeability and the like. To this end, the particular polymeric material may be selected by those skilled in the art to have such properties where desired.
Generally speaking, for the insulating glass industry, the insulating strip or body will have appropriate dimensions which in turn, will also vary depending on the size and type of glass lites; typically, this strip will be from e.g. 1/4" by 1/4" to 1" by 1" or more depending on its application.
In another form of the invention, at least one of the insulating body or the back-fill retaining member will have rigidity characteristics such that it is non-compressible or compressible only to a predetermined extent sufficient to retain the opposed substrates in a spaced apart relationship. Thus, in the case of solid insulating bodies, the degree of compressibility, where the insulating body is chosen to be the component to maintain the opposed substrates in a spaced apart relationship, of a nature such that the body will only slightly compress or be substantially non-compressible as desired. In the case of foamed insulating bodies, the compressibility may be controlled by providing a solid, rigid foam which may normally be compressible to a limited extent or at least when compressed, still maintains sufficient spacing between the opposed substrate surfaces.
In accordance with the present invention, the insulating body is provided with a desiccating material. The material is impregnated within the insulating body for absorption of moisture from the space or chamber defined between a pair of juxtaposed substrates secured together by the sealant strip of the present invention.
In a particularly preferred form of the present invention, the insulating body may be a foamed body having the desiccant therein. Suitable desiccants include zeolites, potassium chloride, calcium chloride, silicon gels or any other hygroscopic material. The foam body will vary in density depending on application as will the amount and type of desiccating material used.
Typically, the desiccant material may comprise 1% to 50% or more of the insulating body depending on application.
The back-fill retaining member of the present invention comprises a body having a first member adapted to be operatively associated with or engage the insulating body, and a second body member spaced from the first body member adapted to provide an anchoring or engaging member for back-fill material inserted between the opposed substrates for finishing purposes. To this end, the anchoring or engaging member of the body has a configuration which may be of a suitable geometrical configuration such as a "T" or arrowhead shaped profile which provides surfaces with which the back-fill material can engage with when the back-fill material is added or placed in juxtaposition with the retaining member. It will be appreciated that other configurations may also be employed for this purpose, so long as they provide a surface with which the back-fill material can engage.
The base member is adapted to fixedly secure or otherwise engage the back-fill member to the insulating body; to this end, the first member preferably has a surface or profile coextensive with a mating and engaging surface of the insulating body. Generally speaking, the insulating body may have a substantially flat planar and correspondingly, the first member will be of a substantially flat planar configuration.
In one form, the base member comprises an elongated planar length of material having opposed top and bottom surfaces.
The base member may be fabricated from materials having shape retention while being generally non-compressible. Such materials suitable to this end include polyethylene, polypropylene, polystyrene, composite materials, etc.
The base member includes an axially projecting continuous element projecting upwardly from one surface thereof. It is preferred that the projecting element includes recesses to engage with the back-fill material.
The back-fill retaining means may either be a generally flexible or rigid member, bearing in mind that preferably at least one of the back-fill member or the insulating body will have sufficient rigidity to function as a spacer. Preferably, this characteristic is provided with the back-fill retaining member for manufacturing ease and to this end, the back-fill retaining member may be any suitable plastic (resinous) or metal material.
Suitably, any thermoplastic material such as the polyolefins, polyamides, polyvinylchlorides, or the like may be employed while in the case of metals, materials such as aluminum, steel alloys, etc. may be used. Such back-fill members may be extruded in an appropriate profile by simple extrusion operations.
As noted above, the back-fill member may also be of a metallic material; this is possible since with the assembly of the present invention, as used in insulating glass, the metallic material will not necessarily or desirably form or have any insulating function but rather, it may be used strictly for structural integrity purposes. In other cases, however, this invention also permits the use of totally flexible, very thin, back-fill retaining members which need not have any structural strength characteristics where the spacing function of the sealant strip is provided by the insulating body. Thus, even thin flexible strips of e.g. "Mylar" can be employed.
The present invention provides for several possible arrangements of the back-fill retaining member; in one case, these may project from the insulating body whereby the first member of the back-fill retaining member is within or forms part of the actual insulating body with only the second member projecting from the insulating body; in other embodiment, the back-fill member may be provided as a separate member which is secured by e.g. suitable adhesives to a surface of the insulating body whereby the back-fill retaining member is a separate entity placed in juxtaposition with the insulating body.
Having thus generally described the invention, reference will now be made to the accompanying drawings, illustrating preferred embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of one form of a sealant strip according to the present invention;
FIG. 2 is a side view of the embodiment of FIG. 1;
FIG. 3 is a perspective view of the strip as positioned between opposed substrate surfaces;
FIG. 4 is a perspective view of the back-fill material; and
FIG. 5 is an enlarged view of the strip and backfill material as positioned between opposed substrate surfaces.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, shown is a perspective view and a side view of the sealant strip of the present invention generally indicated by numeral 10. The strip comprises an elongated generally rectangular planar length 12 of material which is preferably non-compressible or compressible only to a certain predetermined extent sufficient to retain opposed substrates, e.g. glass, plastic, etc. in a spaced apart relationship. Suitable materials to provide the necessary rigidity include, for example, polyolefins, polyamides, polyvinylchlorides or, in the case of metals, aluminum, steel, suitable alloys or composite materials.
The elongated length, having a top face 14 and bottom face 16, preferably includes a continuous element 18 projecting normally of the top surface 14. The projecting element is spaced inwardly from the opposed spaced apart sides 20 and 22 of the strip 10 and is unitary with the elongated strip 12. The projecting element 18, according to this embodiment, has a T-shaped in profile having recesses 18A and 18B. Although this is illustrated, the projecting element 18 may comprise numerous profiles which are sufficient to retain back-fill material typically used in insulating glass assemblies. Other useful engaging surface profiles may be, for example, arrowhead shapes, or any other profile which defines inwardly extending recesses 18A and 18B between the top face 14 of the strip 12 and the profile of the projecting element 18. The strip 12, in greater detail, may be as is conventional in the art, extruded to produce the same with the projecting element in an extrusion process. Further, it is preferred that an insulating body, generally referenced in the drawings by numeral 24, be associated with the bottom face 16 of the strip 12. The insulating body 24 may be bonded to the face 16 by suitable means e.g. chemical bonding by adhesives, oxidants etc. or by thermal bonding, e.g. ultrasonic methods.
Referring to the insulating body 24 in greater detail, the body preferably is elongated and projects normally of surface 16 of strip 12 and includes spaced apart sides 26, 28, bottom face 30 and spaced apart top face 32 which is bonded to bottom surface 16 as herein previously described. The sealant strip will vary in size depending on application and the size of glass panes employed, but typically the strip will be from 0.25" by 0.25" to about 1" by 1" or more.
The insulating body 24 is preferably formed of suitable solid or foamed cellular structures which may, in turn, be any suitable thermoplastic or thermo-setting polymeric materials. In a preferred embodiment, the material is foamed polyurethane and contains an impregnated desiccant therein. It will be understood that other suitable polymers may be used in a solid or foamed structure such as polyethylene, polypropylene, copolymers thereof, polysilicones, polyvinylchlorides etc. Suitable desiccants impregnated in the polyurethane foam include calcium chloride, silica gel, zeolites, potassium chloride or any other suitable hygroscopic material. The hygroscopic material may be added to the polyurethane material during a foaming step to ensure adequate impregnation as is the convention in the art. In addition, the rigid materials of the strip 12 are preferably malleable facilitating ease of use and, more importantly, shape retention. This will be discussed in greater detail hereinafter.
The insulating body, i.e. the foam body 24 may be coextruded with the strip 12 or affixed thereto in a separate step. The foam body 24 may be from about 0.125" to 2" or more wide and will vary according to the application. Generally, the width of the insulating body 24 will preferably be wide enough to provide supporting generally non-compressible surfaces in order to support panes of glass on both sides thereof.
Referring to FIG. 3, shown is a perspective view of the sealant strip 10 in position between two opposed sheets of glass 34. As illustrated, the strip 10 is one continuous elongated length, which is preferably discontinuous at only one point, namely, the point where the ends of the strip meet. In this arrangement, the insulating capability of the strip is not appreciably affected. It is preferred that the sealant strip 10 be spaced inwardly from the outside edges 36 of the glass substrates 34 to facilitate the placement of back-fill sealant material 38 therein. This is illustrated in FIG. 4. Suitable back-fill material includes thermoplastics e.g. butyl polymers, styrene-butadiene polymers, thermosetting materials e.g. acrylic polymers or thermoplastic-thermosetting compounds, such as those known in the art. This material may be extruded co-terminously or simultaneously with the elongated length of strip 12 and insulating body 24. Preferably back-fill material 38 comprises an elongated length of material having opposed top 39 and bottom 41, and a face 40 in which there is centrally located an axial channel 42 recessed inwardly of the face 40. It is particularly preferred that the channel 42 include spaced apart lateral recesses 44 and 46 which are adapted to receive and cooperate with the projecting element 18 and, more specifically, cooperate with recesses 18A and 18B. The top 39 and bottom 41 may include suitable adhesives known in the art to bond substrate surfaces thereto. Thus, in insulated glass assembly as illustrated in FIG. 5 by mounting the sealant strip 10 between a pair of opposed surfaces and anchoring the same with back-fill material adapted to cooperate with the strip 10.
In an alternate form, the material 38 may be injected using known techniques for contact with the top face 14 of the strip 12 thus filling in the recesses of the projecting element 18 which thus results in the sealant being retained by the element 18 when the sealant has set. This material, once set, seals the panes 34 and sealant strip 10 into a unitary insulated glass assembly. | There is disclosed a sealant strip which can be used between substrate surfaces such as a pair of glass sheets or panes, the strip includes a shape retaining base member having an insulating body associated therewith. The body further incorporates an insulating material having a desiccant material impregnated therein. | 4 |
BACKGROUND OF THE INVENTION
1) Field of the Invention
The present invention relates to decorative ornaments primarily for use on Christmas trees and other display usages.
2) Description of the Prior Art
There are numerous different types of decorative ornaments used to decorate Christmas trees, wreaths and the like. Also, decorative ornaments are commonly suspended from fixed structures located within homes. A common version of a decorative ornament is a suspension ornament where the ornament includes an attachment for attaching the ornament in a suspending manner to the item being decorated. Although there are numerous ornaments that have been previously designed, there is always a need for a novel configuration of ornament that is attractive in appearance.
SUMMARY OF THE INVENTION
The subject matter of the present invention comprises a tubular decorative ornament that is designed to be mounted in a suspending manner from the structure that is to be decorated. The decorative ornament includes an elongated, rigid core which is adjustable in length. To the ends of this core there is mounted in a winding manner a section of thin, flimsy, sheet material. This sheet material has been previously cut producing a mass of slits and between each directly adjacent pair of slits is located a thin, narrow strip of the sheet material. The sheet material is wound on the core with the sheet material attached only at the opposite ends of the core. Adjusting of the length of the core results in the sheet material changes the shape from tubular to various sizes of globular configurations. The slits can be arranged in different patterns within the section of sheet material with each pattern producing a slightly different appearance of the decorative ornament. A decoration may be fixedly mounted in conjunction with the core with the decoration being located interiorly of the globe but being observable through the slits which will produce an ornament of a different appearance.
One of the objectives of the present invention is to construct a decorative ornament which is most attractive in appearance and which can be manufactured at a relatively inexpensive price and therefore sold to the ultimate consumer at a rather inexpensive price.
Another objective of the present invention is to construct a decorative ornament that provides a new and unusual ornament for Christmas trees so that such can be decorated in a novel fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top plan view of the sheet material which has a polygonal configuration of slits which is utilized to produce the decorative ornament of the present invention;
FIG. 2 is a top plan view of the sheet material of FIG. 1 showing such being mounted in conjunction with a core;
FIG. 3 is an exploded view of a core the decorative ornament of the present invention showing connection to a decoration which could be fixedly mounted on the core;
FIG. 4 is a front view of the decorative ornament of the present invention that has been constructed utilizing the sheet material section shown in FIG. 2 depicting the final, constructional steps that are required in order to produce the final configuration of the decorative ornament;
FIG. 5 is a view of the decorative ornament of the present invention similar to FIG. 4 but showing the decorative ornament in its completed stage of manufacture and showing the core in an extended position;
FIG. 6 is a cross-sectional view of the decorative ornament of the present invention taken along line 6--6 of FIG. 5 showing the decorative ornament with a decoration mounted on the core;
FIG. 7 is a view of the decorative ornament of the present invention similar to FIG. 5 but showing the core in a shortened position;
FIG. 8 is a top plan view of the sheet material for the decorative ornament of the present invention similar to FIG. 2 where the sheet material section has a truncated cone-shaped pattern of slits as opposed to the polygonal-shaped pattern of FIGS. 1 and 2;
FIG. 9 is a view of the decorative ornament of the present invention constructed with the truncated cone-shaped slit pattern of FIG. 8 with the core of the decorative ornament in a shortened position;
FIG. 10 is a cross-sectional view of the decorative ornament of the present invention taken along line 10--10 of FIG. 9;
FIG. 11 is a top plan view of the sheet material for the decorative ornament of the present invention similar to FIG. 8 where the slit pattern assumes a stepped configuration rather than the truncated cone-shaped configuration of FIG. 8;
FIG. 12 is a front view of the decorative ornament of the present invention constructed utilizing the stepped slit pattern configuration shown in FIG. 11 with the core of the decorative ornament being located in a shortened position; and
FIG. 13 is a cross-sectional view of the decorative ornament of the present invention taken along line 13--13 of FIG. 12.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring particularly to FIGS. 1-7 of the drawings, there is shown a thin, flexible section 20 of sheet material. A preferable material of construction for the section 20 would be a metallic foil. However, the section 20 could be constructed of plastic and possibly even of paper. The section 20 should be highly colorful and possibly may include a design. The section 20 includes a top edge 22 and a bottom edge 24. The section 20 also includes a right side edge 26 and a left side edge 28. Mounted on the inner surface 30 directly adjacent the right side edge 26 is a adhesive border strip 32. A similar adhesive border strip 34 is mounted on the inner surface 30 directly adjacent the left side edge 28. The border strips 32 and 34 are located parallel to each other. Formed within the section 20 are a plurality of slits 36. Within section 20 there are actually fifty-nine in number of the slits 36. However, it is to be understood that the number of the slits 36 can be increased or decreased without departing from the scope of this invention. In between each pair of directly adjacent slits 36 is a narrow strip 38. Therefore, it is to be understood that there will be approximately sixty in number of the narrow strips 38. It is to be noted that the length of the slits 36 are all the same within the embodiment shown within FIGS. 1-7. The pattern of the slits 36 is that of a polygonal-shape such as a square or rectangle. The slits 36 terminate directly adjacent the border sections 40 and 41. Mounted on the border section 40 is a border strip 32 and mounted on the border section 41 is a border strip 34. Slits 36 constitute no more than a knife-type cut with all the cuts being parallel.
There is a core which is constructed of an inner member 42 and an outer member 44. The outer member 44 constitutes a cylindrical tube which has a through hole 46. Telescopingly mounted within the through hole 46 is the inner member 42. The inner member 42 is also cylindrical. The inner end 48 of the inner member 42 is formed into a plurality of flared fingers 50. These flared fingers 50 are to be inserted within the through hole 46 which creates a small amount of outwardly directed pressure against the wall of the through hole 46. The result is the inner member 42 is capable of telescoping movement relative to the outer member 44. Because of the flared fingers 50, this movement is not completely free but is a snug type of movement. At any point in this movement, the inner member 42 can be stopped and will remain in that position relative to the outer member 44. The outer end of the inner member 42 is formed into a cylindrical plug 52. The diameter of the plug 52 is equal to or greater than the diameter of the outer member 44.
It may be desirable to mount a form of decoration on the outer member 44. An example of such a decoration is a ball 54. The ball 54 includes a through hole 56 and a tight fit is to occur between the outer member 44 and the ball 54 when the outer member 44 is inserted within the hole 56. The ball 54 is to be positioned where desired and it will remain in that position relative to the outer member 44. It is to be understood that other than the ball 54, there could be utilized numerous different types of decorations.
The outer end of the outer member 44 is placed against the adhesive border strip 34. The cylindrical plug 52 is placed against the adhesive border strip 32. This locating of the core is such that the longitudinal center axis of the core is located parallel to the slits 36. The section 20 and the border strips 32 and 34 is then wound onto the core with border strip 34 being wound onto outer member 33 and border strip 32 being wound onto the cylindrical plug 52. The adhesiveness of the adhesive border strips 32 and 34 functions to fixedly secure section 20 to the core. It is to be understood that the decorative ornament of this invention may not include the ball decoration 54 and if so, the decorative ornament is in a tubular shape. With the ball decoration, the ornament assumes a globe shape. Once the adhesive border strips 32 and 34 are completely wound onto the core, it may be necessary to do a little trimming at each end of the decorative ornament 58 that is now produced. The removed material is shown as 62 from the border strip 34 and the removed material is shown as 60 from the border strip 32. Once the material 60 has been removed, a cap 64 is fixedly secured onto the decorative ornament covering the border strip 32. The cap 64 is to be fixedly secured in position by an adhesive, which is not shown.
A cap 66 is fixedly mounted about the border strip 34 and is similarly adhesively secured. It is to be noted that the cap 66 includes an eyelet hole 68. A hangar or a piece of string is designed to connect with the eyelet hole 68 permitting mounting in a suspended manner the decorative ornament 58 of this invention. It is to be noted that the decorative ornament 58 has a longitudinal center axis 70.
Referring particularly to FIG. 8, there is a modified form of the decorative ornament of the present invention which shows a sheet material section 72 located in a flat, uninstalled position. Like numerals have been utilized to refer to like parts. The difference of the sheet material section 72 from the sheet material section 20 is in the pattern of the slits 36. It is noted that observing FIG. 8 that the pattern of the slits 36 is that of a truncated cone. To help to understand how this pattern differs from the polygonal-shaped pattern of FIGS. 1 and 2, the letters A, B, C, D, E, F, G, H, and I have been used to refer to different portions of the sheet material section 72. When the sheet material section 72 is wound on the core composed of inner member 42 and outer member 44 starting with the end of the section 72 that has the shortest length of slits 36, there is produced a decorative ornament as shown in FIG. 9 when the core is in the shortened position. The different portions of the sheet material section 72 that have been designated A to I are used to denote the different corresponding narrow strips in the cross-sectional view of FIG. 10. In observing of the cross-sectional view of FIG. 10, it can be seen that the strips 38 that are located within area A extend the farthest from the longitudinal center axis 70 of the decorative ornament 74 which is shown in FIGS. 9 and 10. Section B doesn't extend quite as far out as Section A, Section C doesn't extend quite as far out as Section B, Section D doesn't extend quite as far out as Section C and so forth until finally Section I locates the strips 38 that are shortest in length and extend the shortest distance out from the longitudinal center axis 70 and is closest to the center axis 70.
Referring particularly to FIG. 11, there is shown the sheet material section 76 which is basically similar to prior sections 20 and 72. Again, like numerals have been employed to refer to like parts. It is to be noted that the section 76 is a stepped pattern configuration. The letters J, K and L are being used to refer to different sections of the stepped pattern. That means the slits 36 within the area J extend entirely across the sheet material section 76 from border section 40 to border section 41. Within area K, the slits 36 extend some shortened distance. Within area L, the slits 36 extend a still further shortened distance. The configuration of the slits 36 within area J is that of a rectangle which is also true of slits 36 within area K and area L. The sheet material section 76 is to be wound in the same manner as previously discussed on the core which is composed of inner member 42 and outer member 44 and cylindrical plug 52. The decorative ornament 78 that is produced using the stepped version of the sheet material section 76 is shown in FIG. 12. Again, like numerals have been employed to refer to like parts. The sheet material section 76 is to be a wound on the core again starting with the end of the section 72 that has the shortest length slits 36.
Referring particularly to FIG. 13, the decorative ornament 78 of FIG. 12 is shown in transverse cross-section. It can be seen that the longer length slits 36 located within area J form narrow strips 38 that are located the furthest from the core. The slits of area K form strips that are located nearer the core. The slits within area L form strips 38 that are located nearest the core.
It is to be understood that following the concept of this invention that numerous other different configurations of slits 38 arranged within the sections 20, 72 and 76 could be utilized without departing from the scope of this invention. | A suspending ornament that is designed primarily for Christmas trees that is composed of a sheet material member that is wound on a core member. The core member is to be adjustable in length and when shortened produces a tubular configuration of the sheet material. The sheet material member includes a mass of slits which produces an attractive stringy type of appearance when in the tubular configuration. The sheet material member should be designed to be colorful. There may be mounted on the core member a decoration which would be observable through the slits of the tubular configuration of the sheet material member changing the tubular configuration to a globular configuration. | 3 |
FIELD OF THE DISCLOSURE
[0001] This invention relates to crash guards to provide protection against out-of-control vehicles and debris.
BACKGROUND
[0002] The purpose of the present invention is to provide protection against out-of control vehicles for people congregating near moving vehicles. Typical locations where the invention would be useful include bus stops and outdoor dining areas situated near roadways or parking lots. Although outdoor dining areas have existed for some time, the advent of indoor smoking prohibitions have caused many bars, restaurants and like establishments to establish or expand outdoor dining areas. Due to property constraints many of these outdoor dining areas have been placed adjacent to roadways or parking lots where vehicle traffic is prevalent.
[0003] Likewise, both for convenience and land constraints bus stops are typically placed adjacent to roadways where vehicular traffic occurs. It is very common that sidewalks are often poured right up to the curb, leaving scant feet between traffic and pedestrians to begin with. Bus stops and the accompanying benches and waiting areas, are often anchored to the sidewalk just a few feet from the curb. Some communities recognizing the danger have passed legislation allowing public easements that oftentimes allow shelters to be placed behind the sidewalk. Although of some benefit, these measures at best place a few additional feet between the waiting people and an out-of-control vehicle. Some communities have attempted to locate bus stops behind utility poles that could act as barriers. Other communities have installed or considered installing bollards—concrete posts—around the bus shelters. Using utility poles of course is subject to a utility pole being conveniently located and relies largely on luck that an out-of-control vehicle would come from a direction and in a manner such that it would hit the pole rather than the people at the bus stop. At best, the use of utility poles would provide protection only in some accidents. The inventors recognized that an additional problem with respect to utility poles, concrete bollards and other methods is that although a vehicle hitting such barriers may be stopped, the impact oftentimes allows for portions of the vehicle to intrude into the area to be protected by the bollards or utility poles and/or sends pieces of the concrete bollards, the utility pole or the vehicle and fluids from the vehicle into the people the barrier is meant to protect.
[0004] The present invention addresses these needs and many objects and advantages derived from the present invention will become apparent to those skilled in the art from this specification. Although the above background has emphasized the invention's use with respect to outdoor dining areas and bus stops, the invention is certainly not limited to the uses or locations described. Rather, the invention could be used wherever protection of people near moving vehicles is desired.
SUMMARY OF THE INVENTION
[0005] Disclosed herein is a crash guard to resist intrusion of a vehicle from a traffic lane into an area and to resist intrusion into that area of debris caused by an impact of a vehicle into the crash guard or into another vehicle. The traffic lane could be any area where moving vehicles are present and need not be a traditional traffic lane. It could, for example, be a parking lot or similar area. The crash guard includes two or more front bollards anchored into the ground between the traffic lane and the area to be protected. The front bollards define at least one perimeter of the area and are of sufficient construction and sufficiently anchored to the ground so as to resist the intrusion of vehicles across the perimeter into the area to be protected. There is at least one guard rail designed to resist intrusion across the perimeter attached between the bollards. A vertical debris shield is attached above the front bollards and extending along the vertical plane of the perimeter. There may also be a debris shield attached between the front bollards.
[0006] The crash guard may also include two or more rear bollards which define a second perimeter of the area to be protected. Roof decking support beams may extend vertically from the rear bollards and roof decking may be attached to the roof decking support beams and extend over the area to be protected. The roof decking may be attached to the front of the crash guard or may simple cantilever from the roof decking support beams and extend over the crash guard. Alternatively, a portion of the roof decking, preferably a portion over the front of the area to be protected, may instead be of canopy debris shields. These embodiments may also include a debris shield between the front bollards.
[0007] The crash guard may also be connected to an existing structure either by attaching the canopy debris shields or roof decking to the existing structure. For example, a crash guard could include front bollards, a guard rail and vertical debris screens and either roof decking or canopy debris shields attached or adjacent to the roof structure of an existing bus stop shelter or other structure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] These and other features and advantages will become appreciated as the same becomes understood with reference to the description, claims and drawings wherein:
[0009] FIG. 1 is an exterior front perspective view of one embodiment of the invention;
[0010] FIG. 2 is a top plan view of one embodiment of the invention;
[0011] FIG. 3 is an exterior side perspective view of one embodiment of the invention;
[0012] FIG. 4 is an exterior rear perspective view of one embodiment of the invention;
[0013] FIG. 5 is a side view of one aspect of the invention;
[0014] FIG. 6 is an exterior front perspective view of another embodiment of the invention; and
[0015] FIG. 7 is a top plan view of another embodiment of the invention.
DESCRIPTION
[0016] Turning to FIGS. 1-4 , there is shown a first embodiment of a bus stop crash guard of the invention generally designated by reference number 10 . In this embodiment, an interior space is defined by a crash guard 10 the components of which include front bollards 12 , rear bollards 13 , guard rails 14 , debris shields 16 , canopy debris shields 18 and roof decking 26 all connected via various framework components as described in more detail below. As best seen in FIGS. 3 and 4 , the crash guard 10 may define thresholds 28 on either side of the crash guard 10 through which ingress and egress may be made. The crash guard components and the framework components of the crash guard 10 may be made of a variety of materials so long as adequate crash and debris protection is provided. In one embodiment shown in FIGS. 1-5 , the materials and construction are as follows.
[0017] As seen in FIG. 5 , the bollards 12 are preferably made of steel tubes 30 filled with concrete 32 . The bollards 12 are approximately three feet six and one-quarter inches high above the ground and are sunk approximately six feet into concrete foundations 32 below the sidewalk 34 or other area upon which the crash guard 10 may be located. Steel plate end caps 36 are attached to the top of each bollard and galvanized steel debris shield supports 24 are attached to the steel plate end caps 36 . In this embodiment, the steel tubes 30 are constructed of galvanized steel TS6″×6″×¼″ and filled with 2500 psi concrete. The guardrails 14 are TOGA galvanized, for example Grainger #1CWR3. There are preferably two guardrails 14 placed on the front of the crash guard 10 with the center of the lower guardrail approximately ten and one-half inches above grade and the center of the upper guardrail approximately one foot nine inches above the center of the lower guardrail. The end caps 36 on the bollards 12 may be made of ¼″ steel plate. In the embodiment just described, the bollards 12 are designed for a 10,000-pound maximum horizontal point load located at two feet eight inches above grade. The rear bollards 13 may be constructed similarly to the front bollards 12 but it may not be necessary if crash protection is not needed or needed minimally from the rear side of the crash guard 10 . If no protection or only minimal protection is needed, the rear bollards 13 need only be strong enough to structurally support the roof decking support beams 42 and the roof decking 26 . Depending on local codes, ordinances and the like and/or the degree of intrusion protection desired with respect to a particular location, the bollards 12 , 13 and the guardrails 14 may be of different materials, construction and installation than as just described above with respect to this particular embodiment. For example, embodiments could include only one guardrail or three or more guard rails. The guard rails need not be of galvanized steel but could be of sufficiently strong rubber, plastic or composite or otherwise constructed to meet the varying codes, ordinances, regulations or building practices of various locales in which the crash guard 10 may be deployed. Likewise, the bollards could be constructed entirely of concrete or other materials or may have different combinations of steel and concrete than as specified above.
[0018] Continuing with FIGS. 1 through 4 , the debris shields 16 are attached to the debris shield supports 24 by flat bar tabs 38 and via weld to a flat bar frame 22 . The flat bar frame is also welded to the debris shield supports 24 . The canopy debris shields 18 are attached to the debris shield supports 24 by blade brackets 40 and to the truss frame 20 by flat bar tabs 38 . The roof decking 26 is attached to the crash guard 10 via the truss frame 20 and the roof decking support beams 42 . The roof decking support beams 42 are inserted into the rear bollards 13 .
[0019] In the embodiment shown, the debris shield supports 24 are galvanized steel such as TS2″×2″× 3/16″. The truss frame 20 is 2″×2″ steel. The flat bar frames 22 are 2″×⅛″ steel. In the embodiment shown, the debris shields 16 and the canopy debris shields 18 are made of metal wire mesh screen such as a square opening wire mesh plain steel square weave with an opening size of approximately two inches and ¼-inch wire diameter. The roof decking 26 is made of metal. The debris shields are attached to the debris shield supports 24 via ⅛″ steel flat bar tabs 38 with ⅜″ bolts or other suitably strong attachment methods or devices. The canopy screens 18 are attached to the truss frame 20 via ⅛″ steel flat bar tabs 38 with ⅜″ bolts or other suitably strong attachment methods or devices and to the screen supports 24 via ¼″ steel blade brackets 40 or other suitably strong attachment methods or devices. The canopy screens may also be made of a wire mesh screen similar to that of the debris shields. Both, the debris shields and canopy screens may be made of other sufficiently strong materials including wire mesh made of materials other than steel or solid materials such as metal plate, plexiglass, rubber, plastics, etc.
[0020] The method and means of attachment of the various components of the crash guard 10 shown in FIGS. 1 through 5 and described above is just one such method of attaching the various components. Other methods of attachment and materials as is known in the trade of engineering, architecture, building and construction could be used without departing from the basic operating principles and concepts of this disclosure.
[0021] It can also be seen that alternative embodiments are available depending on the degree of protection needed, local site factors and cost. If additional protection is desired from debris intruding into the interior space by passing between the bollards 12 or the guardrails 14 , additional debris shields 16 may be attached either to the bollards 12 or to the guardrails 14 . In some crash scenarios it is possible that debris could be thrown over the debris shields. Accordingly, the embodiment shown in FIGS. 1-4 includes canopy debris shields 18 . However, if protection from debris intruding into the interior space defined by the crash guard by going over the debris shields 16 is not desired or deemed to be of minimal risk, the crash guard 10 need not include the canopy debris shields 18 . Alternatively, if additional protection from very small debris or liquid debris is desired the debris shields 16 , whether attached to the debris shield supports 20 , to the bollards 12 or to the guardrails 14 may instead of being constructed of wire mesh may be constructed of a suitably strong solid material such as steel plate, plexi-glass, or like materials that provide the desired degree of protection from intrusion of small debris and liquids. Likewise, various combinations of different types of debris shields 16 and canopy screens 18 may be used depending on the risks for which protection is sought. Thus, the debris shields attached to the bollards 12 or guardrails 14 could be of a solid material to protect against a greater likelihood of liquid debris that may occur at the point of impact with the crash guard 10 while the debris shields 18 attached to the debris shield supports 24 may be of a mesh or screen type material to protect against solid debris only. Likewise the canopy debris shields 18 may be of solid material to provide additional protection from the weather or the less likely liquid debris from the point of impact or may be of a lighter screen or mesh material to protect only from the relatively smaller sized debris that would be thrown up from the point of impact to that height. In another embodiment, there may be no canopy debris shields 18 but the roof decking 26 could nonetheless extend from the rear decking support beams 42 across the entire structure to overhang in front of the debris shields 16 and the debris shield supports 24 . In such an embodiment the roof could be either entirely constructed of canopy debris shields 18 or, preferably, solid roof decking 26 to protect against weather and debris. The roof could also include or be comprised of photovoltaic (solar) panels and the crash guard could include equipment to store power to power lights, advertising and the like that are associated with the crash guard or the bus stop or other area, businesses, etc. that the crash guard protects. The crash guard may also include equipment to connect the crash guard to an existing power grid either to take power from the grid to power lights, advertising, etc., or to feed/sell power back to the grid or some combination thereof.
[0022] Yet other embodiments may depend on local site factors. For example, FIG. 6 shows an embodiment that could be used where the local site already has an existing bus stop shelter 44 and FIG. 7 shows an embodiment where the local site already has an existing bench 46 . In these embodiments shown in FIGS. 6 and 7 , the components of the crash guard 10 include front bollards 12 , guardrails 14 , debris shield supports 24 , and debris shields 22 . In the embodiment shown in FIG. 6 , the crash guard could optionally include canopy debris shields 18 attached to the existing shelter 44 .
[0023] While I have shown and described certain embodiments of the present invention, it should be understood that the same is subject to many modifications and changes by those skilled in the art without departing from the basic concepts and operating principles of the disclosure. | A crash guard configured to resist intrusion of a vehicle from a traffic lane into an area and to resist intrusion into an area of debris caused by an impact of a vehicle into the crash guard or into another vehicle. | 4 |
FIELD OF THE INVENTION
This invention relates to turbocharged internal combustion engines that use waste gates as a means of limiting boost pressure (charge air pressure) over the high engine speed range of operation.
BACKGROUND OF THE INVENTION
Turbochargers that are used on both diesel and gasoline engines to increase power output and reduce fuel consumption are becoming more and more prevalent in the marketplace since they also contribute to lowering exhaust emissions. They will be a significant factor in meeting the federally mandated mileage and emission standards that must be met by 2016.
Engines that are required to produce high power and high torque at low engine speeds, diesel truck engines for example, or passenger car engines that need to accelerate rapidly, require turbochargers that are capable of supplying high charge air pressure at low engine speeds, up to the torque peak speed of the engine. Above the torque peak speed, turbochargers with waste gates have been employed to prevent the turbocharger from exceeding its speed limit, and to maintain the charge air pressure constant over the high engine speed range. Turbochargers with waste gates are in common use today to bypass exhaust gas around the turbocharger turbine wheel to limit the speed of the turbocharger rotor and hold the boost pressure constant.
A predetermined maximum boost pressure generated by the turbocharger compressor is used to open the waste gate valve that is usually built into the hot turbocharger turbine casing. The waste gate valve and its operating mechanism represent a significant cost addition to the turbocharger.
Some turbochargers used on gasoline engines are subjected to higher exhaust gas temperatures than those used on diesel engines and require a cooling jacket in the bearing housing to protect their internal components from excessive heat. Currently, the cooling medium is engine coolant that must be piped from the engine to the turbocharger at its location within the engine enclosure and returned to the engine cooling system from the turbocharger cooling jacket.
Dr. William E. Woollenweber's patent application Ser. No. 12/803,618, titled “Air-Cooled Turbocharger with Optional Internal Pressure Relief Valve”, discloses a turbocharger that uses compressed air from the engine air intake system to cool the turbocharger, thus eliminating the need for engine coolant and its accompanying piping to and from the turbocharger. One embodiment of the air cooling system uses a spring-loaded valve mounted downstream of an air-to-air aftercooler in the air intake system of the engine that limits the boost pressure to the engine to a predetermined value, and the air that is taken from the intake manifold is piped to the cooling jacket of the turbocharger to cool its internal parts. The use of a waste gate is thereby eliminated.
BRIEF SUMMARY OF THE INVENTION
In this invention, boost pressure to the engine is controlled at a selectable value by bleeding compressed air from the engine air intake system with a novel spring-loaded bleed valve located downstream of an air-to-air aftercooler.
The spring-loaded valve of this invention is made adjustable by either changing the spring tension by a fixed set screw, or by taking pressurized air from the turbocharger compressor and directing it through a modulating valve to the spring-loaded bleed valve. The modulating valve can be mounted in the driver compartment of a vehicle where the operator can vary the boost pressure to the engine to suit various driving conditions.
Bleeding air from the intake system requires the turbocharger to produce a higher quantity of compressed air, thus requiring more power to be generated by the turbocharger turbine. This additional turbine power is available over the high engine speed range through utilization of the excess energy that is present in the engine exhaust gas due to its high exhaust gas temperature.
The air that is bled from the engine intake manifold system has been cooled by passing through an air-to-air aftercooler where the cooling medium is ambient air. Thus, the compressed air to the engine is of the order of 100° F. to 140° F., depending on the ambient air temperature and the effectiveness of the aftercooler. This cooled air can be used effectively to cool the internal parts of a turbocharger.
The utilization of the novel adjustable bleed air valve in the engine air intake of this invention, downstream of an air-to-air aftercooler, is a unique method of preventing the turbocharger from exceeding its maximum speed limit and concurrently providing cooling air for the hot internal parts of a turbocharger. As previously stated, this invention eliminates the conventional waste gates and liquid coolant lines when liquid engine coolant is used to cool the hot internal parts of a turbocharger. Elimination of the waste gate results in a substantial cost saving since the adjustable boost pressure control valve is less complicated than a waste gate, has no connection with the hot exhaust parts of the turbocharger and can be made of less expensive materials than the exhaust gas by-pass valves or waste gates.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional view of one embodiment of an adjustable boost pressure control valve of the invention.
FIG. 2 is a cross-sectional view of an adjustable boost pressure control valve of FIG. 1 adjusted for a higher boost pressure level.
FIG. 3 is a cross-sectional view of another adjustable boost pressure control valve of the invention adapted for remote variation and control of boost pressure.
FIG. 4 illustrates a boost pressure control system of the invention, including an adjustable boost pressure control valve of FIG. 3 , wherein air pressure from a turbocharger compressor casing is ducted through a modulating valve within a vehicle to the boost pressure control valve.
DETAILED DESCRIPTION OF THE INVENTION
As noted above, this invention discloses a boost pressure control system for a turbocharged engine which may, in a preferred embodiment, provide a selectable constant boost pressure over the high speed range of the engine or, in another embodiment, provide a variable boost pressure over the high speed range of the engine.
FIG. 1 illustrates an embodiment of the constant pressure control valve 10 . The control valve 10 comprises a valve cap 11 , and a valve body 12 that house a spring-loaded valve 21 seated against a valve seat 22 . The valve 21 includes a valve closure portion 21 a and a stem 21 b projecting from the valve closure portion 21 a , and a compression spring 20 surrounds and is carried by the valve 21 . Spring 20 (coils not shown) is compressed to a fixed length by spring retainer 19 and nut 18 . A piston 17 carried in a cylindrical portion 12 a of the valve body 12 , bears against spring retainer 19 and forces the spring retainer 19 to compress spring 20 to a fixed length and thus the force of the piston 17 to compress the spring 20 acts as a means for increasing the force imposed on the valve 21 by the spring 20 and can be increased by turning adjusting screw 15 . Jam nut 16 locks the adjusting screw 15 in place. Once the piston 17 is positioned by the adjusting screw 15 . a selected predetermined boost pressure in the engine intake manifold 8 ( FIG. 4 ) will act against the valve face 23 and open the valve 21 , allowing compressed air from the engine intake manifold 8 to escape through valve body 12 and out through opening 24 . The compressed air escaping through opening 24 can be vented to the atmosphere or be piped to a turbocharger 9 ( FIG. 4 ) cooling jacket to air-cool internal parts of the turbocharger.
FIG. 2 illustrates the control valve 10 of FIG. 1 , where the adjusting screw 15 has been locked in a position that has moved the piston 17 and spring retainer 19 to compress spring 20 to a shorter overall length. This shorter length of spring 20 increases the force applied to the valve closure portion 21 a and requires a higher boost pressure from the intake manifold to move the valve closure portion 21 a from the valve seat 22 and open the valve. Thus, in the configuration illustrated in FIG. 2 , the engine will be supplied with a higher boost pressure than the valve configuration shown in FIG. 1 .
FIG. 3 illustrates a boost pressure control valve 26 with a valve cap 27 that has a pipe tap threaded opening 28 in its center for the purpose of admitting air pressure to the cavity 29 formed in the bottom surface of valve cap 27 .
FIG. 4 illustrates the boost pressure control system where air pressure from the turbocharger compressor casing 9 is transmitted through a duct 33 to a modulating valve 30 and, after adjustment, if any, through a second duct 34 to the threaded opening 28 in the control valve cap 27 . The modulating valve 30 can be remotely located, for example, in the cab of a vehicle where the vehicle operator can adjust the pressure in cavity 29 that acts on the top of the piston 17 . The air pressure in cavity 29 acts to force the piston 17 to compress the spring 20 and acts as a means for increasing the force imposed on the valve 21 by the spring 20 like the adjusting screw 15 , shown in FIGS. 1 and 2 , by exerting a force on piston 17 . This force can be varied by adjusting the modulating valve 30 between the air pressure lines 33 and 34 . The boost pressure to the engine can be varied by a vehicle operator by using the modulating valve 30 to control the pressure in cavity 29 . When the modulating valve 30 is closed, any pressure remaining in cavity 29 will bleed out through the clearance between the piston 17 and valve body 12 .
The invention thus provides means for adjustably controlling the boost pressure of cylinder charge air from a turbocharger 9 to an internal combustion engine by providing a valve body 12 , forming a closed chamber 12 a with a charge air inlet 13 adapted for connection with a charge air duct between the turbocharger 9 and an internal combustion engine, such as the engine's intake manifold 8 , and with a charge air outlet 24 connected with the surrounding environment. The valve body 12 carries a valve seat 22 around the charge air inlet 13 and a spring-loaded valve closure 21 a for the valve seat 22 . The spring-loading of the valve closure 21 a holds the valve closure 21 a against the valve seat 22 and is adjustable to vary the charge air pressure at which the valve closure 21 a is moved from the valve seat 22 by the pressure of the charge air from the charge air duct (e.g., the intake manifold 8 ), acting on the valve closure 21 a and permits charge air to escape from the charge air duct to the surrounding environment through opening 24 .
As stated previously, current turbocharged engines employ an exhaust gas bypass valve (waste gate) in the turbocharger turbine casing to keep the turbocharger rotating assembly from exceeding its speed limit over the high engine speed range. The waste gate remains closed usually up to the torque peak speed of the engine, at which point the boost pressure provided by the turbocharger has reached a predetermined maximum value. Above the torque peak speed of the engine, the predetermined value of boost pressure opens the waste gate, thereby bypassing exhaust gas around the turbocharger turbine to hold the boost pressure to the engine constant over the high engine speed range.
The boost pressure control valve 10 of this invention accomplishes the same result as the waste gate by bleeding compressed air from the intake manifold system of the engine. Accordingly, the valve is mounted on the cool side of the engine and is not subjected to the hot exhaust gases of the engine, as are the waste gates.
As shown in FIGS. 1 and 2 , the spring 20 is compressed to a predetermined length by the spring retainer 19 and nut 18 and exerts a predetermined force on valve 21 . The sub-assembly, consisting of valve 21 , spring 20 , spring retainer 19 and nut 18 , is held in place against the valve seat 22 by the piston 17 and adjusting screw 15 .
In the embodiment shown in the figures, the valve base 13 can be fastened to the engine intake manifold downstream of an air-to-air after cooler by welding (or bolting) and admits the boost pressure existing in the engine intake manifold to exert a force against the valve face 23 of valve 21 . When the boost pressure generated by the turbocharger compressor reaches a predetermined value, the force acting in valve seat 23 can overcome the spring force holding the valve closed, and open the valve. Pressurized air can then escape into the valve body 12 and exit through opening 24 . As previously stated, the escaping air has been cooled by the after cooler 35 and can be piped via a conduit 37 , to a turbocharger bearing housing 39 to cool internal components of the turbocharger 9 . Alternately, the escaping air can be vented to the atmosphere if the turbocharger bearing housing does not have a cooling jacket 39 in its bearing housing.
Various springs 20 can be employed to offer a range of boost pressures and each individual spring has the ability to control boost pressure over a limited range of boost pressure. For example; a listing of springs and the boost pressure range for each follows:
Spring
Boost Pressure Range
A
15 to 21 psi
B
21 to 28 psi
C
27 to 35 psi
D
34 to 42 psi
E
44 to 54 psi
The valve design can accommodate a number of different springs of the same wire diameter to offer boost pressure control over any range as required by commercial diesel and gasoline engines, or as desired by special vehicle operators. | A variable boost pressure control system for turbocharged internal engine systems comprising an adjustable charge air vent valve connectable with the charge air input to an internal combustion engine to provide selection and adjustment of the charge air pressure to the internal combustion engine, either at the site of the charge air vent valve or at a location remote from the charge air vent valve and to provide, if desirable, a flow of cool charge air to a turbocharger cooling jacket. | 5 |
CLAIM FOR PRIORITY
[0001] This application claims the benefit of priority to Korean Patent Application No. 2004-039353, filed on May 31, 2004 which is hereby incorporated by reference as if fully set forth herein.
FIELD OF THE INVENTION
[0002] The present invention relates to an organic electroluminescence display that prevents a lighting emitting element from malfunctioning by retaining image signals upon applying each scanning signal by applying a set voltage to pixels and driving the same before applying scanning signals, and a method of driving the same.
DESCRIPTION OF THE BACKGROUND ART
[0003] Generally, a cathode ray tube (CRT) has been one of widely used display devices. The CRT is mainly used for television monitors, in measuring instruments, information terminal equipment, etc. However, with the demand for miniaturization and lightweight design of electronic products, the CRT is problematic due to the weight and size of the products.
[0004] Therefore, to replace the above cathode ray tube, various flat panel display (FPD) devices such as liquid crystal display (LCD) devices, plasma display panels (PDPs), field emission display (FED) devices and electroluminescence display (ELD) devices have been researched and developed. The FPD devices thin, lightweight and have low power consumption, compared with CRTs.
[0005] Among these display devices, the organic electroluminescence display is a display device that electrically excites fluorescent organic compounds to emit light, which can display an image by voltage-driving or current-driving an array of M×N organic light emitting pixels.
[0006] The organic electroluminescence display can display colors close to natural colors since it can express visible light such as blue. The organic electroluminescence display has a high brightness and low power consumption. Moreover, the organic electroluminescence display does not have a limited viewing angle and is stable under low temperature conditions, unlike a liquid crystal display device provided with a liquid crystal layer. In addition, because the organic electroluminescence display is self luminescent, it is suitable for an ultra-thin type display device, and its production cost can be lowered because it has a simple manufacturing process. The organic electroluminescence display is also suitable for displaying moving images device as the response time is a few microseconds (μs).
[0007] As an organic electroluminescence display, an active matrix type in which a plurality of pixels is arranged in a matrix form and image information is selectively supplied to each pixel through a switching element, such as a thin film transistor, has been widely applied.
[0008] FIG. 1 is an exemplary view showing a general active matrix organic electroluminescence display.
[0009] Referring to FIG. 1 , the organic electroluminescence display includes a plurality of gate lines GL 1 to GLm and data lines DL 1 to DLn arranged on a substrate 1 in longitudinal and transverse directions, a plurality of pixels P 1 provided on areas defined by the gate lines GL 1 to GLm and the data lines DL 1 to DLn crossing each other, a data driving unit 30 for supplying an image signal to the pixels P 1 via the data lines DL 1 to DLn, and a gate driving unit 20 for applying scanning signals to the pixels P 1 via the gate lines GL 1 to GLm.
[0010] The gate driving unit 20 applies scanning signals to the gate lines GL 1 to GLm in sequence. Switching elements electrically connected to the gate lines GL 1 to GLm to which the scanning signals are applied are conductive, and the data driving unit 30 applies image signals to the data lines DL 1 to DLn, thereby applying the image signals to the pixels P 1 via the conductive switching elements. Each pixel P 1 generates light by an organic electroluminescence device (not shown) according to the voltage level of input image signals.
[0011] With recent improvement of the resolution of organic electroluminescence displays, it is possible to realize sharper images. However, this is restricted by a limited space of the substrate 1 because a great deal of data lines DL 1 to DLn has to be formed on the substrate 1 in order to realize a high resolution. Therefore, intervals between the lines to be formed get narrower and thus, signal interference occurs between the lines, thereby resulting in degradation of image quality.
[0012] To solve such problem, a block driving method was employed, which can supply image signals to the entire pixels P 1 by limiting the number of data lines DL 1 to DLn to be formed on the substrate 1 and repeatedly using the formed data lines DL 1 to DLN many times.
[0013] The aforementioned block driving method will now be described in detail with reference to the accompanying drawings.
[0014] FIG. 2 is an exemplary view showing a block-driven organic electroluminescence display.
[0015] Referring to FIG. 2 , the organic electroluminescence display includes a plurality of gate lines GL 11 and GL 12 and data lines DL 11 to DL 1 n arranged on a substrate at regular intervals, a plurality of signal lines 140 arranged on the substrate at regular intervals, crossing the gate lines GL 11 and GL 12 , and connected to the data lines DL 11 to DL 12 , a plurality of pixels P 11 provided on areas defined by the signal lines 140 and the gate lines GL 11 and GL 12 crossing each other, and a plurality of switching blocks BL 1 to BLk provided on the signal lines 140 , respectively, and controlling image signals delivered to the pixels P 11 via the data lines DL 11 to DL 1 n.
[0016] In the block driving method, the display device is driven by dividing the entire screen of the display device and supplying image signals to pixels P 11 via each switching block BL 1 to BLk. In FIG. 2 , a multiplicity of switching blocks BL 1 to BLk for dividing the entire screen perpendicularly is shown.
[0017] In the drawing, the data lines DL 11 to DL 1 n are formed on the substrate in a horizontal direction which is the same as the direction of the gate lines GL 11 and GL 12 . As above, the number of the data lines DL 11 to DL 1 n formed on the substrate is consistent with the, number of the signal lines 140 connected to each of the switching block BL 1 to BLk. That is, only the number of the data lines DL 11 to DL 1 n required for simultaneously transmitting an image signal to one switching block BL 1 to BLk are formed. The switching blocks BL 1 to BLk consist of a plurality of switches 111 , and each switch 111 is electrically connected to the data lines DL 11 to DL 1 n , respectively, via the signal lines 140 .
[0018] The signal lines 140 and the gate lines GL 11 and GL 12 define a plurality of pixels P 11 by crossing each other perpendicularly. The pixels P 11 are arranged in a matrix on the substrate.
[0019] Each of the pixels P 11 is provided with a device, such as a thin film transistor. This thin film transistor is electrically connected to the gate lines GL 11 and GL 12 and the signal lines 140 .
[0020] One side of the signal lines 140 is electrically connected to one of the plurality of data lines DL 11 to DL 1 n , while the other side thereof is electrically connected to one of the plurality of pixels P 11 . Each of the signal lines is provided with a switch 111 for conducting or blocking signals from the pixels P 11 to the data lines DL 11 to DL 1 n.
[0021] In the thus constructed organic electroluminescence display, when scanning signals are applied to the gate lines GL 11 and GL 12 , the thin film transistors connected to the corresponding gate lines GL 11 and GL 12 are turned on. An image signal applied to the data lines DL 11 to DL 1 n during the turn-on period is applied to the pixels P 11 in units of the switching blocks BL 1 to BLk via the signal lines 140 .
[0022] Because the plurality of data lines DL 11 to DL 1 n are commonly connected to each switching block BL 1 , they do not need to be formed so as to correspond to the entire substrate and the number of data lines to be formed can be reduced.
[0023] FIG. 3 is an exemplary view showing the timing of signals upon block driving.
[0024] Firstly, though a low voltage driving or high voltage driving may be selected according to the type of thin film transistors provided in the pixels, a description thereof will be based on a p-type thin film transistor that is turned on at a low voltage level.
[0025] As shown in FIG. 3 , a scanning signal GS 11 supplied from a gate driving unit (not shown) to gate lines is changed from a high voltage level to a low voltage level, block driving signals BE 11 to BE 1 k are sequentially applied to switching blocks in a low voltage level section.
[0026] When each block driving signal BE 11 to BE 1 k is sequentially applied to each switching block corresponding to the entire panel in a first horizontal period during which the scanning signal GS 11 maintains a low potential level, every switching block is conductive once and image signals are supplied to corresponding pixels via the connected switching blocks. In this manner, the pixels connected to the gate lines, to which the scanning signal GS 11 is applied in the first horizontal period, are all supplied with the image signals. As shown therein, the first block driving signal BE 11 to the K-th block driving signal BE 1 k are applied at a low potential level pulse.
[0027] Generally, a resistance component, a capacitor component and a conductance component exist on a line to which an electric signal is delivered. Likewise, a capacitor component exists on the aforementioned signal lines, and thus the problem of signal distortion may occur.
[0028] In a case where block driving signals BE 11 to BE 1 k are sequentially supplied to the switching blocks during the first horizontal period, the signal lines electrically connected to each switch of the switching blocks switched on are supplied with image signals from the data lines. Consequently, these image signals are supplied to the pixels. Since the scanning signal GS 11 sequentially applied to the gate lines is generated at regular intervals so that each signal does not overlap with each other, it is not until a predetermined (dummy) time passes after the scanning signal GS 11 becomes a low voltage level that the next scanning signal GS 11 is generated.
[0029] However, a portion of the electric charge corresponding to the image signals remain on the signal lines even during this dummy time, and may affect the driving of the pixels. Moreover, as shown therein, as each switching block is conductive during the previous horizontal period, the image signals applied to the signal lines cannot be supplied with new image signal until each switching block is conductive in the next horizontal period. For example, the image signals applied in the previous horizontal period still remain on the signal lines during a dummy time A from the falling edge of the scanning signal GS 11 to the first block driving signal BE 11 , a dummy time B from the falling edge of the scanning signal GS 11 to the second block driving signal BE 12 , and a dummy time C from the falling edge of the scanning signal GS 11 to the k-the block driving signal BE 1 k . Therefore, the image signals corresponding to the previous horizontal period may be supplied to the organic electroluminescence device of the pixels during the dummy times A, B and C of the next horizontal period. The above organic electroluminescence device may generate undesired light emission by maintaining components of the image signals applied during the short dummy times A, B and C because it has a fast reaction speed. This problem may not be serious in a liquid crystal display using liquid crystal with relatively low reaction speed, but may lead to picture quality degradation in the organic electroluminescence device. Especially, in a case where white images with a high brightness are displayed in the pixels in the previous horizontal period and black images with a low brightness are displayed in the same pixels in the next horizontal period, the light emission of the luminescence device caused by the remaining components of the image signals will degrade the picture quality greatly.
SUMMARY OF THE INVENTION
[0030] By way of introduction only, an organic electroluminescence display and method of display are presented which prevent picture quality degradation by suppressing light emission from a light emitting element caused by components of image signals remaining on signal lines by supplying a lowest gray level voltage to each of the signal lines prior to supplying a new image signal.
[0031] In one aspect, an organic electroluminescence display comprises: a plurality of data lines and gate lines arranged on a substrate in a first direction; a plurality of signal lines arranged on the substrate in a second direction and electrically connected to the data lines, respectively; a plurality of pixel regions defined by the gate lines and the signal lines crossing each other; switching elements provided in the pixel regions, respectively, and electrically connected to the signal lines and the gate lines; a plurality of switching blocks that open and close an electrical connection between the signal lines and the pixels; a second driving unit that makes conductive the switching elements connected to the corresponding gate lines and the signal lines by outputting scanning signals to the gate lines; a first driving unit that outputs a first control signal for each horizontal period before the second driving unit outputs scanning signals, sequentially making conductive the switching blocks by a second control signal, and outputting image signals to the data lines; and a pre-charging unit connected between the signal lines and the first driving unit, the pre-charging unit being made conductive according to the first control signal of the first driving unit for setting the signal lines at a set voltage supplied from the first driving unit.
[0032] In another aspect, a method of driving an organic electroluminescence display is presented. The organic electroluminescence display comprises a plurality of data lines and gate lines arranged on a substrate in a first direction, a plurality of signal lines electrically connected to the data lines, respectively, a plurality of pixels electrically connected to the gate lines and the signal lines, and a plurality of switching blocks for conducting or blocking image signals supplied to the pixels via the signal lines. The method comprises providing a pre-charging unit electrically connected to the signal lines; applying a set voltage to the signal lines through the pre-charging unit; maintaining the set voltage on the signal lines; applying scanning signals to the pixels via the gate lines; making the switching blocks conductive one by one; supplying image signals to the pixels via the signal lines by applying the image signals to the signal lines through the conductive switching blocks; and displaying images according to the image signals by the pixels.
[0033] In another aspect, an organic electroluminescence display comprises: a plurality of data lines and gate lines arranged on a substrate in a first direction; a plurality of signal lines arranged on the substrate in a second direction and electrically connected to the data lines, respectively; a plurality of pixel regions defined by the gate lines and the signal lines crossing each other; a plurality of switching blocks for opening and closing an electrical connection between the signal lines and the pixels; a first driving unit for outputting a first image signal and a second image signal to the data lines, setting the signal lines to a voltage level of the first image signal by making the switching blocks conductive by a first control signal and a second control signal and supplying the second image signal to the pixel regions via the signal lines; and a second driving unit for outputting scanning signals to the gate lines after the first driving unit outputs the first control signal.
[0034] In another aspect, a method of driving an organic electroluminescence display is presented. The organic electroluminescence display comprises a plurality of data lines and gate lines arranged on a substrate in a first direction, a plurality of signal lines electrically connected to the data lines, respectively, a plurality of pixels electrically connected to the gate lines and the signal lines, and a plurality of switching blocks for conducting or blocking image signals supplied to the pixels via the signal lines. The method comprises applying a first control signal to every switching block to make every switching block conductive; applying a first image signal of a set voltage level to the signal lines through the conductive switching blocks; terminating the first control signal; applying scanning signals to the pixels via the gate lines; sequentially applying a second control signal to the switching blocks to make the switching blocks sequentially conductive; supplying a second image signal to the pixels via the signal lines by applying the second image signal to the signal lines through the conductive switching blocks; and displaying images according to the second image signal at the pixels.
[0035] In another aspect, a method of driving an organic electroluminescence display is presented. The organic electroluminescence display comprises a plurality of data lines and gate lines arranged on a substrate in a first direction, a plurality of signal lines electrically connected to the data lines, respectively, a plurality of pixels electrically connected to the gate lines and the signal lines, and a plurality of switching blocks that supply signals to the pixels via the signal lines when the switching blocks are conductive. In each display cycle the method comprises: supplying a set voltage level to all of the signal lines prior to applying scanning signals to the pixels via the gate lines; applying scanning signals to the pixels via the gate lines; sequentially applying a control signal to first switching blocks of the plurality of switching blocks to make the first switching blocks sequentially conductive; supplying image signals to the signal lines through the conductive first switching blocks; and terminating supply of the image and scanning signals to the pixels after all pixels have been supplied with the image signal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0037] In the drawings:
[0038] FIG. 1 is an exemplary view showing a general active matrix organic electroluminescence display;
[0039] FIG. 2 is an exemplary view showing a block-driven organic electroluminescence display;
[0040] FIG. 3 is an exemplary view showing the timing of signals upon block driving;
[0041] FIG. 4 is a view showing an organic electroluminescence display according to a first embodiment of the present invention;
[0042] FIG. 5 is a timing diagram showing the driving waveform of a signal of FIG. 4 ;
[0043] FIG. 6 is a view showing an organic electroluminescence display according to a second embodiment of the present invention; and
[0044] FIG. 7 is a timing diagram showing the driving waveform of a signal of FIG. 6 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0045] FIG. 4 is a view showing an organic electroluminescence display according to a first embodiment of the present invention.
[0046] Referring to FIG. 4 , the organic electroluminescence display includes; a plurality of data lines DL 21 to DL 2 n arranged at regular intervals on a substrate in a transverse direction; a plurality of gate lines GL 21 to GL 2 n arranged on the substrate in the same direction as the data lines DL 21 to DL 2 n ; a plurality of signal lines 240 electrically connected to the data lines DL 21 to DL 2 n and the gate lines GL 21 to GL 2 m ; a plurality of pixels P 21 provided on areas defined by the gate lines GL 21 to GL 2 m and the data lines DL 21 to DL 2 n crossing each other; a plurality of switching blocks BL 21 to BL 2 k provided on the signal lines 240 , respectively, and conductive or blocked by block driving signals BE 21 to BE 2 k for applying image signals D 1 to Dn applied from the data lines DL 21 to DL 2 n to the pixels P 21 ; a first driving unit 230 for supplying an image signal DATA to the signal lines 240 via the data lines DL 21 to DL 2 n ; a second driving unit 220 for supplying scanning signals GS 21 to GS 2 m to the gate lines GL 21 to GL 2 m ; and a pre-charging block PBL connected to the ends of the signal lines 240 , respectively, and made conductive by a pre-charge signal PCS 11 of the first driving unit 230 for applying a setting voltage PV to the signal lines 240 .
[0047] The data lines DL 21 to DL 2 n are electrically connected to the pixels P 21 via the signal lines 240 . The signal lines 240 are formed at regular intervals on the substrate in a perpendicular direction, thus they cross the data lines DL 21 to DL 2 n and the gate lines GL 21 to GL 2 m . The pixels P 21 are provided on areas defined by the gate lines GL 21 to GL 2 m and the data lines DL 21 to DL 2 n crossing each other.
[0048] The pixels P 21 are arranged in a matrix on the substrate, and are provided with thin film transistors (not shown), respectively. The thin film transistors are electrically connected to the data lines DL 21 to DL 2 n and the gate lines GL 21 to GL 2 m , so they are driven by signal delivered via the data lines DL 21 to DL 2 n and the gate lines GL 21 to GL 2 m.
[0049] A plurality of signal lines 240 are electrically connected to each of the plurality of switching blocks BL 21 to BL 2 k formed on the substrate, and the switching blocks BL 21 to BL 2 k are commonly connected to the data lines DL 21 to DL 2 n via the signal lines 240 . Thus, the same image signals can be supplied to any switching blocks BL 21 to BL 2 k via the signal lines 240 by only a small number of data lines DL 21 to DL 2 n . The switching blocks BL 21 to BL 2 k consist of a plurality of switches 211 . The switches 211 are devices that are turned on or turned off by block driving signals BE 21 to BE 2 k . The switches 211 correspond to the signal lines 240 , respectively, and the switches 211 provided on the same switching blocks BL 21 to bL 2 k are simultaneously turned on or turned off by the block driving signals BE 21 to BE 2 k . That is, because the switches 211 perform the same operation even if the switching blocks BL 21 to BL 2 k are provided with the plurality of switches 211 , the switching blocks BL 21 to BL 2 k perform one of integrated operations including conducting and blocking.
[0050] One side of each switch 211 provided on the switching blocks BL 21 to BL 2 k is connected to the data lines DL 21 to DL 2 n via the signal lines 240 , while the other side of each switch 211 is connected to the pre-charging block PBL via the signal lines 240 .
[0051] The first driving unit 230 supplies image signals D 1 to DN to the data lines DL 21 to DL 2 n , and sequentially applies block driving signals BE 21 to BE 2 k to the switching blocks BL 21 to BL 2 k . Since every switching block BL 21 to BL 2 k is commonly connected to the data lines DL 21 to DL 2 n , only one of the switching blocks BL 21 to BL 2 k is made conductive by the block driving signals BE 21 to BE 2 k . The block driving signals BE 21 to BE 2 k are supplied once to every switching block BL 221 to BL 2 k within the first horizontal period.
[0052] The first driving unit 230 applies a pre-charge signal PCS 11 to the pre-charging block PBL. A plurality of switches 215 of the pre-charging block PBL are simultaneously turned on by this pre-charge signal PCS 11 . A thin film transistor may be applicable to the switches 215 . As above, in a case where the pre-charging block PBL is made conductive by the pre-charge signal PCS 11 , the first driving unit 230 applies an initialization voltage PV to the pre-charging block PBL via the line commonly connected to the switches 215 of the pre-charging block PBL. The initialization voltage PV is applied to the signal lines 240 through the pre-charging block PBL.
[0053] Meanwhile, the second driving unit 220 sequentially applies scanning signals GS 21 to GS 2 m to the gate lines GL 21 to GL 2 m in each frame. While the scanning signals GS 21 to GS 2 m are applied to the gate lines GL 21 to GL 2 m , a plurality of thin film transistors electrically connected to the corresponding gate lines GL 21 to GL 2 m enter a turned-on state. The first driving unit 230 supplies image signals D 1 to DM to the data lines DL 21 to DL 2 m , and sequentially applies block driving signals BE 21 to BE 2 k to the switching blocks BL 21 to BL 2 k . Therefore, only one of the switching blocks BL 21 to BL 2 k is made conductive, to thus deliver the image signals D 1 to Dn of the data lines DL 21 to DL 2 n to the pixels P 21 . Though not shown in the drawings, a light emitting element (not shown) provided in the pixels P 21 emits light according to the input image signals D 1 to DN. The aforesaid driving of the first driving unit 230 and second driving unit 220 is all performed during the first horizontal period, and is repeated in each horizontal period.
[0054] The first driving unit 230 and the second driving unit 220 may be constructed as separate circuits, but also may be constructed as an integrated circuit.
[0055] The pixels P 21 are supplied with image signals D 1 to Dn in units of switching blocks BL 21 to BL 2 k . Because the switching blocks BL 21 to BL 2 k are conductive only once in the first horizontal period, the image signals D 1 to Dn are applied to the signal lines 240 through the conducted switching blocks BL 21 to BL 2 k . If every switch 211 of the switching blocks BL 21 to BL 2 k is blocked after a predetermined time, the signal lines 240 enter a floating state, and thus a portion of the remaining charge of the image signals D 1 to DN are left on the signal lines 240 . That is, the signal lines 240 have a constant voltage level, and this voltage level is introduced into the pixels P 21 until the corresponding switching blocks BL 21 to BL 2 k are made conductive to apply new image signals D 1 to DN to the signal lines 240 even if the next horizontal period has arrived.
[0056] To prevent degradation of picture quality caused by remaining components of the image signals D 1 to Dn left on the signal lines 240 , the pre-charging block PBL is provided. A detailed description of the driving of the organic electroluminescence display of FIG. 4 will be presented, including FIG. 5 in which a driving waveform is shown.
[0057] FIG. 5 is a timing diagram showing the driving waveform of a signal of FIG. 4 .
[0058] The driving waveform of FIG. 5 is shown under the assumption that a p-type transistor, which is turned on at a low voltage level, is applied to both switches 211 of the switching blocks BL 21 to BL 2 k of FIG. 4 and the switches 215 of the pre-charging block PBL. Hence, in a case where the p-type transistor of the switches 211 and 215 is replaced by an n-type, the potential of the driving waveform of FIG. 5 has to be replaced by an opposite potential.
[0059] The organic electroluminescence display displays images at a plurality of gray levels like a liquid crystal display does. The gray levels mean brightness levels of an image. The organic electroluminescence device has a different light emission brightness according to the size of a supplied current or voltage. Thus, remaining components of image signals D 1 to Dn are left on the signal lines 240 , the gray level of an image can be varied by changing the intensity of light emitting from the organic electroluminescence device. Hence, in order to prevent an image of an undesired gray level from being displayed, a voltage corresponding to the lowest gray level is applied to the signal lines 240 before the organic electroluminescence device emits light by new image signals D 1 to Dn, thereby driving the corresponding pixels P 21 to display black.
[0060] When a first scanning signal GS 21 of low voltage level is applied to gate lines GL 21 to GL 2 m , the thin film transistors of the pixels P 21 connected to the corresponding gate lines GL 21 to GL 2 m are all turned on and thus are supplied with image signals D 1 to Dn through switching blocks BL 21 to BL 2 k sequentially made conductive by block driving signals BE 21 to BE 2 k . However, since the block driving signals BE 21 to BE 2 k are generated after a predetermined time from the point of time of the falling edge of the first scanning signal GS 21 as shown in the drawings, and each block driving signal BE 21 to BE 2 k is periodically generated at regular time intervals, a predetermined dummy time exists until each block driving signal BE 21 to BE 2 k is generated. The remaining components of the image signals D 1 to Dn remaining on the signal lines 240 are removed during this dummy time, so that the remaining components may not be introduced into the pixels P 21 through the thin film transistors turned on by the first scanning signal GS 21 .
[0061] As above, in order to remove the image signal D 1 to Dn components left on the signal lines 240 , the first driving unit 230 outputs a pre-charge signal PCS 11 and applies it to the pre-charging block PBL before applying the first scanning signal GS 21 . The pre-charging block PBL is made conductive to thus apply an initialization voltage PV of the first driving unit 230 to the signal lines 240 . The initialization voltage PV is a voltage corresponding to the lowest gray level of an image. If the initialization voltage PV is applied to the organic electroluminescence device of the pixels P 21 through the thin film transistors, the organic electroluminescence emits light at the minimum level, and thus the pixels display black. As the initialization voltage PV, a ground voltage can be set. That is, at this time, as the pre-charging block PBL, is conducted, the signal lines 240 are grounded.
[0062] After the block driving signals BE 21 to BE 2 k are sequentially output from the first driving unit 230 during the low voltage level section of the first scanning signal GS 21 , the first scanning signal GS 21 is changed to a high voltage level. After the passage of a predetermined time, a second scanning signal GS 22 of low voltage level is applied to the gate lines GL 21 to GL 2 m . After the application of the first scanning signal GS 21 is finished, a pre-charge signal PCS 11 of low voltage level is re-generated before the second scanning signal GS 22 is generated. The first driving unit 230 outputs the pre-charge signal PCS 11 and applies it to the pre-charging block PBL before the second driving unit 220 outputs the second scanning signal G 32 . The pre-charge signal PCS 11 is generated in the same cycle as the scanning signals GS 21 to GS 2 m of the second driving unit 220 , but at a different period within the cycle.
[0063] In this way, the first driving unit 230 can remove image signals D 1 to Dn components that have been previously left on the signal lines 240 by presetting the signal lines 240 to a certain voltage level through the pre-charging block PBL before the second driving unit 220 outputs scanning signals GS 21 to GS 2 m.
[0064] In the aforementioned first embodiment of the present invention, a pre-charging block PBL consisting of switches 215 each connected to one side of the signal lines 240 is provided. Additionally, to control the pre-charging block PBL, a circuit for outputting the pre-charge signal PCS 21 and the initialization voltage PV is added to the first driving unit 230 . Consequently, additional manufacturing costs may be incurred, and the construction may be more complicated than a conventional organic electroluminescence display.
[0065] Accordingly, FIG. 6 is a view showing an organic electroluminescence display according to a second embodiment of the present invention. FIG. 7 is a timing diagram showing the driving waveform of a signal of FIG. 6 .
[0066] In the organic electroluminescence display according to the second embodiment, the pre-charge signal of the pre-charging block and the initialization voltage outputting circuit of the first driving unit in the first embodiment can be eliminated. Similar portions of the first and second embodiments will be briefly described.
[0067] A plurality of signal lines 340 arranged on a substrate in a longitudinal direction and a plurality of gate lines GL 31 to GL 3 m arranged in a transverse direction are crossed perpendicularly to define a plurality of pixels P 31 . The pixels P 31 are arranged in plural number on the substrate along the gate lines GL 31 to GL 3 m . Each pixel P 31 is provided with a thin film transistor (not shown) electrically connected to the gate lines GL 31 to GL 3 m and the signal lines 340 .
[0068] When a second driving unit 320 sequentially outputs scanning signals GS 41 to GS 4 m to the gate lines GL 31 to GL 3 m , the thin film transistors of the pixels P 31 connected to the corresponding gate lines GL 31 to GL 3 m to which the scanning signals GS 41 to GS 4 m are applied are all turned on.
[0069] The first driving unit 330 applies image signals D 11 to D 1 n to the gate lines DL 31 to DL 3 n , and the image signals D 11 to D 1 n are applied to the pixels P 31 conducted by the scanning signals GS 41 to GS 4 m of the second driving unit 320 via the signal lines 340 connected to the data lines DL 31 to DL 3 n . That is, the driving timing of the first driving unit 330 is synchronized with the driving timing of the second driving unit 320 .
[0070] In order for the image signals D 11 to D 1 n output from the first driving unit 330 to be delivered to the pixels P 31 , the switching blocks BL 41 to BL 4 k are sequentially made conductive. The first driving unit 330 sequentially applies block driving signals BE 41 to BE 4 k to the switching blocks BL 41 to BL 4 k.
[0071] However, while in the first embodiment, the signal lines are first set at a certain voltage by the first driving unit 230 outputting a pre-charge signal to make a pre-charging block conductive before the second driving unit 220 outputs scanning signals GS 21 to GS 2 m in every horizontal period, in the second embodiment, the same driving as in the first embodiment is performed using block driving signals supplied to the switching blocks BL 41 to BL 4 k without a pre-charging block.
[0072] As shown therein, the first driving unit 330 increases the number of times of outputting block driving signals BE 41 to BE 4 k for every horizontal period. That is, for every horizontal period, the first driving unit 330 simultaneously outputs every block driving signal BE 41 to BE 4 k before the second driving unit 320 outputs scanning signals GS 41 to GS 4 m . Therefore, every switching block BL 41 to BL 4 k formed on the substrate is simultaneously made conductive to thus conduct the signal lines 340 and data lines DL 31 to DL 3 n at the pixels P 31 side through the switching blocks BL 41 to BL 4 k . The block driving signals BE 41 to BE 4 k simultaneously generated from the first driving unit 330 are referred to as a pre-charge pulse PCP 31 for the convenience of explanation. The pre-charge pulse PCP 31 is output during a dummy section in which the previous scanning signals GS 41 to GS 4 m are changed to a high voltage level and the next scanning signals GS 41 to GS 4 m are not output yet.
[0073] As above, in order to increase the number of times of outputting block driving signals BE 41 to BE 4 k , the output timing of the first driving unit 330 may be controlled. The first driving unit 330 and the second driving unit 320 are integrated, thus signals may be output by internal synchronization of the output timing of every signal.
[0074] With every switching block BL 41 to BL 4 k made conductive by the pre-charge pulse PCP 31 simultaneously output from the first driving unit 330 , all of the signal lines 340 are set to a predetermined voltage level. However, since no pre-charge block is provided in the second embodiment, the signal lines 340 can all be set to a certain voltage level by adjusting the voltage level of the image signals D 1 to D 1 n delivered to the signal lines 340 via the data lines DL 31 to DL 3 n . That is, like the first embodiment, the voltage level of the image signals D 1 to D 1 n are set to the lowest gray level voltage before the second driving unit 320 outputs scanning signals GS 41 to GS 4 k so that the signal lines 340 may be set to the lowest gray level voltage. Alternatively, the signal lines 340 may be set to a ground voltage by applying a ground voltage to the data lines DL 31 to DL 3 n.
[0075] As described above, it is possible to prevent the picture quality of the organic electroluminescence display from being degraded, due to the light emitting element of the pixels emitting light by a voltage left on the signal lines before new images are displayed from the pixels, by presetting the signal lines electrically connected to the pixels to a certain voltage before scanning signals are output to conduct the pixels according to the first embodiment and second embodiment.
[0076] It will be apparent to those skilled in the art that various modifications and variations can be made in the present invention without departing from the spirit or scope of the inventions. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents. | An organic electroluminescence display has data, gate, and signal lines arranged on a substrate. Pixel regions are defined by the gate and signal lines. Switching elements provided in the pixel regions are electrically connected to the signal lines and the gate lines. Switching blocks open and close an electrical connection between the signal lines and the pixels. A driving unit drives the switching elements by supplying scanning signals to the gate lines. The driving unit also supplies a first control signal before the scanning signals are supplied and a second control signal when the scanning signals are supplied. The second control signal makes the switching blocks sequentially conductive, during which time image signals are supplied to the data lines. The first control signal permits the signal lines to be set at a predetermined voltage. | 6 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates in general to diode-laser pumped, digitally modulated, solid-state and optically pumped semiconductor (OPS) lasers. The invention relates in particular to closed-loop control of power output in such lasers.
DISCUSSION OF BACKGROUND ART
[0002] In diode-laser pumped, digitally modulated, solid-state lasers and OPS lasers a predetermined output power level is set and analog-controlled automatically by monitoring power output of the laser, comparing that monitored power with a preset level, and adjusting optical pump power by adjusting the drive current of the diode-laser (or array thereof) to maintain the output power at the pre-set level. The laser is digitally modulated by switching the diode-laser current on and off with the “on” current value being that corresponding to the preset power level.
[0003] FIG. 1 schematically illustrates a typical arrangement 10 of such a diode-laser pumped, digitally modulated, solid-state laser. Here, laser-radiation paths are designated by fine lines, and electrical connections are designated by bold lines. Arrangement 10 includes a laser optics unit 12 , including a laser resonator 14 . Resonator 14 includes a solid-state gain medium (not shown) which is energized (pumped) by radiation R P from a diode-laser radiation source 16 . Source 16 can be a single diode-laser or an array of such diode lasers.
[0004] In response to the energizing (pumping), laser resonator 14 delivers radiation R F having a fundamental wavelength characteristic of the gain medium to an optional frequency convertor 18 . The frequency convertor can include one or more optically nonlinear crystals arranged to convert radiation R F to radiation R C having a wavelength different from the fundamental wavelength. By way of example, the frequency convertor can include one crystal arranged to convert the fundamental-wavelength radiation to second-harmonic (2H) radiation, or two crystals arranged to convert the fundamental-wavelength radiation to third-harmonic (3H) or fourth-harmonic (4H) radiation. Alternatively, frequency-conversion can be carried out by one or more crystals located within the laser resonator. In either case, the frequency-converted radiation provides the laser output-radiation.
[0005] A pick-off mirror 20 directs a sample 22 , for example about 1%, of the output radiation to a photo-detector (photo-diode) 24 the output of which is connected to a detector calibration circuit 26 . The detector calibration circuit 26 sends a signal 27 representative of the instant actual laser output power to light (output radiation) regulation circuitry 28 . Light regulation circuitry 28 receives an input signal 29 representative of a desired laser output power. Based on a comparison of signals 27 and 29 , light regulation circuitry 28 communicates a signal 30 to a diode-laser current-source 32 which varies the output current 38 of the current-source until the actual output power laser 12 matches the desired output power.
[0006] Modulation of the output of laser 12 is achieved by switching the output of the current-source between zero or some predetermined bias (minimum) current 36 and a maximum value determined instantaneously by the signal from the light regulator circuitry. Switching is accomplished by a digital modulation input signal 34 (going low-to-high or high-to-low) from an external source (not shown) such as a microprocessor or a PC. Bias current 36 provides for faster switching (modulation) of laser 12 from an “off” condition to an on condition at the expense of a lower modulation depth or contrast ratio of the laser output.
[0007] FIG. 2 is a functional circuit diagram schematically illustrating details of one example 40 of the light regulation and modulation circuitry of FIG. 1 . Here detector calibration circuit 26 includes a variable resistor R 1 connected in series with photo-diode 24 of FIG. 1 . Signal 27 from the calibration circuitry is connected via a fixed resistor R 2 to one input of an operational amplifier 42 . The set power signal 29 is connected to the other input of the operational amplifier. Amplifier 42 , here, is configured as an integrator, using the combination of R 3 and C 1 as a feedback loop, to optimize gain at low modulation frequencies. Output 30 of the operational amplifier is communicated to the diode-laser current source 32 .
[0008] A principal disadvantage of the light-regulation and modulation method of FIGS. 1 and 2 is that the time required for the power output to stabilize at the set level after modulation “turn-on” is inversely dependent on the set level value. By way of example, a diode-laser pumped, external cavity surface-emitting semiconductor laser (OPS laser) having a fundamental wavelength of 976 nm intra-cavity frequency-doubled to provide output radiation having a wavelength 488 nm was tested to determine stabilization time as a function of set-power. Intra-cavity frequency doubling was achieved using a lithium borate (LBO) crystal. At a set output level of 20 milliwatts (mW) power stabilized at the set level at about 20 microseconds (μs) after turn-on. When the set level was reduced to 3 mW, about 200 μs were required for the output to stabilize at the set level.
[0009] A primary reason for this inverse dependence of stabilizing time on set-power level is that the gain (response time) of the light regulation circuit is limited by the laser build-up time, thereby reducing the maximum possible gain for higher modulation frequencies. The build-up time is essentially dead time for the light regulation circuit, limiting the rise time of the circuitry.
[0010] FIG. 3A , FIG. 3B , and FIG. 3C together form a timing diagram schematically illustrating the operation of the apparatus of FIGS. 1 and 2 for one cycle of digital modulation turned on at time t 0 and off at time t 1 . Light regulation is in operation during the whole digital modulation cycle. It can be seen that for a low set-level of laser power current ramp-up and corresponding output power ramp-up to stabilized values take longer than for a higher set-level. This is because the gain of the light regulator amplifier is proportional to the difference between the actual power and the set power.
[0011] This, unfortunately, means that stabilized power is delivered for a shorter time during any fixed digital modulation cycle the lower the desired power level. This is unfortunate, because in a digitally modulated laser the modulation frequency is often required to be the same for both low peak power and high peak power.
[0012] There is a need for a method of operating a digitally modulated diode-laser pumped solid-state laser such that the delivery time for stabilized laser power is about the same for any desired output power of the laser, and stabilized power is delivered through most of the digital modulation cycle. Preferably, high modulation frequency should be possible, independent of the stabilized level of laser output power.
SUMMARY OF THE INVENTION
[0013] In one aspect of the present invention, the invention is directed to a method of controlling power output in a digitally modulated laser energized by a diode-laser radiation source. The diode-laser radiation source is powered by current from a current-source, and output power of the laser is controllable by a light regulator arrangement cooperative with the current-source. The method comprises disabling the light regulator, then, with the light regulator disabled, increasing current from the current-source until output power of the laser reaches a predetermined value. When the laser output power reaches the predetermined value, the light regulator is enabled and the laser output power is controlled by using the light regulator arrangement to control current delivered by the current source.
[0014] In a preferred embodiment of the method, the light regulator controls current delivered by the current source such that the laser output power is maintained about constant at the predetermined value. After a predetermined time-period, the laser is turned off by disabling the current-source.
[0015] In another aspect of the present invention, optical apparatus comprises a laser and a diode-laser radiation source for energizing the laser to provide laser output power. A current-source is provided for delivering power for powering the diode-laser radiation source. A light regulator arrangement is provided and is cooperative with the current-source for controlling the current delivered by the current-source to the diode-laser radiation source. A power monitor arrangement is provided for monitoring the output power of the laser, the power monitor arrangement being cooperative with the light regulator arrangement. The output power monitor arrangement and the light regulator arrangement are configured such that, when the laser is turned on, the light regulator arrangement is disabled, current from the current-source to the diode-laser radiation source is increased until the monitored laser output power reaches a predetermined value, then the light regulator arrangement is enabled and controls the laser output power by controlling current delivered to the diode-laser radiation source by the current-source.
[0016] In a preferred embodiment of the apparatus, a current regulator arrangement is provided for controlling the rate of current increase after the laser is turned on. When the monitored output power reaches the predetermined level and the light regulator arrangement is enabled, the light regulator arrangement takes over control of the laser output power and controls the current delivered by the current source to the diode-laser radiation source such that the output power is maintained about constant at the predetermined level.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The accompanying drawings, which are incorporated in and constitute a part of the specification, schematically illustrate a preferred embodiment of the present invention, and together with the general description given above and the detailed description of the preferred embodiment given below, serve to explain principles of the present invention.
[0018] FIG. 1 schematically illustrates a prior-art, digitally modulated, diode-pumped, solid-state laser including a laser resonator energized by a diode-laser radiation source for causing the resonator to deliver fundamental-wavelength radiation, a frequency convertor for converting the fundamental-wavelength radiation to frequency converted output radiation, a current supply for powering the diode-laser radiation source, an arrangement for monitoring the frequency converted output power of the laser resonator and supplying the monitored power to a light regulator, the light regulator arranged to control the current supply such that, when a modulation cycle is initiated in response to one digital command, output power rises to a predetermined value and is maintained at the predetermined value until the modulation cycle is terminated by another digital command.
[0019] FIG. 2 is an electronic circuit diagram illustrating details of the power monitoring arrangement and the light regulator of the laser of FIG. 1 .
[0020] FIG. 3A , FIG. 3B , and FIG. 3C form a timing diagram graphically schematically illustrating initiating and terminating modulation commands, temporal response of the current supply, and temporal response of the output power for two predetermined values of the output power in one modulation cycle of the laser of FIG. 1 .
[0021] FIG. 4 schematically illustrates a preferred embodiment of a digitally modulated, diode-pumped, solid-state laser in accordance with the present invention, similar to the laser of FIG. 1 , but further including a current regulator and a comparator arrangement cooperative with the power monitor arrangement the light regulator and the current regulator, and wherein on the initiation of a modulation cycle the light regulator is initially disabled, the current regulator allows the diode-laser current from the current supply to rise rapidly and cause a corresponding rapid rise of the monitored frequency-converted output power, the comparator arrangement compares the monitored power with the predetermined power, and, when the rising laser output power reaches the predetermined power, enables the light regulator and transfers control of the current supply to the light regulator for maintaining the output power at the predetermined output power until the modulation cycle is terminated.
[0022] FIG. 5 is a circuit diagram schematically illustrating details of the monitor arrangement, the comparator arrangement, the current regulator, and the light regulator in the laser of FIG. 4 .
[0023] FIG. 6A , FIG. 6B , FIG. 6C , and FIG. 6D form a timing diagram graphically schematically illustrating initiating and terminating modulation commands, temporal response of the current supply, temporal response of the output power and temporal response of the comparator arrangement for two predetermined values of the output power in one modulation cycle of the laser of FIG. 4 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] Continuing with reference to the drawings, wherein like components are designated by like reference numerals, FIG. 4 schematically illustrates one preferred embodiment 50 of a digitally modulated diode-pumped solid-state laser in accordance with the present invention. Laser 50 is similar to laser 10 of FIG. 1 but includes additional elements including sensor 62 for monitoring current delivered from diode-laser current source 32 to diode-laser 16 . It should be noted, here, that, as discussed above, the combination of the laser resonator and external frequency convertor could be replaced by an intra-cavity frequency-converted resonator without departing from the spirit and scope of the present invention.
[0025] A current regulator 60 is responsive to a signal 63 from the current sensor, a signal 57 from a set-current generator 56 and digital modulation input signal 36 . The set-current generator signal 57 is switchable, depending on the operational state of the laser, between a current limit input signal 59 and a value which is function of the set power input 29 . The switching is accomplished by the output of a combination of a comparator 52 and a latch 54 . A signal combiner 58 provides that diode-laser current source 32 can be controlled by a signal 65 from diode current regulator 60 or signal 30 from light regulator 28 A.
[0026] FIG. 5 depicts more detail of the circuitry of FIG. 4 . Here, light regulator 28 A is configured similar to light regulator 28 of FIG. 2 , with an exception that regulator 28 A includes a switch 74 operable by the output of comparator 52 and latch 54 to switch the regulator into an inactive (buffer) mode via a loop 75 . Current regulator 60 is configured similar to light regulator 28 A and includes a switch 76 operable by the digital modulation input signal for activating or deactivating the regulator. The current regulator includes an operation amplifier 80 , resistors R 4 , R 5 , and R 7 , and a capacitor C 2 . A series combination of resistor R 5 and capacitor C 2 has the same feedback-loop function as resistor R 3 and capacitor C 1 in the light regulator. Resistor R 4 prevents the output of set current generator 56 from being shorted to ground by switch 76 . Resistor R 7 determines the gain of the current regulator in combination with R 5 and C 2 .
[0027] Current sensor 62 functions by converting sensed current to a voltage across a resistor R 8 and amplifying the voltage using an amplifier 85 . Signal combiner 58 combines the output of the light regulator and the current regulator into a current-source driving-signal 88 using diodes D 1 and D 2 and a pull-up resistor R 6 . Due to the polarity of the diodes a low voltage signal at the output of any one of the regulators will pull down the current source driving signal 88 . Set-current generator 56 includes a switch 72 operated by the output of comparator 52 and latch 54 . Switch 72 switches the output between the current limit input and a value generated from the set power input by an arithmetic unit 86 . Detector calibration unit 26 is configured as described above with reference to the circuitry of FIG. 2 .
[0028] FIG. 6A , FIG. 6B , FIG. 6C , and FIG. 6D form a timing diagram schematically illustrating operation of laser 50 over one cycle of digital modulation from an “off” state to an “on” state at time t 0 and from the “on” state back to the “off” state at time t 1 . A description of this operation is set forth below with reference to the timing diagram of FIGS. 6A-D and with reference in addition to the circuitry of FIG. 4 , and FIG. 5 .
[0029] In a general description of the inventive digital modulation method, when digital modulation is switched on at time t 0 (see FIG. 6A ), the diode-laser current is allowed to rise toward a set value calculated by the arithmetic unit 86 (see FIG. 6B ). The calculated current set value is determined by an addition of a constant offset value and a fraction of the set-power value. This is discussed further herein below. The slope of the current rise is determined by the time-constant of the regulator, which is determined, here, by the values of R 5 and C 2 .
[0030] After the laser build up time is passed, the laser power begins to rise quickly corresponding to the high current value that has been reached at that time. While the current is rising, in a current regulation mode, the laser power is monitored. When the monitored power reaches the set power, the current-rise is interrupted and control of the diode-laser current is transferred to a light-regulation mode in which the light regulator controls the current supply to provide whatever current is necessary to maintain the laser output power at a constant level. In FIG. 6B , the current is depicted as falling while the power stays constant. This is due to thermal effects as the laser stabilizes. The fall of the current is exaggerated in FIG. 6B for convenience of illustration. At time t 1 , the diode current is cut off, laser power falls and the light-regulation period is terminated.
[0031] In a detailed description of the inventive method, with reference in particular to the circuitry of FIG. 5 , in the “off” state of the laser, the diode-laser current is (or has been) switched off by the digital modulation input. Accordingly, there is no diode-laser current sensed by current sensor 62 . Switch 74 has set light regulator 28 A to a buffer mode as indicated in FIG. 5 . The modulation input has caused switch 76 to set the input to current regulator 60 to zero volts as indicated in FIG. 5 . This leads to a low voltage output of the current regulator. The output of photodiode 24 is also zero, as laser radiation is not being generated. The comparator/latch ( 52 / 54 ) output has been set to zero by the digital modulation input.
[0032] In order to start an “on” cycle of the laser, the digital modulation input is raised from low (digital zero) to high (digital one) with the comparator/latch output remaining, initially, at zero. This digital modulation input enables the diode-laser current-source, corresponding to input from current regulator 60 . Switch 76 opens and transmits the set-current signal from set-current generator 56 to current regulator 60 . This set-current signal is calculated by arithmetic unit 86 of the set current-generator from the set power value and an additional offset value according to a predetermined function of the laser set power as a function of diode current. The predetermined function can be readily determined by experiment for any laser. The offset value provides that the calculated value is higher than the highest anticipated current-value required for the set power level, but is less than the current-limit. The diode-laser current rises, as the current regulator is not stabilized, and the set-current value is higher than the actual current being monitored by current-sensor 62 .
[0033] The comparator/latch combination is activated by the digital modulation input rise from low to high, and begins to compare the set power input signal with the output of laser power monitor 26 (the actual power). When the actual power reaches the set power, the output of comparator 52 will toggle from low to high (digital 0 to digital 1 , see FIG. 6D ) and the value will be stored by latch 54 until digital modulation goes from high to low (the end of the modulation cycle). The toggling of the comparator changes the status of switches 72 and 74 . Changing the status of switch 72 switches the set current for the current regulator from the value calculated by arithmetic unit 86 to the current-limit input value. Changing the status of switch 74 activates the light regulator by switching the regulator from the buffer mode to a free regulator mode.
[0034] Signal combiner 58 combines signals 30 (from the light regulator) and 65 from the current regulator in such a way that signal 88 transmitted to diode-laser current source 32 is a function of the minimum value of signals 30 and 65 . This means that, provided signal 30 never commands a current above the current set limit, control of the current supply will be only by light regulator 28 A, with the current regulator only functioning as a current limiter to protect the laser-diode from excess current.
[0035] In this condition, the laser can be defined as having been switched by the comparator from the current regulation mode to a light regulation mode. As this mode-switch occurs essentially instantaneously, at a time when the set power and actual power are equal, the slight overshoot of laser power at the beginning of the light regulation mode period (see FIG. 6C ) is minimized. Further, as the light regulator is only activated when the actual power is equal to the set power the value of feedback capacitor C 1 can be much lower than in the prior art regulator of FIG. 2 . This provides for a much faster regulation response time which would allow for fast analog modulation (if desired) during an “on” period. Output noise, particularly at higher modulation frequencies is also considerably reduced by the use of the smaller capacitor value.
[0036] At the end of the digital modulation cycle, the digital modulation input signal goes from high to low. This disables current supply 32 and the current set point is switched back to zero by switch 76 . The state of the comparator/latch combination is reset to low (digital zero) which changes back the status of switches 72 and 74 putting the light regulator back in a buffered state, and the set-current generator ready for current regulation at the beginning of a next digital modulation cycle.
[0037] It can be seen from FIG. 6C , that the inventive arrangement and operating method of laser 50 , wherein laser output power is controlled first by a current regulator and then by a light regulator, provides that stabilized power at low and high set values begins to be delivered a very short time after the laser build up time has elapsed. This, in turn, provides that, for any chosen duration of a modulation cycle, stabilized power is delivered over a greater portion of the modulation cycle than in a prior-art laser in which laser output power is controlled entirely by a light regulator. Further, the portion of the modulation over which the stabilized power is delivered is only weakly dependent on the peak laser power. What dependence there is the opposite of that of the prior-art laser, with stabilized power being reached slightly faster for lower peak power than it is reached for higher peak power.
[0038] By way of example, the above-described laser intra-cavity frequency-doubled OPS laser, which required 200 μs for stabilization at 2 mW set power compared with about 20 μs for stabilization at 20 mW set-power, was modified with the additional circuitry and components of FIG. 4 and FIG. 5 . At set power levels of 20 mw, 10 mW, 5 mW, and 2 mW, stabilization times were 24 μs, 20 μs, 16 μs, and 18 μs, respectively. In the circuitry of FIG. 5 , values for R 2 , R 3 , R 4 , R 5 , R 6 , R 7 , and R 8 were 1000 Ohms, 10 Ohms, 1000 Ohms, 10 Ohms, 1000 Ohms, 10,000 Ohms, and 0.1 Ohms, respectively. Values for C 1 and C 2 were 3.3 nanofarads and 100 picofarads, respectively. Diodes D 1 and D 2 were each type 1PS76SB10 diodes, available from Philips NV of Eindhoven, Holland.
[0039] It should be noted, here, that functional electronic circuitry described above for implementing the inventive method of operation of a digitally modulated diode-pumped solid-state laser is merely one example of such circuitry. Those skilled in the electronic art, from the description of the present invention provided herein may devise other circuitry for implementing the inventive operation method without departing from the spirit and scope of the present invention.
[0040] In summary, the present invention is described above with reference to a preferred embodiment. The invention, however, is not limited to the embodiment described. Rather, the invention is limited only by the claims appended hereto. | A method of operating a digitally modulated solid state laser is disclosed. The laser is optically pumped by a current-supply driven diode-laser radiation and with output-power stabilized at a desired value by a light regulator cooperative with a power monitor and the current source is disclosed. When the laser is turned on, the current-source is enabled and the light-regulator is disabled. A current regulator allows current from the current-supply to increase until the monitored power reaches the desired value. At this point, the light regulator is enabled and the light regulator assumes control of the current-supply for maintaining the output-power at the desired level. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority to Sweden Patent Application 1050359-7, filed Apr. 13, 2010 and PCT/SE2011/050396, filed Apr. 4, 2011.
FIELD OF THE INVENTION
[0002] The present invention concerns a vibration arrangement for a vehicle steering wheel.
[0003] The present invention is included as an important part of an active safety system for motor vehicles. In such a system, there are included a detection component, which detects situations of impending danger, and a calculation component, which raises an alarm. This alarm takes place in a warning component, which warns the driver when danger has been detected. The warning component may use a steering wheel vibrator according to the invention.
BACKGROUND OF THE INVENTION
[0004] The development of active safety systems for motor vehicles has focused on not only the detection of traffic dangers but also on suitable driver alarms in various situations of danger. The alarms that have been tested have been visual, acoustic, and haptic alarms, and combinations of these.
[0005] Different types of alarms may prove to be more suitable and effective depending on the traffic situation.
[0006] Visual alarms can be used in a traffic situation in which the driver is fully awake and alert, but become completely ineffective if the driver has fallen asleep or is in the process of falling asleep. Acoustic alarms are less appropriate in situations in which the driver has impaired hearing or in which the surrounding noise level is high.
[0007] Both acoustic and haptic alarms can be used in cases in which the driver falls into a short-lived or unbroken sleep. A haptic alarm in the form of mechanical vibration in the steering wheel has the major advantage over both an acoustic alarm and a haptic alarm located in other locations, such as in the seat belt or in the driver's seat, in that the feeling of vibration in the hands and fingers of the driver leads to an immediately and distinct grip on the steering wheel, while the driver is at the same time awakened, as has been described in WO 2007/136 338 A1. The present invention uses this knowledge.
[0008] Many different ways of creating vibration in a vehicle steering wheel are known. Arrangements based on electromagnetic or piezoelectric vibrators have been described with the installation of such between a fixed point in the vehicle and the shaft of the steering wheel, or between the center part of the steering wheel and its spokes, or between the spokes of the steering wheel and its ring. Imbalance motors are known, whose installation is normally in direct physical contact with some part of the supporting metal structure of the steering wheel, for example a spoke, or for installation onto the steering wheel. A further previously known arrangement uses piezoelectric layers at some part of the outer cover of the steering wheel, with piezoelectric crystals or piezoelectric tape.
[0009] In order for the vibration to be experienced around the complete ring of the steering wheel, it has been suggested that the complete metallic part of the steering wheel be placed into an oscillation condition. This requires, however, an equivalent electromechanical power in a vibrator in order to achieve the vibration. Furthermore, the complex geometry of the steering wheel leads to vibration in several directions, which, together with different resonance frequencies in different parts of the steering wheel, easily creates phase distortions and irregular oscillation modes. It is therefore very complicated to produce vibration that corresponds to a desired frequency in the surface of the steering wheel.
[0010] Experience shows, in addition, that the maxima of amplitude vary in an undesired manner around the ring of the steering wheel when the known methods of installing vibrators are used.
[0011] The steering wheel vibrator is primarily suited to be an integral part of a vehicle steering wheel, but it can be designed also to be a part of externally mounted supplementary equipment on a vehicle steering wheel such as in a cover, which can also contain a detection component and a calculation component.
[0012] The present invention consists of a vibration arrangement that removes the disadvantage of a large vibration body, which the metal structure of the steering wheel is, and thus removes the requirement for a powerful vibrator, the disadvantage of poor distribution of vibration in the irregular body, and the disadvantage of oscillatory interference. Furthermore, the present invention offers the possibility of achieving a desired vibratory effect in the surface of the steering wheel independently of the design of the steering wheel.
[0013] The present invention thus relates to a vibration arrangement for a vehicle steering wheel comprising one or more vibrators mounted to a ring of the steering wheel, the ring having a metallic part that is mechanically coupled to a steering wheel hub, and where at least one vibrator is arranged to produce a vibration frequency, wherein the vibrator is attached to a vibration body, wherein the vibration body is elongated, wherein the vibration body extends around at least a majority of the ring of the steering wheel without being in contact with the metallic part of the ring of the steering wheel, and wherein the vibration body is positioned close to the external surface cover that a driver grips when driving the vehicle.
[0014] A vibration arrangement according to the invention for a vehicle steering wheel comprises one or more vibrators at or in the ring of the steering wheel. A vibration body and a vibrator can be arranged to be electrically connected to a source of voltage. The vehicle steering wheel has a ring with a metallic part that is mechanically coupled with a steering wheel hub. The metallic part of the ring of the steering wheel can be connected to spokes that pass to a steering wheel hub. At least one vibrator is arranged to produce a vibration frequency in the vibration body.
[0015] The vibrator can be, according to the invention, coupled to the vibration body. The vibration body can be elongated and arranged to extend around at least a majority of the complete ring of the steering wheel without being in contact with the metallic part of the ring of the steering wheel. The vibration body can be arranged to be positioned close to the external surface cover that a driver grips when controlling the vehicle.
[0016] In one form, the vibration body is in the form of a rod.
[0017] In one form, the vibration body has two free ends and the vibrator is mounted at one of the free ends.
[0018] In one form, the vibrator is attached at the two free ends of the vibration body such that a closed ring is formed.
[0019] In one form, the vibration body is a closed ring, and the vibrator is mounted to the closed ring.
[0020] In one form, the vibrator is an imbalance motor coupled with the vibration body, joined to form a single unit.
[0021] In one form, the vibration body is made of metal.
[0022] In one form, in which one or more vibrators are integrated with the steering wheel, the diameter of each ring-shaped vibration body coupled to the vibrator is less than the outer diameter of the steering wheel and greater than its inner diameter.
[0023] In one form, two more vibrators are each coupled to an individual vibration body.
[0024] In one form, the individual vibrations bodies lie separated from each other.
[0025] In one form, one of the two or more vibrators is located close to the upper side of the steering wheel ring, and another of the two or more vibrators is located close to the lower side of the steering wheel ring, and the vibrators are configured to operate at different angular frequencies.
[0026] In one form, the vibration body is mechanically coupled with an imbalance motor that is encapsulated in a suitable manner. A vibration arrangement according to the invention contains at least one ring-shaped vibration body, which can also be referred to as a “vibrator ring”, which is coupled with the cover of at least one imbalance motor. The vibration arrangement is an integrated part of a vehicle steering wheel and is installed inside the ring of the steering wheel close to its outer cover.
[0027] In another form, the vibration body, or vibrator ring, and its encapsulated vibrator, or imbalance motor, are located inside a specially designed cover, wherein this cover can be mounted onto an existing steering wheel in a motor vehicle. The integration of the steering wheel vibrator with the cover can be designed in a similar manner in order to allow vibration even when hard hand pressure influences the cover.
[0028] In one form, the one or more vibrator and the one or more vibration body are arranged such that the external surface cover of the ring of the steering wheel vibrates with a frequency and an amplitude such that the Pacinian or Meissner corpuscles in the fingers or hands of the driver are stimulated.
[0029] The embodiments according to the invention are based on a similar vibration arrangement comprising an imbalance motor, or vibrator, and an open or closed vibrator ring, or vibration body, coupled with it. It is an aspect of the solution and the invention that the ring can be designed with respect to material, mass and cross-sectional form in such a manner that the desired amplitude is achieved at a selected degree of imbalance and a selected rate of revolution of the motor, which determines the applied vibration frequency.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] So that the invention may be more readily understood, and so that further features thereof may be appreciated, embodiments of the invention will now be described by way of example with reference to the accompanying drawings in which:
[0031] FIG. 1 is a plan view of a freed steering wheel vibrator assembly;
[0032] FIG. 2 is an enlarged partial plan view of a vibrator of the vibrator assembly of FIG. 1 ;
[0033] FIG. 3 is a plan view of a vehicle steering wheel with the steering wheel vibrator assembly;
[0034] FIG. 4 is a cross-sectional view of the vehicle steering wheel taken along line A-A of FIG. 3 ;
[0035] FIG. 5 is a plan view of another steering wheel with another steering wheel vibrator assembly;
[0036] FIG. 6 is a cross-sectional view of the steering wheel of FIG. 5 taken along line B-B;
[0037] FIG. 7 is a cross-sectional view of the steering wheel of FIG. 5 taken along line C-C;
[0038] FIG. 8 is a plan view of a steering wheel vibrator assembly mounted in a cover for a steering wheel, and
[0039] FIG. 9 is a cross-sectional view of the cover taken along line D-D.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0040] The object of the invention is to be able to generate in an efficient and controlled manner haptic vibration signals around the ring of a steering wheel to the driver of a motor vehicle, where the driver's hands and fingers grip the steering wheel.
[0041] FIG. 1 shows a steering wheel vibrator assembly 1 including a vibrator 2 and a ring-shaped vibration body 3 . FIG. 2 shows the central parts of the vibrator 2 , where 21 denotes an imbalance motor, 22 denotes an imbalance element, 23 denotes a protective cover, 24 denotes electrical conductors, and 3 denotes the vibration body 3 of the steering wheel vibrator assembly 1 .
[0042] The motor unit or vibrator 2 of the steering wheel vibrator assembly 1 in FIGS. 1 and 2 is mechanically mounted to the vibration body 3 through brazing or welding or other known technology, such that the motor shaft of the imbalance motor 21 is parallel with the tangential direction of the vibration body 3 at the point of attachment.
[0043] As is shown in FIG. 2 , the vibrator 2 comprises the motor 21 with its displaceable imbalance element 22 and the protective cover 23 , which is mounted to the motor 21 and arranged so that the imbalance element 22 can rotate freely.
[0044] The cross-sectional area of the ring-shaped vibration body 3 shown in FIGS. 1 and 2 is circular, but it may also have another form and it may be selected, for example, such that the desired vibration is primarily directed towards the normal of the external surface cover of the steering wheel after installation. The ring-shaped vibration body 3 should oscillate most easily in a direction that is perpendicular to the longest side of the cross-sectional area.
[0045] In FIG. 3 , the reference number 4 denotes a steering wheel of a motor vehicle, 41 its central part, 42 its spokes, 43 the ring of the steering wheel, 44 a metallic supporting structure of the steering wheel, and 45 a soft outer cover of the steering wheel, which cover 45 is fixed at the metallic supporting structure 44 of the steering wheel 4 .
[0046] The outer cover 45 of the steering wheel has been drawn in FIG. 3 with full lines and the metal supporting structure 44 of the steering wheel with dashed lines, while the steering wheel vibrator assembly 1 , with its vibrator 2 and vibration body 3 , has been drawn with dot-dashed lines. The steering wheel 4 in this design is provided with the steering wheel vibrator assembly 1 , which is located close to the outer diameter of the steering wheel 4 .
[0047] According to one highly preferred embodiment, the elongate vibration body 3 is arranged in or on the ring 43 of the steering wheel 4 . Furthermore, the vibration body 3 and the vibrator 2 are surrounded by a soft and flexible material.
[0048] According to a significant embodiment, the vibration body 3 is arranged in a track or a groove 451 , located in the ring 43 of the steering wheel 4 under the outer cover 45 of the ring 43 .
[0049] The reference number 451 in FIG. 4 denotes the groove in the ring 43 of the steering wheel 4 , 31 denotes a soft spacer material, and 32 a shock-absorbing reinforcement, of a suitable material, for the walls of the groove 451 .
[0050] FIG. 4 , which shows an enlarged cross-section A-A in FIG. 3 , shows how the vibration body 3 is oriented in the groove 451 in the outer cover 45 of the ring 43 of the steering wheel 4 , which generally lies around the complete circumference of the ring 43 of the steering wheel 4 . The location of the vibration body 3 in the groove 451 is such that the vibration body 3 can vibrate easily, without large counteracting forces from the walls of the groove 451 , and such that the vibration is not easily propagated to these walls. It is preferred that the vibration body 3 be held in place by means of a soft and flexible spacer material 31 between the vibration body 3 and the walls of the groove 451 . It is preferred that the spacer material 31 be plastic. During manufacture, the vibration body 3 and its flexible spacer material 31 can be provided with an outer cover 32 that forms a wall at the site of plastic injection at the steering wheel 4 , such that the outer cover 45 of the steering wheel 4 conceals the vibration body 3 . That which has been described here is valid to the same extent for the vibrator 2 that is fixed at the vibration body 3 .
[0051] According to one preferred embodiment, more than one vibrator 2 is present, where one of the vibrators 2 is coupled to a first vibration body 11 and another vibrator 2 is coupled to a second vibration body 12 . It will be appreciated that additional vibrators could be coupled to additional vibration bodies.
[0052] In this approach, the vibration bodies 11 and 12 lie separated from each other, and each one of the first and second vibration bodies 11 and 12 is coupled to its respective vibrator 2 , as shown in FIGS. 6 and 7 .
[0053] In this approach, the first vibration body 11 is located close to the upper side of the ring 43 of the steering wheel 4 and the second vibration body 12 is close to the lower side of the steering wheel 4 . These first and second vibration bodies 11 and 12 , along with their respective vibrators 2 , are designed such that they can operate at different angular frequencies.
[0054] FIGS. 5-7 show a design of steering wheel vibrators 2 installed in the steering wheel 4 . The steering wheel 4 for a passenger vehicle with three spokes is shown in this case as an example. The metallic supporting structure 44 of the steering wheel 4 has been omitted from FIG. 5 for reasons of clarity. This variant shows an example of how a steering wheel can be designed with the aid of the invention to have, at the same time, haptic alarms with two different frequencies with limited interference between the two frequencies.
[0055] The reference number 11 in FIGS. 5-7 denotes the first steering wheel vibration body that operates at a first angular frequency ω 1 and the reference number 12 denotes the second steering wheel vibration body, that operates at a second angular frequency ω 2 .
[0056] FIG. 5 shows in a view from above a vehicle steering wheel 4 and a steering wheel vibration body 11 , shown with dashed lines, that lies inside it. FIG. 6 shows a cross-section B-B of the ring 43 of the steering wheel 4 , where it is clear that the upper side of the steering wheel 4 is provided with the first vibration body 11 , and the lower side of the ring 43 of the steering wheel 4 is provided with the second steering wheel vibration body 12 . The metallic supporting structure 44 of the steering wheel 4 is suggested with oblique hatching cross-section in FIGS. 6 and 7 .
[0057] The uppermost steering wheel vibration body 11 , which operates at the angular frequency ω 1 , lies in a groove at the upper side of the ring 43 of the steering wheel 4 , while the lower steering wheel vibration body 12 , which operates at the angular frequency ω 2 , is located in a groove at the lower side of the ring 43 of the steering wheel 4 . Both steering wheel vibrators 11 and 12 are at the boundary of the respective side of the outer cover 45 of the ring 43 of the steering wheel 4 , which cover 45 thus absorbs the vibration ω 1 at the upper side and the vibration ω 2 at the lower side. Both vibration bodies 11 and 12 have free mobility on other sides since they are bounded by a very flexible spacer material 31 , such as extra-soft foamed plastic, which reduces the damping of vibration and leads to a low variation in amplitude around the vibration bodies 11 and 12 . When the hand pressure against the ring 43 of the steering wheel 4 increases, through a stronger grip from the driver, these forces are absorbed by the ring 43 of the steering wheel 4 , while the vibration bodies 11 and 12 do not exert any other counteracting force that their own forces of deformation. In this way, significantly dampened vibration is limited when hand pressure increases.
[0058] FIG. 7 shows a cross-section C-C in FIG. 5 , with the location of the vibrators 2 associated with the vibration bodies 11 and 12 . The plastic external surface cover 45 of the ring 43 of the steering wheel 4 is sufficiently hard and shock-absorbent, such that no reinforcement 32 of the groove 451 is necessary in this approach.
[0059] According to a second embodiment of the invention illustrated in FIGS. 8 and 9 , the vibrator assembly 1 , including the vibrator 2 and the vibration body 3 , is located in a cover 5 that can be applied and removed, arranged to lie around the ring 43 of the steering wheel 4 .
[0060] The reference number 5 in FIGS. 8 and 9 denotes an alternative cover for a steering wheel. The reference number 51 denotes a protuberance of the cover 5 , and 551 denotes a groove in the cover 5 .
[0061] The protuberance 51 contains a compartment for the vibrator 2 and an alarm-raising arrangement, which may be arranged as specified by the Swedish patent SE 539317, containing a detection component with a sensor for movement of the steering wheel and units for setting and indication, etc.
[0062] FIG. 8 shows the cover 5 equipped with a steering wheel vibrator assembly 1 according to the invention. The compartment of the protuberance 51 for the alarm-raising arrangement is suggested in FIG. 8 .
[0063] The steering wheel vibrator assembly 1 in its design follows the same principles that have been described above for a steering wheel vibrator according to the invention installed in the steering wheel 4 and located in a groove 551 of the cover 5 in such a manner that the cover 5 absorbs forces of pressure from the hands without placing any pressure load onto the vibrator assembly 1 through it being positioned inside a very flexible spacer material 31 in the groove 551 .
[0064] The power supply for the alarm-raising arrangement may be from a small battery and/or an electrical conductor with a contact, adapted to the cigarette lighter fitting of the vehicle, not shown in FIG. 8 .
[0065] FIG. 9 shows a cross-section through D-D of the cover in FIG. 8 , where the vibrator assembly 1 is located at the outer part of the cover 5 and rests against a flexible spacer material 31 in a groove 551 in the cover 5 , as shown in FIG. 9 .
[0066] According to a further embodiment of the invention, one or more steering wheel vibrator assemblies 1 are integrated into the cover 5 for the car steering wheel 4 , which is equipped, in addition to this, with an alarm-raising arrangement.
[0067] Independently of the designs described above, it is a preferred embodiment that the vibrator 2 and the vibration body 3 are arranged such that the external surface cover 45 of the ring 43 of the steering wheel 4 vibrates with a frequency and an amplitude such that the Pacinian or Meissner corpuscles in the fingers or hands of the driver are stimulated. In the case in which two vibration bodies, such as the vibration bodies 11 and 12 each with a vibrator 2 , are present, one of the vibration bodies 11 or 12 can vibrate with a frequency and an amplitude such that the Pacinian corpuscles are stimulated, while the other of vibration bodies 11 or 12 can vibrate with a frequency and an amplitude such that the Meissner corpuscles are stimulated.
[0068] The present invention solves the problems described in the introduction. The invention concerns an arrangement that can be designed to give an even, desired frequency and amplitude of vibration and an even distribution of the vibration around the ring 43 of the steering wheel 4 . The arrangement can be generally used for vehicle steering wheels without extra fitting.
[0069] By using two steering wheel vibrator assemblies 1 separated from each other in the steering wheel 4 , the invention makes possible, at the same time, the presence of two different frequencies around the ring 43 of the steering wheel 4 , as is suggested in WO 2007/136 338 A1, and without any noticeable interference arising between these two vibrations.
[0070] Through the arrangement containing a vibration body 3 that has considerably less mass than the metal structure 44 of the steering wheel 4 , considerably less electromotor energy will need to be supplied, while at the same time a haptic alarm obtains a higher quality through its even distribution and the distinctive character of its frequency.
[0071] It is obvious that one skilled in the art can develop alternative locations of the vibrator assembly 1 and other embodiments of the invention, and that such a person can modify the arrangements described and achieve the desired functionality, without deviating from the innovative concept of the present invention.
[0072] While the invention has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. It will be appreciated that the invention is susceptible to modification, variation, and change without departing from the proper scope and fair meaning of the accompanying claims. | A vibration arrangement for a vehicle steering wheel includes at least one steering wheel vibrator assembly at or in the ring of the steering wheel, the steering wheel ring having a metallic part that is mechanically coupled to a steering wheel hub and where the at least one vibrator assembly is arranged to produce a frequency of vibration. The vibrator assembly includes a vibrator coupled to an elongate ring-shaped vibration body, arranged to lie around at least a majority of the steering wheel ring without being in contact with the metallic part of the steering wheel ring. The vibration body is arranged to be positioned close to an external surface cover of the steering wheel, which a driver grips while controlling the vehicle. The vibrator assembly can produce a vibration to alert the driver. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2007-260147 filed Oct. 3, 2007.
BACKGROUND
(i) Technical Field
The present invention relates to an optical module.
(ii) Related Art
Generally, an electronic device includes plural elements in many cases. For example, a copier includes an image inputting unit and an image outputting unit. In the copier, image data input from the image inputting unit is sent to the image outputting unit through an electrical cable to be printed on a printing medium such as a paper sheet.
In recent years, with development of high capability of an electronic device, a volume of transmission capacity between devices has been increased. In order to deal with the high capacity using a known parallel transmission method, a method of increasing the number of channels or a method of speeding up synchronous clock can be taken into consideration. However, an error caused due to skew between channels caused by a difference of a wiring length or a decrease in timing margin may easily occur. Accordingly, in order to solve this problem, a serial transmission method of transmitting data signals through one transmission path has become attracted.
However, since a transmission rate increases in the serial transmission method, it is difficult to embody signal transmission while maintaining good signal quality in an electrical cable by nature. As a technique for solving such a problem, a method of using an optical signal which can perform broadband signal transmission has been under examination.
SUMMARY
According to an aspect of the invention, there is provided an optical module comprising: an optical element array comprising plural optical elements that emits or receives light; and an optical waveguide comprising a clad and plural cores respectively with optical path changing portions, the cores being disposed in the clad with an interval, wherein the plural optical path changing portions are optically connected to the plural optical elements, and the plural optical path changing portions are arranged in a first direction having an angle with respect to a formation direction of the cores, the first direction being corresponding to an arrangement direction of the plural optical elements.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the present invention will be described in detail based on the following figure, wherein:
FIGS. 1A and 1B are diagrams illustrating an optical module according to a first exemplary embodiment of the invention, in which FIG. 1A is a side view illustrating the optical module and FIG. 1B is a partly expanded view illustrating an optical waveguide;
FIG. 2 is a top view illustrating the optical module shown in FIG. 1A ;
FIG. 3 is a top view illustrating the optical waveguide shown in FIG. 1A ;
FIG. 4 is a front view illustrating an optical module according to a second exemplary embodiment of the invention;
FIG. 5 is a top view illustrating the optical module shown in FIG. 4 ;
FIG. 6 is a top view illustrating an optical waveguide shown in FIG. 4 ;
FIG. 7 is a top view illustrating a configuration of an optical module according to a third exemplary embodiment of the invention;
FIG. 8 is a top view illustrating an optical waveguide of the optical module according to the third exemplary embodiment;
FIG. 9 is a top view illustrating a configuration of an optical module according to a fourth exemplary embodiment of the invention;
FIG. 10 is a top view illustrating an optical waveguide of the optical module according to the fourth exemplary embodiment; and
FIG. 11 is a sectional view illustrating an optical module according to a fifth exemplary embodiment of the invention.
DETAILED DESCRIPTION
First Exemplary Embodiment
(Configuration of Optical Module)
FIGS. 1A and 1B are diagrams illustrating an optical module according to a first exemplary embodiment of the invention. FIG. 1A is a side view illustrating the optical module and FIG. 1B is a partly expanded view illustrating an optical waveguide. FIG. 2 is a top view illustrating the optical module shown in FIG. 1A . FIG. 3 is a top view illustrating the optical waveguide shown in FIG. 1A .
The optical module 100 has a configuration for converting electric signals of four channels into optical signals to simultaneously transmit the converted optical signals and for simultaneously receiving the optical signals of the four channels to convert the optical signals into the electric signals. In addition, the number of channels is four in this exemplary embodiment, but any number of channels can be set. The same is also applied to the following exemplary embodiments.
As shown in FIGS. 1A , 1 B, and 2 , the optical module 100 includes a board 1 which is a mounting board for mounting optical elements; a light-emitting element array 2 which is mounted on the board 1 ; a light-receiving element 3 which is mounted on the board 1 and gets away from the light-emitting element array 2 by a gap g between the light-emitting elements and receiving elements; a driving IC 4 which is electrically connected to the light-emitting element array 2 to be mounted on the board 1 ; an amplifying IC 5 which is electrically connected to the light-receiving element array 3 and mounted on the board 1 ; a spacer 6 which is mounted on the board 1 ; and an optical waveguide 7 which is fixed onto the spacer 6 and includes mirrors 74 A to 74 D and 75 A to 75 D as a light path changing portion formed on a 45° inclined surface on each one end thereof.
The board 1 , which is made of an epoxy resin, for example, includes electrode pads 11 A to 11 D connected to the light-emitting element array 2 , the light-receiving element array 3 , the driving IC 4 , and the amplifying IC 5 .
(Configuration of Light-Emitting Element Array 2 )
The light-emitting element array 2 is composed of four VCSELs (Vertical Cavity Surface Emitting Laser) 20 A to 20 D for generating modulation light of four channels, for example. In this exemplary embodiment, as shown in FIG. 2 , in order to facilitate connection with the driving IC 4 , the light-emitting element array 2 is arranged so that an element mount direction thereof is reverse to the element mount direction of the light-receiving element array 3 . At this time, the element mount direction refers to a direction of taking out a bonding wire from the light element array. In this exemplary embodiment, the element mount directions of the light-emitting element array 2 and the light-receiving element array 3 are reverse to each other by 180°.
The VCSELs 20 A to 20 D each include an light-emitting portion having a laminated configuration in which an n-type lower reflector layer, an active layer, a current narrowing layer, a p-type upper reflector layer, a p-type contact layer, and a p-side electrode are laminated on an n-type GsAs board having an n-side electrode on the rear thereof. In addition, each of the p-side electrodes is connected to each of electrode pads 11 B of the board 1 by the bonding wire (signal line) 2 a.
(Configuration of Light-Receiving Element Array 3 )
The light-receiving element array 3 is composed of, for example, four photodiodes (PD) 30 A to 30 D as a light-receiving element for performing an optical-electric conversion of four channels. In particular, it is preferable to use GaAs series in the PDs 30 A to 30 D since a high-speed response can be obtained.
As shown in FIG. 2 , the light-receiving element array 3 is mounted so that a gap g between the VCSELs 20 A to 20 D and the PDs 30 A to 30 D is larger than a pitch p, that is, a relation of g>p is satisfied, assuming that the pitch p is a pitch between the elements in a direction in which the VCSELs 20 A to 20 D and the PDs 30 A to 30 D are adjacent to each other.
For example, on the GaAs board, the PD 30 A to 30 D include a p layer, an I layer, and an N layer, which form PIN junction, a p-side electrode formed on the p layer, and an n-side electrode formed on the N layer. The p-side electrode has an opening, and the inside of the opening is a light-receiving portion for receiving a laser beam. Each p-side electrode and each n-side electrode of the light-receiving element array 3 are connected on each electrode pad 11 C of the board 1 by a bonding wire (signal line) 3 a.
(Configurations of Driving IC 4 , Amplifying IC 5 , and Spacer 6 )
The driving IC 4 is a driving circuit for performing current-driving of the light-emitting element array 2 on the basis of transmitting data. In this exemplary embodiment, a flat package (FP) type surface-mounting package is used in the driving IC 4 .
The amplifying IC 5 is a amplifying circuit which includes transimpedance amplifiers (TIA) (not shown) of four channels for converting current variation of the light-receiving element array 3 into voltage variation and limiting amplifiers (LA) (not shown) of four channels for amplifying and outputting the output voltage of the TIA so as to become predetermined output voltage. In this exemplary embodiment, a flat package (FP) type surface-mounting package is used in the amplifying IC 5 .
The spacer 6 positions and fixes the optical waveguide 7 so as to maintain an optical connection distance between the light-emitting element array 2 and the light waveguide 7 and between the light-receiving element array 3 and the light waveguide 7 . The spacer 6 is formed of an insulating material board such as an epoxy resin board or a Si board. The spacer 6 is adhered to the optical waveguide 7 by an adhesive, but may be positioned by means of a different supporting adhering way such as fitting.
(Configuration of Optical Waveguide 7 )
As shown in FIG. 3 , the optical waveguide 7 includes cores 71 A to 71 D of four channels for transmitting a transmitting optical signal, cores 72 A to 72 D of four channels for transmitting a receiving optical signal, and a clad 73 for surrounding the cores 71 A to 71 D and the cores 72 A to 72 D.
The cores 71 A to 71 D and the cores 72 A to 72 D are made of an acrylic resin or an epoxy resin, for example. The clad 73 can be made of a film material which has a refractive index smaller than that of the cores 71 A to 71 D and the cores 72 A to 72 D, an optical property such as optical transparency, mechanical strength, heat resistance, flexibility, etc. Examples of the film material include an acrylic resin, a styrene resin, an olefinic resin, and a vinyl chloride series resin.
As shown in FIG. 1B , each one end (front ends) of the cores 71 A to 71 D and the cores 72 A to 72 D is formed so as to have a 45° inclined surface. In addition, each of mirrors 74 A to 74 D and mirrors 75 A to 75 D is formed on the inclined surface 7 a . The mirrors 74 A to 74 D and the mirrors 75 A to 75 D are each formed in a manner in which the 45° inclined surface 7 a is formed by removing each one end of the cores 71 A to 71 D and the cores 72 A to 72 D, and an Au film or the like is deposited on the surface of each one end by electron beams. In addition, the mirrors may be formed by a precision mold. As shown in FIG. 3 , a gap G of the mirrors 74 A to 74 D and the mirrors 75 A to 75 D is configured so as to be equal to the gap g between the VCSELs 20 A to 20 D and the PD 30 A to 30 D.
(Operation of Optical Module 100 )
Next, an operation of the optical modules 100 will be described. When a transmitting signal is input to the driving IC 4 , a modulation signal is applied to the light-emitting element array 2 in accordance with the transmitting signal, and driving current flows to the VCSELs 20 A to 20 D. The VCSELs 20 A to 20 D emit light in accordance with the drive current, and the output light is incident to the mirrors 74 A to 74 D provided in the cores 71 A to 71 D of the optical waveguide 7 .
The optical signal incident to the mirrors 74 A to 74 D is incident to the cores 71 A to 71 D after the optical signal is reflected on the mirrors 74 A to 74 D and the optical path thereof is changed. The optical signal incident to the cores 71 A to 71 D propagates through the cores 71 A to 71 D in the right direction of FIG. 3 and reaches the end of the cores 71 A to 71 D to be transmitted to a different optical module which is not shown.
On the other hand, when an optical signal is incident to the cores 72 A to 72 D of the optical waveguide 7 , the optical signal propagates through the cores 72 A to 72 D from the right direction to the left direction of FIG. 3 to be incident to the mirrors 75 A to 75 D. The optical signal incident to the mirrors 75 A to 75 D is incident to the PD 30 A to 30 D after the optical signal is reflected on the mirrors 75 A to 75 D and the optical path thereof is changed.
The PD 30 A to 30 D converts the incident optical signal into current. An electric output generated from the PD 30 A to 30 D is sent to an image processing IC, which is not shown, after the amplifying IC 5 converts the current into voltage to obtain an electric signal and performs predetermined amplifying.
In the first exemplary embodiment, the arrangement of the light-emitting element array 2 and the light-receiving element array 3 is just an example, and the arrangement of light-emitting element array 2 and the light-receiving element array 3 may be changed with each other to be mounted in the board 1 .
Second Exemplary Embodiment
FIG. 4 is a front view illustrating an optical module according to a second exemplary embodiment of the invention. FIG. 5 is a top view illustrating the optical module shown in FIG. 4 . FIG. 6 is a top view illustrating an optical waveguide shown in FIG. 4 . In addition, in FIGS. 4 to 6 , a configuration of a light-receiving side is now shown.
In this exemplary embodiment, the VCSELs 20 A to 20 D of the light-emitting element array 2 according to the first exemplary embodiment are disposed at a predetermined angle θ (for example, 45°) with respect to a direction in which the cores 71 A to 71 D of the optical waveguide 7 are formed. In addition, the rest configuration is the same as that according to the first exemplary embodiment.
As shown in FIG. 5 , the VCSELs 20 A to 20 D are disposed at the angle θ with respect to the end surface of the optical waveguide 7 and at an angle α with respect to the direction in which the cores 71 A to 71 D and the cores 72 A to 72 D are formed. A pitch p of the cores 71 A to 71 D of the optical waveguide 7 satisfies a relation of p=P cosθ for a pitch P between the VCSELs 20 A to 20 D. That is, the pitch p between the cores 71 A to 71 D is narrower than the pitch P of the VCSELs 20 A to 20 D.
In the second exemplary embodiment, the light-emitting element array 2 may be configured in place of the light-receiving element array 3 . Moreover, a light-receiving element array 3 and the corresponding cores may be added to the configuration shown in FIG. 5 . Moreover, a plurality of the light-emitting element arrays 2 may be configured.
Third Exemplary Embodiment
FIG. 7 is a top view illustrating a configuration of an optical module according to a third exemplary embodiment of the invention. FIG. 8 is a top view illustrating an optical waveguide of the optical module according to the third exemplary embodiment.
In this exemplary embodiment, the light-emitting element array 2 and the light-receiving element array 3 according to the first exemplary embodiment are disposed at an angle θ with respect to the end surface of the cores 71 A to 71 D and the cores 72 A to 72 D of the optical waveguide 7 and are disposed at an angle α with respect to a direction in which the cores 71 A to 71 D and the cores 72 A to 72 D are formed, in the same manner as that according to the second exemplary embodiment. In FIG. 7 , the spacer described in the first exemplary embodiment is not shown. Likewise, the optical waveguide 7 is configured in a manner in which mirrors 74 A to 74 D and mirrors 75 A to 75 D are provided so that each end surface of the cores 71 A to 71 D and each end surface of the cores 72 A to 72 D are disposed at the angle θ with respect to the end surface 7 b of the optical waveguide 7 and the two optical waveguide 7 according to the second exemplary embodiment are arranged in parallel with each other which is shown in FIG. 6 .
As shown in FIG. 7 , the driving IC 4 and the amplifying IC 5 are arranged more outside than the light-emitting element array 2 and the light-receiving element array 3 , so that the light-emitting element array 2 and the light-receiving element array 3 are approximated to each other and the mirrors 74 A to 74 D and the mirrors 75 A to 75 D shown in FIG. 8 get together in the end of the optical waveguide 7 . A gap g between the VCSELs 20 A to 20 D and the PDs 30 A to 30 D is larger than the pitch P, that is, a relation of g>P is satisfied.
Fourth Exemplary Embodiment
FIG. 9 is a top view illustrating a configuration of an optical module according to a fourth exemplary embodiment of the invention. FIG. 10 is a top view illustrating an optical waveguide of the optical module according to the fourth exemplary embodiment.
In this exemplary embodiment, the light-receiving element array 3 according to the third exemplary embodiment rotates by 90° to be mounted so that PDs 30 A to 30 D of the light-receiving element array 3 is disposed at right angles with respect to a direction in which VCSELs 20 A to 20 D of the light-emitting element array 2 are arranged. Mirrors 74 A to 74 D and mirrors 75 A to 75 D of the optical waveguide 7 are arranged in accordance with the arrangement of the light-emitting element array 2 and the light-receiving element array 3 . The rest configuration is the same as that according to the third exemplary embodiment.
In this case, the light-receiving element array 3 is disposed so that the cores 71 A to 71 D and the cores 72 A to 72 D of the optical waveguide 7 have the same pitch and the PDs 30 A to 30 D have the same pitch p as that of the VCSELs 20 A to 20 D.
In the fourth exemplary embodiment, the mirrors 74 A to 74 D and the mirrors 75 A to 75 D of the optical waveguide 7 may be arranged in a V shape. In this case, the light-emitting element array 2 and the light-receiving element array 3 are arranged so that the VCSELs 20 A to 20 D and the PDs 30 A to 30 D shown in FIG. 9 are formed in a V shape.
Fifth Exemplary Embodiment
FIG. 11 is a sectional view illustrating an optical module according to a fifth exemplary embodiment of the invention.
In this exemplary embodiment, the optical waveguide 7 according to the first exemplary embodiment is disposed on the board 1 and the spacer 6 is removed. In addition, the light-emitting element array 2 is mounted as an optical wiring of the board in a face-down manner. The rest configuration is the same as that according to the first exemplary embodiment. Moreover, the fifth exemplary embodiment may be also applied to the second to fourth exemplary embodiments.
An optical module 100 includes the board 1 on which the optical waveguide 7 is mounted and a light-emitting unit 200 mounted on the board 1 .
The board 1 includes an insulating layer 1 a ; a clad portion 70 which is formed on the insulating layer 1 a and on which the optical waveguide 7 is formed; a core portion 71 of which a refractive index is larger than that of the clad portion 70 ; and a wiring layer 1 b which is formed on the upper surface of the waveguide 7 and on which electrode pads 12 A and 12 B are provided.
Like the description according to the first exemplary embodiment, in the optical waveguide 7 according to the this exemplary embodiment, cores 71 A to 71 D are formed on the clad portion 70 and mirrors 74 A to 74 D are each formed on an inclined surface 7 a formed on each one end of the cores 71 A and 71 D. A translucent resin material having the same refractive index as that of the clad portion 70 fills up portions of each inclined surface 7 a and the mirrors 74 A to 74 D.
The light-emitting unit 200 includes a wiring board 201 with electrode pads 202 A and 202 B on the rear surface thereof; solder balls 203 mounted on the electrode pads 202 A and 202 B, a light-emitting element array 2 mounted on the rear surface of the wiring board 201 ; and a driving IC 4 mounted on the surface of the wiring board 201 .
Other Exemplary Embodiments
The invention is not limited to the above-described exemplary embodiments, but may be modified in various forms within the scope of the invention without departing the gist of the invention. For example, in the first, third, and fourth exemplary embodiments, only one of the light-emitting side and the light-receiving side may be configured.
In the above-described exemplary embodiments, the board 1 may include cores 75 A to 75 D of four channels for receiving light in addition to the cores 74 A to 74 D of four channels for transmitting light. Moreover, the electric wiring layer for transmitting the electric signal may be configured as a multi-layer.
The foregoing description of the exemplary embodiments of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The exemplary embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to understand the invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents. | An optical module comprises: an optical element array comprising plural optical elements that emits or receives light; and an optical waveguide comprising a clad and plural cores respectively with optical path changing portions, the cores being disposed in the clad with an interval. The optical path changing portions are optically connected to the optical elements. The optical path changing portions are arranged in a first direction having an angle with respect to a formation direction of the cores, the first direction being corresponding to an arrangement direction of said plurality of optical elements. | 7 |
RELATED APPLICATIONS
[0001] The present application claims the benefit of U.S. Provision Patent Application No. 60/299,925, filed Jun. 21, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a improved bullet targets. More specifically, the present invention relates to targets which improve the visual stimulation and/or function of the target to improve shooter abilities and to decrease broken targets.
[0004] 2. State of the Art
[0005] In order to maintain proficiency in the use of firearms, it is common for law enforcement officers and sportsmen to engage in target practice. While many perceive target practice as simply a method for improving accuracy, it is important for law enforcement officers and the like to conduct target practice in scenarios which imitate real life situations. While accuracy is important for law enforcement officers, appropriate use of deadly force is even more important. While hitting a perpetrator in the arm or leg may cause some additional risk to the officer, firing at an innocent bystander or firing at a perpetrator who is not a risk raises greater concerns. Each year considerable controversy is raised by law enforcement officers who shoot unarmed individuals or otherwise use deadly force when not appropriate.
[0006] In order to properly train police officers, it is important that they develop both hand-eye coordination and that they receive sensor stimulation which is associated with actual conditions. Thus, it is important for law enforcement officers to be able to see when a target has been hit. It is also important that the target remain upright sufficiently to simulate the reactions of a typical target. Thus, for example, a target which falls when hit by a single shot may nott provide appropriate stimulus to the officer, when a typical perpetrator would take several rounds before being sufficiently incapacitated that he would no longer pose a threat.
[0007] It is also important to train officers by requiring them to repeatedly be in situations in which they are forced to decide whether the target poses a threat within a fraction of a second. In real life situations, hesitating to fire can cost the officer his life. Firing too quickly can result in the death of an innocent party.
[0008] While there are high-tech shooting ranges which are configured to place an officer in a variety of situations, such shooting ranges are too expensive for many law enforcement agencies. Additionally, many existing shooting ranges cannot be readily adapted to use the technological advances. Thus, there is a need for simple bullet targets which provide improved situation stimulus and improved wear.
SUMMARY OF THE INVENTION
[0009] It is the object of the present invention to provide improvements in bullet targets.
[0010] In accordance with the above and other objects of the invention, an improved bullet target is provided, including a head plate which is configured to be impacted by a bullet, an arm for holding the head plate in a line of fire and an attachment mechanism for connecting the head plate to the arm.
[0011] In accordance with one aspect of the invention, the attachment mechanism is formed by a rubber block or some other resilient or semi-resilient material. The rubber block attaches the head plate to the arm in such a manner that the head will deflect each time it is hit but will substantially return to its initial position (generally vertical) shortly after the impact. Thus, the head gives the visual appearance of being impacted as it is hit with each bullet, consistent with the reaction of a person who has been struck by a bullet. The head plate, however, does not fall down after being struck by the preliminary round as is currently done in the prior art. Rather it returns to the original position or a position close thereto. Those skilled in the art will appreciate that this is more similar to many real life situations in which a perpetrator rushing a police officer will be momentarily stopped or knocked backward when hit by a round, and then will resume rushing the officer.
[0012] In accordance with another aspect of the present invention, the improved target includes a head plate which is attached to the arm by a stop. The stop is configured to allow the head plate to rotate between a first presented position and a second retracted position. As the head plate is hit by a bullet, the bullet rotates from the first presented position to the second retracted position. However, because no hinge is directly formed on the head plate, the head is able to withstand a larger number of rounds, and welds on the arms or stops last considerably longer.
[0013] In accordance with another aspect of the invention, the hinge formed between the arm or base and the head plate is formed from flat pieces of steel. Such a hinge is not only more durable than conventional hinges, it can be made relatively inexpensively from scraps of steel left over when making bullet traps, targets and the like.
[0014] In accordance with yet another aspect of the present invention, a pair of targets are disposed behind a chest plate. The targets are then selectively raised so that a user is selectively presented with targets having a color and/or shape representing an enemy and one representing an innocent party. The heads plates may be presented so that a single head is raised requiring the shooter to determine whether it is a target or not and then proceed with firing, if indicated, or the head plates may be advanced in unison so that the shooter first shoots the first target and then shoots the rear target, if appropriate.
[0015] In accordance with still another aspect of the invention, the targets can be presented to the shooter in alignment. Thus, the shooter may have to knock down the first target and then decide whether to fire at the second target, thereby forcing the shooter to closely monitor the status of the initial target. As will be appreciated, such a shooting scenario is analogous to shooting at a perpetrator, but ceasing the shooting as soon as the perpetrator falls to prevent shooting by-standers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] The above and other objects, features and advantages of the invention will become apparent from a consideration of the following detailed description presented in connection with the accompanying drawings in which:
[0017] FIG. 1 shows a fragmented perspective view of an improved target made in accordance with the principles of the present invention;
[0018] FIG. 2 shows a perspective view of another embodiment made in accordance with the principles of the present invention; and
[0019] FIG. 3 shows a perspective view of a chest plate and a pair of bullet targets made in accordance with the principles of the present invention.
DETAILED DESCRIPTION
[0020] Reference will now be made to the drawings in which the various elements of the present invention will be given numeral designations and in which the invention will be discussed so as to enable one skilled in the art to make and use the invention. It is to be understood that the following description is only exemplary of the principles of the present invention, and should not be viewed as narrowing the pending claims.
[0021] Turning now to FIG. 1 , there is shown a perspective view of an improved target, generally, indicated at 10 , made in accordance with the principles of the present invention. The target includes a head plate 14 and an arm 18 , which is used to hold the head plate in a line of fire.
[0022] Those skilled in the art will appreciate that current targets typically include a head plate which is attached to the arm by a hinge. Often this is formed by welding a pipe to the head plate and passing a bar through the pipe of the head plate so that a shot hitting the head plate causes the head plate to pivot downwardly with respect to the arm.
[0023] In accordance with the present invention, the head plate 14 is attached to the arm 18 by a resilient attachment member 22 . Typically, the resilient attachment member 22 is formed from rubber, a spring or some other resilient or semi-resilient material.
[0024] The attachment member 22 is attached to the head plate 14 and to the arm 18 by screws 24 , bolts, or some other fastener. Those skilled in the art will appreciate that it is preferable that such fasteners be configured to decrease the likelihood of ricochets.
[0025] In the present invention, the attachment member 22 provides both visual indication of impact on the head plate 14 while returning the head plate to a generally upright or facing position. In training law enforcement officials and military personnel to more accurately shoot, it is important that there be some visual indication when the target has been hit, as well as auditory information confirming the hit. In the prior art configuration, this was accomplished by the head plate making a noise upon impact of the bullet and pivoting downwardly following impact. This, however, allows for only a single shot to hit the target. In most common shooting situations, however, the initial shot is insufficient to bring down the enemy. Thus, in accordance with the present invention, the resilient or semi-resilient attachment mechanism deflects with each shot to provide a visual indication that the head plate of the target has been hit. However, the resilient attachment mechanism returns the head plate to a generally upright position allowing the shooter to repeatedly hit the target and thereby insure that a threat is no longer present.
[0026] Turning now to FIG. 2 , there is shown an alternate embodiment of an improved target, generally indicated at 50 , made in accordance with the principles of the present invention. The target 50 includes an arm 54 and a head plate 58 . The head plate 58 is held to the arm 54 by one or more stops 62 . The stops 62 are typically formed from flat pieces of steel which have been cut. Because the pieces a flat, scrap steel left over from making bullet traps, head plates and the like can be used to form the hinge with relatively minor handling.
[0027] The stops have channels 66 formed therein and which are configured to allow a tab 58 a of the head plate 58 to rotate between a generally vertical and a generally horizontal position. Unlike the previous embodiment, the head plate 58 if configured to fall into a generally horizontal position.
[0028] In additional to the above, the head plate 58 could fall 180 degrees if desired by simply modifying the configuration of the channels 66 . Additionally, the configuration of the channel can be used to regulate how forceful of a hit or hits the head plate 58 must take before it will drop. The, for example, ledge 62 a which defines part of the channel 66 could be raised on lowered to respectively increase or decrease the force necessary to tip the target.
[0029] In the prior art target, the head plate is pivotably attached to the arm. This is typically accomplished by welding a cylinder to the head plate and then extending a rod therethrough to act as a hinge. During repeat fire situations, the weld which holds the hinge in place breaks due to the vibration of repeated rounds hitting the head. This eventually causes the head plate to fall off. The head plate is then either thrown away, or recycled by welding another cylinder onto the head plate.
[0030] By having the head plate 58 pivot with respect to the stops 62 without being directly attached thereto, a substantial amount of the vibration is dissipated before the head plate impacts the back part of the channel 66 of the stop. This, in turn, reduces the amount of vibration which is conveyed to any weld 70 between the stops and the arm (or other base). Even if a weld 70 is present and breaks however, the head plate 58 may still be used so long as some retention interaction, such as a slotted groove engagement (sown by the dashed lines 74 , exists between the head plate and the arm 54 .
[0031] Yet another advantage of the configuration shown in FIG. 2 is that the configuration allows for ready replacement of targets. Because the head plate is not fixedly attached to the stops 62 , the tabs 58 a and channels 66 can have sufficiently loose tolerances that a head plate could be changed by simply sliding it to one side and then the other. This would allow an arm 54 /stop 62 configuration to be quickly modified to provide a different target. Thus, for example, a head plate which is generally round could be used. The head plate could then be replaced with an tall, elongate head plate within a matter of a few seconds. By allowing quick changes, fewer arms or base units need to be purchased to use with a full array of head plates.
[0032] Turning now to FIG. 3 , there is shown a perspective view of an improved target, generally indicated at 100 , made in accordance with the principles of the present invention. The improved target 100 includes a first arm 104 and a second arm 108 . The first and second arms 104 and 108 are positioned behind a chest plate 112 , such as those which are commonly used for pop-up targets.
[0033] Attached on top of the first arm 104 is a target 116 having a first configuration. As shown in FIG. 3 , the first target 116 is generally circular. The first target 116 is typically colored a first color, such as blue. In a preferred embodiment, the functional elements of the target can be configured similar to the target shown in FIG. 2 or to the target shown in FIG. 1 .
[0034] Disposed on the top of the second arm 108 is a second target 120 . The second target 120 is also preferably formed in a manner similar to that shown in FIG. 2 , although other target configurations can be used. The second target 120 may have a second configuration which distinguishes it from the first configuration of the first target 116 . Thus, for example, the second target may be hexagonal and painted a different color than the first target, i.e. red. Each of the arms 104 and 108 are mounted on top of a riser 124 and 128 . The risers 124 and 128 selectively raise the targets 116 and 120 above the chest plate 112 . The risers 124 and 128 allow the person controlling the range to selectively raise and lower either of the targets and thereby change the target which is presented to the shooter. The difference in the configuration of the first target 116 and the second target 120 forces the shooter to distinguish between a perpetrator and an innocent bystander. Thus, the shooter is not only tested on his ability to shoot accurately, but also to make split second decisions on whether or not to shoot.
[0035] While the risers 124 and 128 can be used to activate either of the targets, they can also actuate both targets 116 and 120 simultaneously. The person shooting is presented with the first target 116 which may indicate a perpetrator. When the target 116 has been hit sufficiently, the target will fall, revealing the second target 120 . The second target 120 can be configured to represent an innocent bystander. In such a scenario, the shooter must immediately cease firing after the fall of the first target 116 to avoid hitting the innocent bystander represented by the second target 120 .
[0036] In the alternative, the second target 120 could also be configured to represent a perpetrator. Thus, when the first target 116 falls, the shooter must quickly determine if the second target 120 represents a threat or not. By selectively changing the scenario, i.e. alternating targets representing an innocent bystander and a target representing a threat, the shooter can be conditioned to properly consider the target and to react accordingly.
[0037] Thus, there are disclosed several embodiments of improved targets which can be used to improve the shooting accuracy and decision making capacity of a shooter. Those skilled in the art will appreciate that there are numerous modifications which can be made without departing from the scope and spirit of the invention. | A bullet target configured to improve the skills of a shooter includes, in one embodiment, a head plate which is attached to an arm by a resilient or semi-resilient attachment member to allow the head plate to visually deflect when hit by a bullet and to substantially return to its original position. In another embodiment, the improved target utilizes an attachment mechanism which allows the head to rotate relative to the arm within a stop to minimize transfer of vibrations between the head plate and the arm. In a third embodiment, a plurality of head plates are used in alignment and selectively exposed to the shooter to improve decision making ability. | 5 |
This is a division of co-pending application Ser. No. 764,943 filed Sept. 24, 1991, now U.S. Pat. No. 5,195,287, which is a continuation of application Ser. No. 495,846 filed Mar. 19, 1990, entitled "PANEL AND METHOD FOR MAKING THE SAME", now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to panels having selectively removable cut-outs providing access to wiring behind the panels.
Conventional office panel systems include a portion or raceway holding wires such as electrical, computer and telephone wires. The raceway needs to have openings cut therein for appropriate receptacles so that calculators, phones, computers and the like can be hooked to the wires inside the raceway.
It is known to provide raceway panels with selectively removable cut-outs which when removed provide the necessary openings.
SUMMARY OF THE INVENTION
The invention provides a raceway panel including a hinged cut-out portion that can be pivoted out of place to provide an opening and that can be pivoted back into place to close the opening when the opening is no longer necessary.
More particularly, the invention provides an extruded panel comprising a layer of rigid PVC and a layer of flexible PVC. Preferably, the layer of flexible PVC is formed by a pair of generally parallel, spaced apart strips of flexible PVC extruded integrally with the layer of rigid PVC. The rigid PVC has therein an endless cut dividing the rigid PVC into a main portion and a cut-out portion, and the strips of flexible PVC connect the cut-out portion to the main portion and thereby hold the cut-out portion in place relative to the main portion. The cut-out portion preferably has a width substantially greater than the width of the flexible strips. The panel is extruded without the cut, and then a laser is used to provide the endless cut through the rigid PVC without cutting through the flexible PVC.
In order to provide an opening in the main portion of the rigid PVC, the flexible strips are cut at one end of the cut-out portion, in alignment with the cut in the rigid PVC, so that the flexible strips provide a hinge connection between the main portion and the cut-out portion at the opposite end of the cut-out portion. Thus, the cut-out portion can be pivoted to an open position to provide and opening in the main portion and can be pivoted back into place to close the opening when the opening is no longer required.
The panel also comprises means for securing the cut-out portion in its open position, and means for securing the cut-out portion in place after the cut-out portion is pivoted back to its closed position to close the opening.
Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of a panel embodying the invention.
FIG. 2 is a rear elevational view of the panel.
FIG. 3 is a view taken along line 3--3 in FIG. 2.
FIG. 4 is a view similar to FIG. 2 showing the panel before it is cut.
FIG. 5 is a view taken along line 5--5 in FIG. 4 showing the panel being cut.
FIG. 6 is a perspective view of the back of the panel shown in FIGS. 1-3 showing the flexible strips being cut.
FIG. 7 is a partial rear elevational view of a panel that is an alternative embodiment of the invention.
Before one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A panel 10 embodying the invention is illustrated in FIGS. 1-6. As best shown in FIG. 3, the panel 10 comprises a substantially rigid layer 14 and a flexible layer 18 fixed to the rear of the rigid layer 14. While various suitable materials can be employed, in the preferred embodiment, the rigid layer 14 is fabricated of rigid PVC and the flexible layer 18 is fabricated of flexible PVC. Furthermore, in the preferred embodiment, the flexible layer 18 includes a pair of generally parallel, spaced apart strips 22 of flexible PVC. The rigid layer 14 and the flexible strips 22 have substantially equal thicknesses, as shown in FIG. 5.
The rigid layer 14 has therein (see FIGS. 1-3) two endless cuts 26 dividing the rigid layer into a main portion 30 and two cut-out portions 34. The cuts 26 do not pass through the flexible strips 22. In the illustrated construction, each endless cut 26 defines a rectangle so that the cut-out portions 34 are rectangular. As shown in FIG. 2, the top of each cut-out portion 34 is located above the upper strip 22, and the bottom of each cut-out portion 34 is located below the lower strip 22. Thus, each cut-out portion 34 has a width or height that is substantially greater than the width of either of the strips 22. Because the cuts 26 do not pass through the strips 22, the strips 22 connect the cut-out portions 34 to the main portion 30 and thereby hold the cut-out portions 34 in place, or in a closed position, relative to the main portion 30.
If an opening 38 (FIG. 6) is desired in the main portion 30 of the rigid layer 14, the strips 22 are cut in alignment with the cut 26 in the rigid layer 14 at one end of a cut-out portion 34. The flexible strips 22 can be cut by any suitable means, such as a sharp knife 42 (FIG. 6). As a result, the strips 22 provide a hinge 46 at the opposite end of the cut-out portion 34, and the cut-out portion 34 can be pivoted to an open position (shown on the left in FIG. 6) providing an opening 38 in the main portion 30 of the rigid layer 14.
The panel 10 further comprises mean for securing the cut-out portion 34 in its open position. While various suitable means can be used, in the illustrated construction, such means includes a piece of two-sided "MYLAR"-backed adhesive tape 47 fixed to the rear of the cut-out portion 34 between the strips 22. When the cut-out portion 34 is pivoted to its open position, the tape 47 adheres to the rear of the main portion 30 of the rigid layer 14 and releasably secures the cut-out portion 34 in its open position.
If an opening in the rigid layer 14 is thereafter no longer desired, the cut-out portion 34 can be pivoted back to its closed position. Accordingly, the panel 10 also comprises means for resecuring the cut-out portion 34 in place or in its closed position after the strips 22 have been cut. While various suitable resecuring means can be employed, in the illustrated construction, such means includes (see FIG. 7) a piece of reinforced tape 48 extending across the cut 26 and securing the cut-out portion 34 to the main portion 30.
The panel 10 is preferably extruded as a single extrusion including the rigid layer 14 and the flexible strips 22. The endless cuts 26 are preferably provided with a laser 50, as shown schematically in FIG. 5. A laser is convenient because it can be programmed so that it only cuts through the rigid layer 14 and does not cut through the flexible strips 22. It should be noted, however, that no harm is done by cutting partially through the flexible strips 22, so long as enough of the strips 22 remain uncut to provide the necessary hinge. A laser is also advantageous because it provides a cut having a substantially lesser thickness than a cut provided by a conventional cutting tool. (A conventional cutting tool leaves a gap of 0.100 inch, whereas a laser leaves a gap of only 0.008 inch.) Furthermore, a laser is advantageous because it can be easily reprogrammed to vary the shape of the cut-out portion 34. This is much simpler than providing and repositioning a new die for a conventional punch press.
Because the cut-out portion 34 is reused to close the opening 38, it is not necessary to match the color of an injection molded part to close the opening. Reusing the cut-out portion 34 also eliminates the cost of injection molding a new part.
A panel 100 that is an alternative embodiment of the invention is illustrated in FIG. 7. Except as described hereinafter, the panel 100 is substantially identical to the panel 10, and common elements have been given the same reference numerals.
In the panel 100, the endless cut 26 includes two portions that pass partially through the rigid layer 14 so as to provide a pair of knock-out tabs 104 connecting the cut-out portion 34 to the main portion 30. Preferably, these portions of the cut pass through approximately 75% of the rigid layer 14. (In the panel 10, the entire cut 26 passes completely through the rigid layer 14.) The knock-out tabs 104 must be cut prior to pivoting the cut-out portion 34 to its open position. The endless cut 26 of the panel 100 is preferably provided by a laser, which can be programmed to provide the knock-out tabs 104.
Various features of the invention are set forth in the following claims. | A method of making a panel, the panel comprising a substantially rigid layer, and a flexible layer fixed to the rigid layer, the rigid layer having therethrough an endless cut dividing the rigid layer into a main portion and a cut-out portion, the flexible layer connecting the cut-out portion to the main portion and thereby holding the cut-out portion in place relative to the main portion. | 8 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/343,875, filed Jan. 2, 2002.
BACKGROUND OF INVENTION
1. Field of the Invention
The present invention generally relates to fluid analysis methods and equipment.
More particularly, this invention relates to a fluid analysis device and method that utilize a micromachined filter to separate cells and/or particles from a fluid, such as a biological fluid, and means for sensing the material selectively separated from the fluid with the filter.
2. Description of the Related Art
Various fluids undergo some type of quantitative analysis to determine their composition and physical properties. Notable examples of such fluids include urine, blood, beverages, pharmaceutical mixtures, water, lubricating oils, fuels, and many industrial chemicals. With regard to urological analysis, a variety of parameters are typically measured during urology, including pH, specific gravity, and the amount of blood, leukocytes (white blood cells), glucose, protein, urobilinogen, bilirubin, ketones, nitrite, sodium, chlorine, potassium, magnesium, urea, uric acid, bicarbonate, sulfate, phosphate and calcium. The specific gravity of urine can be used as a screen to indicate renal and hepatic problems, with additional urinary tests being performed as necessary if a problem is indicated.
The specific gravity of urine has been measured by various methods, including ultrasonic and optical techniques as disclosed in U.S. Pat. Nos. 4,664,124 and 4,834,104, respectively. More recently, commonly-assigned U.S. patent application Ser. No. 09/468,628 to Tadigadapa et al. discloses a resonant mass flow and density sensor suitable for quantitative analysis of fluids. The sensor comprises a suspended tube that is vibrated at resonance. As fluid flows through the tube, the tube twists under the influence of the Coriolis effect. The degree to which the tube twists (deflects) when vibrated can be correlated to the mass flow rate of the fluid flowing through the tube, while the density of the fluid is proportional to the frequency of vibration. The tube is fabricated by micromachining, which as used herein denotes a technique for forming very small elements by bulk etching a substrate (e.g., a silicon wafer) or by surface thin-film etching, the latter of which generally involves depositing a thin film (e.g., polysilicon or metal) on a sacrificial layer (e.g., oxide layer) on a substrate surface and then selectively removing portions of the sacrificial layer to free the deposited thin film.
Various other parameters of interest in urological analysis have been measured using reagent test strips. However, there are drawbacks to the use of test strips, including the vulnerability to humidity, finger contamination, and erroneous results due to vitamin C intake prior to testing. Test strips also require a manual operation and the constant expense of replacement since they are consumed by the test.
Biological fluid filtration has also been utilized in the field of fluid analysis. For example, physical filtration of donated blood has been used for years to separate leukocytes from plasma. For urological applications, the concentration of leukocytes is often of interest, as their presence in urine can indicate a urinary tract infection from chronic catheter use as well as renal and hepatic problems. Leukocytes are larger (about twenty micrometers) than other blood or urine components, and so can be physically filtered. Micromachined filters, including silicon filters, capable of use in urological analysis have been proposed, as disclosed in U.S. Pat. Nos. 5,660,728 and 5,922,210.
While fluid analysis techniques and devices of the types described above have been successfully employed, there is a continuing effort to develop improved devices for performing fluid analysis. For example, the capability for continuous monitoring would be desirable, particularly in the form of remote monitoring of disabled catheterized patients. In addition, it would be desirable if components grouped into a single system could perform multiple analysis steps, such that an accurate diagnosis can be made with a single sample.
SUMMARY OF INVENTION
The present invention provides a method and device for performing fluid analysis utilizing a micromachined filter to separate cells and/or particles from a fluid, such as a biological fluid. The device has the additional capability of sensing the relative quantity of cells and/or particulate material selectively separated from the fluid with the filter. Multiple micromachined filters of this invention can be integrated into a single device that produces an electrical output for each of a number of urological parameters, providing a rapid and simplified interface capable of remote and continuous monitoring of a fluid.
According to a first aspect of the invention, the device is a micromachined filtering device comprising a substrate having a first surface, an oppositely-disposed second surface, and a thickness defined by and between the first and second surfaces. A plurality of vias extend through the thickness of the substrate, with the vias being spaced apart and having approximately equal diameters that prevent passage through the substrate of materials (e.g., cells and/or particles) having a diametrical dimension greater than the diameters of the vias, while permitting passage through the substrate of a fluid and any other materials present in the fluid and having a diametrical dimension less than the diameters of the vias. First and second electrodes are, located on the first surface of the substrate so that the materials too large to pass through the vias, and have therefore collected at the first surface of the substrate, will electrically connect the first and second electrodes to produce an output signal in proportion to the amount of the material collected.
As a result of the construction of the device, the present invention makes possible a method of quantitatively analyzing a fluid by flowing the fluid through the vias in the substrate, whereby the fluid and any cells and/or particles smaller than the vias are permitted to pass through the substrate, while cells and/or particles larger than the vias are prevented from passing through the substrate, such that the larger cells/particles collect at the first surface of the substrate. The amount of the collected cells/particles at the first surface of the substrate is indicated by the output signal obtained from the electrodes.
Fluid filtering in accordance with this invention may be preceded or followed by additional analysis, such as the measurement of specific density, pH, and various constituents detected with chemical sensors. In the case of urological analysis, such constituents include glucose, protein, urobilinogen, bilirubin, ketones, nitrite, pH, sodium, chlorine, potassium, magnesium, urea, uric acid, bicarbonate, sulfate, phosphate, and calcium. With the present invention, such analysis can be preformed on multiple substrates within a single device, yielding a single-system sensing and filtering system.
Other objects and advantages of this invention will be better appreciated from the, following detailed description.
BRIEF DESCRIPTION OF DRAWINGS
FIGS. 1 and 2 are cross-sectional and plan views, respectively, of a substrate of a micromachined filtering device in accordance with this invention.
FIGS. 3 and 4 are cross-sectional views of micromachined filtering devices in accordance with two embodiments of the invention.
FIG. 5 represents a urological analysis system utilizing a micromachined filtering device of this invention.
DETAILED DESCRIPTION
FIGS. 1 and 2 represent a substrate 12 for a micromachined filtering device in accordance with the invention, two embodiments of which are represented in FIGS. 3 and 4. The substrate 12 can be formed of silicon, such as silicon doped to be p-type. Alternatively, the substrate 12 can be formed of another semiconductor material, quartz, ceramic, metal, or a composite material. Vias 14 are micromachined in the substrate 12 to have approximately identical diameters, and to extend through the thickness of the substrate 12 between opposing surfaces of the substrate 12 , referred to herein as upstream and downstream surfaces 16 and 18 . The vias 14 are preferably etched through the substrate 12 using known semiconductor processing. For example, if the substrate 12 is formed of silicon, the vias 14 can be formed by masking either of the surfaces 16 or 18 of the substrate 12 , followed by etching with a wet chemical anisotropic etchant, such as ethylenediamine pyrocatechol (EDP), or an alkali-type etchant, such as potassium hydroxide (KOH) and tetramethyl ammonium hydroxide (TMAH).
As seen in FIG. 2, the vias 14 are arranged in an array (rows and columns), with rows of the vias 14 being separated by interdigitized portions of two electrodes 20 and 22 on the upstream surface 16 of the substrate 12 . The vias 14 are arranged and adapted to serve as passages through which a fluid, such as urine, blood, beverage, pharmaceutical mixture, water, oil, fuel, industrial chemical, etc., flows for the purpose of performing quantitative analysis of the fluid. More particularly, the vias 14 are sized to filter from the fluid any cells and/or particles 24 that exceed the diameter of the vias 14 , while permitting the entraining fluid and smaller cells/particles 25 to pass through the substrate 12 , as represented in FIG. 1 . For example, if the fluid is urine, the cells/particles that may be filtered with the substrate 12 include blood, or selectively leukocytes and erythrocytes (red blood cells). As will be discussed below in reference to urological analysis that can be performed with the teachings of this invention, a variety of parameters can be measured with a device utilizing the substrate 12 , including pH, specific gravity, and the amount of glucose, protein, urobilinogen, bilirubin, ketones, nitrite, sodium, chlorine, potassium, magnesium, urea, uric acid, bicarbonate, sulfate, phosphate, and calcium. Other fluids that can be processed with such a device include any that contain biological cells, spores, or particles from essentially any source.
In view of the above, the diameter of the vias 14 is chosen to prevent the passage through the substrate 12 of cells/particles of a particular size and larger, while permitting the entraining fluid and smaller cells/particles 25 to pass through the substrate 12 . For example, leukocytes (diameter of about twenty micrometers) can be filtered with an array of vias 14 on the order of about fifteen to seventeen micrometers in diameters, while allowing water (95% of urine), electrolytes, protein, glucose, and erythrocytes to pass through. The monitoring of the presence of erythrocytes in urine is also desirable as being useful to detect cardiovascular, renal, and hepatic problems. For this purpose, erythrocytes (about eight micrometers in diameter) can be subsequently filtered with a second substrate 12 having appropriately-sized vias 14 , e.g., having a size range of about three to seven micrometers. The quantity of cells filtered from the fluid is then determined by the electrical resistance or current flow that occurs between the electrodes 20 and 22 when a potential is applied across the electrodes 20 and 22 . In particular, as the electrodes 20 and 22 become electrically connected by cells/particles that collect at the upstream surface 16 of the substrate 12 , current flow between the electrodes 20 and 22 will progressively increase, and electrical resistance progressively decrease, to produce an output signal in some proportion to the amount of material collected at the upstream surface 16 . Suitable materials for the electrodes 20 and 22 include platinum or iridium runners of a type known in the art for thick-film hybrid circuits. If the substrate 12 is formed of silicon or another conductive or semiconductive material, the upstream surface 16 on which the electrodes 20 and 22 are formed is preferably oxidized or otherwise provided with an electrically insulating layer prior to the deposition of the electrodes 20 and 22 . In addition to the electrodes 20 and 22 , a chemically-active material can be deposited on the upstream surface 16 in combination with the electrodes 20 and 22 to increase sensitivity. Such a material can be a biological material that attracts leukocytes through an immunological reaction.
As shown in FIGS. 3 and 4, multiple substrates 12 of the type shown in FIGS. 1 and 2 can be utilized in a single filtering device 10 or 110 , so that incrementally, smaller cells/particles can be filtered from a fluid. In FIG. 3, three substrates 12 are bonded together and then packaged in a housing 28 as a single filtering device 10 . The device 110 shown in FIG. 4 differs from that of FIG. 3 by individually packaging the substrates 12 in packages 112 , which are then bonded or otherwise secured together. In both embodiments, the downstream surface 18 of each substrate 12 is shown as having been etched to form a recess 30 that defines a membrane 32 surrounded by a frame 34 . In FIG. 3, the frames 34 of the substrates 12 are bonded directly together, e.g., anodically or with a screen-printed adhesive or glass frit, at the die or wafer bonding level.
In each of the embodiments of FIGS. 3 and 4, the uppermost substrate 12 is preferably micromachined to have vias 14 sized to filter relatively large cells or particles, e.g., leukocytes, while the middle and lowermost substrates 12 of FIG. 3 and the lowermost substrate 12 of FIG. 4 are micromachined to have vias 14 sized to filter relatively smaller cells or particles, e.g., erythrocytes. Alternatively or in addition, the lowermost substrates 12 of FIGS. 3 and 4 can be adapted to sense other parameters of the fluid which, depending on the fluid, may include pH or the amount of certain constituents in the fluid. For example, if the fluid is urine, the lowermost substrates 12 can be adapted to determine the amount of glucose, protein, urobilinogen, bilirubin, ketones, nitrite, sodium, chlorine, potassium, magnesium, urea, uric acid, bicarbonate, sulfate, phosphate, or calcium in the fluid. For this purpose, chemical sensors 36 are shown in FIG. 3 as being embedded in the walls of the vias 14 . Alternatively or in addition, the sensors 36 could be located on the upstream surface 16 of the substrate 12 , or in the walls of the recess 30 in the downstream surface 18 of the substrate 12 . For urology, the chemical sensors 36 are preferably located downstream of substrates 12 used to filter leukocytes and erythrocytes, as represented in FIG. 3 . As also represented in FIG. 3, the substrate 12 on which the chemical sensors 36 are provided can be placed directly in the fluid flow stream. Alternatively, the substrate 12 could be placed so as to be immersed in a relatively static pool of the fluid for longer exposure times. Any number of substrates 12 equipped with chemical sensors can be employed to increase the number of chemicals monitored. The chemical sensors 36 may be formed by a variety of materials, such as certain metal oxides and organic films known in the art to be sensitive to the parameters of interest, an example of which is pH-sensitive iridium oxide films. Other suitable chemical sensors and methods for forming such sensors in the substrate 12 are known to those skilled in the art, and therefore will not be discussed in any further detail here.
According to the invention, the devices 10 and 110 can be modified to sense the specific gravity of the fluid, such as by including the resonant mass flow and density sensor disclosed in commonly-assigned U.S. Pat. No. 6,477,901 to Tadigadapa et al., incorporated herein by reference. For this purpose, another substrate equipped with a suspended micromachined tube would be placed upstream of the uppermost substrate 12 of FIGS. 3 and 4. In accordance with Tadigadapa et al., the tube is fabricated to comprise a fluid inlet, a fluid outlet, and a freestanding portion therebetween, with the freestanding portion being spaced apart from a surface of the substrate. Means is provided for vibrating the freestanding portion of the tube, preferably at resonance, and for sensing movement of the freestanding portion relative to the substrate in a manner that permits the density of the fluid to be determined, from which specific gravity can be calculated by comparing the density of the fluid to the density of water. In urology, the specific gravity of urine obtained in this manner can then be utilized as a screen for renal and hepatic problems. With the present invention, additional quantitative analysis can be advantageously performed immediately downstream of the resonating tube with one or more of the micromachined filtering devices 10 / 110 .
In view of the above, the present invention enables a diagnosis to be obtained using a series of tests performed on a single sample with a single device. FIG. 5 represents such an analysis system, in which a catheter 40 attached to a patient delivers a bodily fluid, e.g., urine, to a filtering device 10 / 110 of this invention. In accordance with the above, the device 10 / 110 may include one or more substrates 12 for filtering urine, as well as one or more substrates 12 equipped with chemical sensors 36 (FIG. 3) and optionally an additional substrate for sensing density in accordance with Tadigadapa et al. The several output signals from the individual substrates 12 are relayed to a computer 42 for analysis, with the filtered urine being dispensed to a drain reservoir 44 . While FIG. 5 shows the device 10 / 110 in series with the catheter 40 and reservoir 44 , the device 10 / 110 could be placed in a passage branching off from the catheter 40 and parallel to a drain tube, with both the drain tube and an output tube from the device 10 / 110 dispensing urine to the reservoir 44 . Other configurations are envisioned, including the sampling of fluid from a sample reservoir that accumulates fluid from the catheter 40 , or sampling fluid directly from the reservoir 44 .
In view of the above, the present invention provides the capability of measuring a wide variety of fluid properties and parameters, providing a physician with the ability to monitor and diagnose a variety of ailments, such as renal, hepatic, pancreatic, gastrointestinal, and cardiovascular problems via urology. The ability to fabricate the device 10 / 110 as a reusable device, miniaturized through the use of micromachining technology, is beneficial to both specialists (e.g., urologists) and general practitioners. The device 10 / 110 of this invention is particularly well suited to provide continuous monitoring of disabled, catheterized patients. By appropriately controlling fluid flow through the device 10 / 110 , a manual or automatic back-flushing operation can be performed to remove cells/particles that have collected at the upstream surface 16 as the need requires. Otherwise, healthcare workers need only intervene if the output of the device 10 / 110 indicates that a medical concern exists, which can be relayed in the form of an alarm system triggered if abnormal cell or chemical levels exceed a predetermined limit over a given period of time or for the flow rate through the device 10 / 110 . The electrical output signal(s) that can be produced by the device 10 / 110 also enables remote computer monitoring of urinary output to provide early indicators of ailments, which is especially important for diabetic and disabled patients and can greatly reduce the cost of long-term health care
While the invention has been described in terms of certain embodiments, it is apparent that other forms could be adopted by one skilled in the art. Therefore, the scope of the invention is to be limited only by the following claims. | A method and device for performing fluid analysis by separating cells and/or particles from a fluid, such as a biological, vehicular or industrial fluid. The device is a micromachined filtering device comprising a substrate with through-thickness vias having approximately equal diameters that prevent passage through the substrate of a first material while permitting passage through the substrate of other materials having diametrical dimensions less than the diameter of the vias. Electrodes are located on a surface of the substrate between vias so that as the first material collects at the surface of the substrate, the electrodes become electrically connected to produce an output signal in some proportion to the amount of the first material collected. The device can incorporate multiple micromachined substrates, yielding an analysis system that produces an electrical output for each of a number of properties or parameters. | 8 |
FIELD OF THE INVENTION
The invention relates to the field of microprocessors, and, more particularly, to a modular arithmetic coprocessor that performs non-modular operations.
BACKGROUND OF THE INVENTION
The Montgomery method makes it possible to carry out modular computations in a finite field (or Galois field) denoted as GF(2 n ), without the performance of divisions. Conventionally, modular operations on GF(2 n ) are used in cryptography for applications such as authentication of messages, identification of a user, and exchange of cryptographic keys. Exemplary applications are described in the French Patent Application No. 2,679,054.
There are commercially available integrated circuits dedicated to such applications. These include, for example, the product referenced as ST16CF54, which is manufactured by SGS-THOMSON MICROELECTRONICS. This product is built around a central processing unit and an arithmetic coprocessor, and is dedicated to the performance of modular computations. The coprocessor enables the processing of modular multiplication operations using the Montgomery method. Further information on this coprocessor can be found in the U.S. Pat. No. 5,513,133.
The basic operation, called a P field operation, is implemented by this coprocessor. Three binary data elements A (multiplicand), B (multiplier), and N (modulo) are encoded on a whole number n of bits. This is done for a binary data element denoted as P field (A, B) N which is encoded on n bits such that P field (A, B) N =A*B*I mod N. I is a binary data element, called an error, which is encoded on n bits such that I=2 −n mod N. More specifically, the value of I depends on the number of k bit blocks considered for the encoding of A, with k being an integer. To perform the operation A*B*I mod N, the data elements are assumed to have been encoded on m words of k bits, with m and k being integers and m*k=n. The words of the data elements A and B are provided to a multiplication circuit having a series input to receive B, a parallel input to receive the k bit blocks of A, and a series output.
In the referenced U.S. Pat. No. 5,513,133, the coprocessor operates with k=32 and m=8 or 16. The coprocessor may be used to produce the result of the modular multiplication A*B mod N. The modular multiplication can be subdivided into two successive elementary P field operations. P field (P field (A, B) N , H) N is computed with H being a data element encoded on n bits, called an error correction parameter, which is equal to 2 2n mod N. For further details on the implementation of modular multiplication, reference may be made to the above referenced U.S. patent. Several possibilities of computation are already known. They include the use either a software method or a specialized circuit, such as the one illustrated in the referenced U.S. patent.
The circuit illustrated in FIG. 1 includes three shift registers 10 , 11 and 12 with a series input and output. These registers include n number of cells, with n=m*k. Multiplexers 13 , 14 and 15 are placed respectively before the inputs of the registers 10 , 11 and 12 . The circuit also includes three registers 16 , 17 and 18 with a series input and a parallel output, with each register having k cells. Two multiplication circuits 19 and 20 include a series input, a parallel input, and a series output. The circuit further includes two k-cell registers 21 and 22 , multiplexers 24 , 25 , 26 , 36 , 37 and 38 , a demultiplexer 39 , series subtraction circuits 27 , 28 and 29 , series addition circuits 30 and 31 , delay cells 32 , 33 and 34 to delay the propagation of binary data elements by k cycle periods, and a comparison circuit 35 . For further details on the arrangements of the different elements with respect to each other, reference may be made to the referenced U.S. patent.
The use of the circuit shown in FIG. 1 enables optimizing in terms of computing duration, memory size, etc. of the processing of modular operations using a fixed data size, e.g., in this case 256 or 512 bits. Cryptography requires machines with increasingly high performance levels, operating at increasingly high speeds, and using increasingly complex cryptographic keys. The trend is towards the manipulation of data elements encoded on 768, 1024, 1536 and even 2048 bits. To process data elements of this size, it may be necessary to construct larger-size circuits by adapting the elements of the circuit to the sizes of the data.
This approach may raise problems in applications such as chip cards, wherein the size of the circuit is physically limited because of differences in mechanical bending stresses between the cards and the silicon substrates. Furthermore, it is becoming increasingly necessary to integrate larger numbers of different functional elements in a card of this kind. The space available for an encryption circuit is thereby correspondingly reduced. Approaches therefore need to be found to limit the increase in the size of this circuit while, at the same time, enabling optimum operation for data elements with a size greater than the size of the initially planned registers.
To carry out modular operations using operands with a size greater than that managed by the coprocessor, it is possible to use the circuit 1 shown in FIG. 2 . In practice, the maximum size is equal to the size of the registers. Circuit 1 includes a standard processor 2 (8, 16 or 32 bits), a memory 3 , the coprocessor 4 of FIG. 1, and a communications bus 5 used to connect the different elements 2 , 3 and 4 together and/or external to the circuit 1 . In the circuit of FIG. 2, the coprocessor 4 is used as a multiplier operating on m*k bits, which is conventionally 256 or 512 bits. The processor 2 is used, in particular, to supervise operations to be performed according to a particular encryption algorithm, and the data exchanges between the memory 3 and the coprocessor 4 .
Performance of the basic operation of modular computations according to the Montgomery method, known as the P field operation, is based upon three binary data elements. These data elements are A (multiplicand), B (multiplier) and N (modulo), which are encoded on a whole number of n bits. They are used for the production of a binary data referenced as P(A, B) N encoded on n bits such that P(A, B)N=A*B*I mod N. I is an error due to the Montgomery method. Should n have a size greater than the size of the registers, namely m*k, it is appropriate to subdivide n into p words of Bt bits. Bt is a working base with a size smaller than or equal to m*k, e.g., m*k. The Montgomery method operates as follows. The variable i is an index varying from 0 to m−1, and the following computation loop is repeated:
X=S i +A i *B,
Y 0 =(X*J 0 ) mod 2 Bt ,
Z=X+(N*Y 0 ),
S i+1 =Z\2 Bt , \ is a whole number division,
if S i+1 is greater than N, then N is subtracted from S i+1 ,
A i corresponds to a word of Bt bits of the breakdown of A, and
S i corresponds to an updated result of the P field operation, and S m =P(A, B) N =A*B*I mod N.
A computation method of this kind requires a larger number of data exchanges between the coprocessors 4 and the memory 3 . The coprocessor 4 of FIG. 1 can carry out only simple operations of multiplication such as A*B=S. A and B are encoded on Bt bits and S is encoded on 2*Bt bits. One approach proposed in U.S. Pat. No. 5,987,489 includes the coprocessor 4 performing an operation of the type S=A*B+C, in which A, B and C are encoded on Bt bits, and S is encoded on 2*Bt bits.
FIG. 3 shows a coprocessor 4 according to the referenced U.S. Pat. No. 5,987,489. The coprocessor 4 illustrated in FIG. 3 includes three shift register 110 , 111 and 112 with serial a input and a serial output. These registers include a number of n cells, and n=m*k, where n, m and k are integers. A multiplexer 113 includes three serial inputs and one serial output. The serial output is connected to the input of the register 110 , the first input is connected to a first input terminal 150 , and the second input is connected to the output of the register 110 . A multiplexer 114 includes two serial inputs and one serial output. The serial output is connected to the input of the register 111 , and the first input is connected to a second input terminal 151 . A multiplexer 115 includes three serial inputs and one serial output. The serial output is connected to the input of the register 112 , the first input is connected to a third input terminal 152 , and the second input is connected to the output of the register 112 .
The coprocessor 4 further includes three k-cell registers 116 , 117 and 118 each having a serial input and a parallel output. The input of the register 117 is connected to a fourth input terminal 153 . Two multiplication circuits 119 and 120 include a serial input, a parallel input to receive k bits, and a serial output. Two registers 121 and 122 , for the storage of k cells, include a parallel input and a parallel output. The input of the register 121 is connected to the output of the register 116 , the output of the register 121 is connected to the parallel input of the multiplication circuit 119 , and the output of the register 122 is connected to the parallel input of the multiplication circuit 120 .
A multiplexer 123 includes two parallel inputs and one parallel output. The first input of the multiplexer 123 is connected to the output of the register 117 , the second input of the multiplexer 123 being connected to the output of the register 118 , the output of the multiplexer 123 is connected to the input of the register 122 . Two multiplexers 124 and 125 each include two serial inputs and one serial output. The output of the multiplexer 124 is connected to the input of the register 116 , the first input of the multiplexer 124 is connected to a fifth input terminal 154 , the output of the multiplexer 125 is connected to the serial input of the multiplication circuit 119 , and the first input of the multiplexer 125 is for receiving a logic zero.
A multiplexer 126 includes three serial inputs and one serial output. The output is connected to the serial input of the multiplication circuit 120 , and the first input is for receiving a logic zero. Subtraction circuits 127 , 128 and 129 each include two serial inputs and one serial output. The first input of the circuit 127 is connected to the output of the register 110 , the output of the circuit 127 is connected to each of the second inputs of the multiplexers 124 and 125 and also to an output terminal 155 , and the first input of the circuit 128 is connected to the output of the register 111 .
An addition circuit 130 includes two serial inputs and one serial output. The first input of the circuit 130 is connected to the output of the circuit 119 , and the output of the circuit 130 is connected to the second input of the multiplexer 126 . An addition circuit 131 includes two serial inputs, one serial output and one carry output. The carry output of the circuit 131 is connected to the first input of the circuit 129 . Delay cells 132 , 133 and 134 delay the propagation of binary data by k cycle times. These cells are typically k bit shift registers. These cells include one serial input and one serial output. The output of the cell 132 is connected firstly to the third input of the multiplexer 126 and secondly to the input of the cell 133 . The output of the cell 133 is connected to the second input of the circuit 129 . The input of the cell 134 is connected to the output of the circuit 130 , and the output of the cell 134 is connected to the first input of the circuit 131 .
A comparison circuit 135 includes two serial inputs and two outputs. The first input is connected to the output of the circuit 131 , and the second input is connected to the output of the circuit 129 . Two multiplexers 136 and 137 each include two serial inputs, one selection input and one serial output. Each of the first inputs are for receiving a logic zero. Each of the selection inputs are connected to one of the outputs of the circuit 135 . The output of the multiplexer 136 is connected to the second input of the circuit 127 , and the output of the multiplexer 137 is connected to the second input of the circuit 128 .
A multiplexer 138 includes two serial inputs and one serial output. The first input is for receiving a logic 1, the second input is connected to the output of the register 112 , and the output is connected firstly to the input of the cell 32 and secondly to the second inputs of the multiplexers 136 and 137 . A demultiplexer 139 includes one serial input and two serial outputs. The input is connected to the output of the circuit 120 , and the outputs are connected respectively to the input of the register 118 and to the second input of the circuit 131 . A multiplexer 140 includes two serial inputs and one serial output. The first input is connected to the output of the circuit 128 , the second input is for receiving a logic 0, and the output is connected to the second input of the circuit 130 . A multiplexer 141 includes two serial inputs and one serial output. The first input is connected to the output of the circuit 130 , the second input is connected to the output of the circuit 131 , and the output is connected to the third inputs of the multiplexers 113 and 115 and to the second input of the multiplexer 114 . Two output terminals 156 and 157 are respectively connected to the outputs of the registers 111 and 112 .
FIG. 3 shows a coprocessor 4 according to the referenced U.S. Pat. No. 5,987,489. The coprocessor 4 illustrated in FIG. 3 includes three shift register 110 , 111 and 112 with serial a input and a serial output. These registers include a number of n cells, and n=m*k, where n, m and k are integers. A multiplexer 113 includes three serial inputs and one serial output. The serial output is connected to the input of the register 110 , the first input is connected to a first input terminal 150 , and the second input is connected to the output of the register 110 . A multiplexer 114 includes two serial inputs and one serial output. The serial output is connected to the input of the register 111 , and the first input is connected to a second input terminal 151 . A multiplexer 115 includes three serial inputs and one serial output. The serial output is connected to the input of the register 112 , the first input is connected to a third input terminal 152 , and the second input is connected to the output of the register 112 .
In the referenced U.S. Pat. No. 5,987,489 one alternative variation shows a circuit that enables the performance of the elementary operation S=A*B+C+D, with A, B, C and D encoded on Bt bits and S encoded on 2*Bt bits. An object of this alternative variation is to carry out a multiplication on p*Bt bits, and an addition on p*Bt bits simultaneously to obtain the computation of X=S i +A i *B and Z=X+(N*Y 0 ) of the Montgomery algorithm at a higher speed.
If the Montgomery algorithm set up by elementary operations of the S=A*B+C+D type is developed, the following loop repetition is obtained.
A) Computation of X=S i +A i *B for providing X p . . . X 0 =S i,p−1 . . . S i,0 +A i *B p−1 . . . B 0 , with X j , S i,j and B j being the Bt bit words of X, S i and B. This is a result of the succession of the following p computations made in the coprocessor 4 :
A 1 ) X′ 1 X 0 =S i,0 +A i *B 0 +0
A 2 ) X′ 2 X 1 =S i,1 +A i *B 1 +X′ 1 . . .
Ap−1) X′ p−1 X p−2 = Si,p −2+A i *B p−2 +X′p−2
Ap) X p X p−1 =S i,p−1 +A i *B p−1 +X′ p−1
X′ 1 to X′ p−1 are Bt bit words of intermediate computation that remain permanently in the coprocessor 4 .
B) Y 0 =(X*J 0 ) mod 2 Bt for providing Y 0 =(X p . . . X 0 *J 0 ) mod 2 Bt , by the following computation made in the coprocessor 4 : Y′ 1 Y 0 =X 0 *J 0 +0. The least significant word Y 0 is the only one of interest.
C) Z=X+N*Y 0 for providing Z p . . . Z 0 =X p . . . X 0 +Y 0 *N p−1 . . . N 0 . Z j , X j and N j are the Bt bit words of Z, X and N using the following succession of p+1 computations made in the coprocessor 4 :
C 1 ) Z′ 1 Z 0 =X 0 +Y 0 *N 0 +0
C 2 ) Z′ 2 Z 1 =X 1 +Y 0 *N 1 +Z′ 1 . . .
Cp−1) Z′ p−1 Z p− 2 =X p− 2 +Y 0 *N p− 2 +Z′ p−2
Cp) Z′ p Z p−1 =X p−1 +Y 0 *N p−1 +Z′ p−1
Cp+1) Z p =X p +0*0+Z′ p
Z′ 1 to Z′ p are Bt bit words of intermediate computation that remain permanently in the coprocessor 4 .
D) S i+1 =Z\2 Bt , \ is an integer division. If S i+1 is greater than N, then N is subtracted from S i+1 .
SUMMARY OF THE INVENTION
An object of the invention is to improve the computation time by eliminating the computation identified as Cp+1 by creating a new S=A*B+C type operation, with S and C encoded on 2*Bt bits and A and B encoded on Bt bits. To carry out this new operation, an overflow storage flip-flop circuit has been added to store a possible overflow at the end of an elementary computation and reinsert the overflow, if any, during the next computation.
Another object of the invention is to provide a computation circuit to carry out an operation A*B+C. A and B are integers encoded on at most m*k bits. C is an integer encoded on at most 2*m*k bits, with m and k being non-zero integers. The computation circuit includes first, second and third (m*k) bit registers for storing data. A fourth k bit register stores a data element. A first multiplication circuit carries out operations of multiplication between the data elements of the first and fourth registers. Addition means carry out an addition of the data elements of the second and third registers, and the result is provided by the multiplication circuit. There are means to store a carry value, if any, resulting from an overflow of the addition. Linking means provide an intermediate result provided by the addition means in the second and third registers. The linking provides the carry value stored during a previous addition to the addition means. This is done to add the carry value in the place of the least significant word which is to be added as soon as the least significant word has been added.
According to one approach, the computation circuit comprises a fifth (m*k) bit register to successively provide k bit words to the fourth register.
The invention also provides that the performance of the same elementary operations is obtained by using the two multipliers in parallel to reduce the computation time by two. The computation circuit comprises a second multiplication circuit for the performance, simultaneously with the first multiplication circuit, of the multiplication of the data element of the first register with a data element of a sixth k bit register. The addition means or adder carries out the addition, with a k bit shift, of the result provided by the second multiplication circuit.
The invention also relates to a modular arithmetic coprocessor including implementation of the modular operations on numbers encoded on m*k bits, with m and k being integers, and the previously defined computation circuit. More generally, the invention relates to a modular computation device including a processor, a memory, and the coprocessor disclosed herein.
Furthermore, another object of the invention is to provide a method for the computation of A*B+C. A and B are integers encoded on at most m*k bits. C is an integer encoded on at most 2*m*k bits, with m and k being non-zero integers. In a multiplication circuit, a data element of a first (m*k) bit register is multiplied by a data element of a fourth k bit register. Data elements of a second (m*k) bit register and a third (m*k) bit register are added with the result provided by the multiplication circuit. A carry value, if any, results from an overflow of the addition stored. An intermediate result is stored in the second and third registers. The previous operations are repeated for changing the data element of the fourth register and adding the carry value, if any, stored in the place of the least significant word to be added as soon as the least significant word has been added.
In one embodiment, an operand is stored entirely in a fifth (m*k) bit register to provide the operand successively to the fourth register. To divide the time needed to perform the method by two, a second multiplication is performed in parallel. The result of this multiplication is added with a k bit shift.
More generally, the invention relates to a method for the computation of modular operations on operands of a size greater than m*k bits in which the operands are processed in m*k bit words by using the method of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be understood more clearly and other particular features and advantages shall appear from the following description, made with reference to the appended drawings, of which:
FIG. 1 illustrates a modular coprocessor, according to the prior art;
FIG. 2 illustrates a modular computation device, according to the prior art;
FIG. 3 illustrates a modular coprocessor according to the prior art; and
FIGS. 4 and 5 illustrate two embodiments of a modular computation coprocessor, according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 4 shows the coprocessor 4 of FIG. 3 modified according to the invention. The modifications performed are the following. The delay cell 132 is used as a k bit shift register. The multiplexer 140 comprises a third input. The inputs of the addition circuit 131 are no longer connected to the outputs of the delay cell 134 and the demultiplexer 139 . A multiplexer 160 comprising two inputs and one output has been added. The first input of the multiplexer 160 is connected to the output of the circuit 130 . The second input of the multiplexer 160 is connected to the output of the delay cell 134 , and the output of the multiplexer 160 is connected to the first input of the circuit 131 .
The modifications further include adding a multiplexer 161 comprising three inputs and one output. The first input of the multiplexer 161 is connected to the output of the delay cell 132 . The second input of the multiplexer 161 is connected to the second output of the demultiplexer 139 . The third input of the multiplexer 161 is for receiving a logic 0, and the output of the multiplexer 161 is connected to the second input of the circuit 131 . A storage flip-flop circuit 162 comprising an input and an output has been added. The flip-flop circuit is used to store a bit. The input of the flip-flop circuit 162 is connected to the carry output of the circuit 131 , and the output of the flip-flop circuit 162 is connected to the third input of the multiplexer 140 . An output terminal 163 connected to the output of the flip-flop circuit 162 makes it possible to output the bit contained in the flip-flop circuit.
The different elements forming the coprocessor 4 of FIG. 4 may furthermore be modified to support additional functions. Thus, it is possible to add computation circuits and additional multiplexers to create new processing capacities that allow the setting up of the paths needed for the running of the operation according to the invention. Similarly, if the multiplexers 140 , 141 , 160 and 161 have their outputs directed respectively to their first and second inputs, the coprocessor 4 of FIG. 1 is formed. To carry out the different functions of the circuit of FIG. 1, reference may be made to U.S. Pat. No. 5,513,133.
To enable the performance of the elementary operation of the invention, i.e., S=A*B+C, it is necessary to neutralize certain elements of the coprocessor 4 of FIG. 4 . Thus, the multiplexers 136 and 137 are positioned to provide a 0 at their output so that the circuits 127 and 128 operate functionally as wires. The multiplexer 160 is positioned to permanently connect the output of the circuit 130 to the first input of the circuit 131 .
For reasons of clarity, no account will be taken of the delays caused by the subtraction and addition circuits 127 , 128 , 130 and 131 , or of any delays caused by the initialization of the different elements of the coprocessor 4 . Indeed, those skilled in the art are capable of synchronizing the circuits with one another. The following explanations enable the necessary stringing of the different elements of the coprocessor 4 to carry out the elementary operation of the invention, i.e., S=A*B+C. A and B are encoded on Bt=m*k bits, with C and S being encoded on 2*Bt=2*m*k bits.
Initialization: I 0 ) By means of the register 116 , the least significant k-bit word A 0 of the operand A is loaded into register 121 . The m*k bits of the operand B are loaded into the register 110 . The m*k least significant bits of the operand C, referenced C 0 , are loaded into the register 111 . The m*k most significant bits of the operand C, referenced C 1 , are loaded into the register 112 . The register 132 and the circuits 130 and 131 are initialized at 0. If it is a first elementary operation, then the flip-flop circuit 162 is initialized at 0.
First iteration: I 1 ) A k bit shift is made in the registers 110 , 111 , 112 and 132 . The data provided by the register 110 is multiplied by the contents of the register 121 using the circuit 119 , and the register 110 has its input connected to its output. The data elements provided by the register 111 are added with the result provided by the circuit 119 using the circuit 130 . The data elements provided by the register 112 are loaded into the register 132 . The data elements entering the register 112 are provided by the output of the circuit 130 .
I 2 ) A (m−1)*k bit shift is made in the registers 110 and 111 . The data elements provided by the register 110 are multiplied by the contents of the register 121 using the circuit 119 . The register 110 has its input connected to its output. The data elements provided by the register 111 are added with the result provided by the circuit 119 using the circuit 130 . The data elements entering the register 111 are provided by the output of the circuit 130 .
I 3 ) A 1 bit shift is made in the registers 111 and 132 . A 0 is sent to the circuit 119 . The bit present in the flip-flop circuit 162 is added with the result provided by the circuit 119 using the circuit 130 . The bit provided by the register 132 is added to the result provided by the circuit 130 using the circuit 131 . The data elements entering the register 111 are provided by the output of the circuit 131 .
I 4 ) A k−1 bit shift is made in the registers 111 and 132 , 0s are sent to the circuit 119 , and 0s are added with the result provided by the circuit 119 using the circuit 130 . The bits provided by the register 132 are added to the result provided by the circuit 130 using the circuit 131 . The data elements entering the register 111 are provided by the output of the circuit 131 . During the last shift, the carry value present in the circuit 131 is stored in the flip-flop circuit 162 .
I 5 ) While the steps I 1 to I 4 are performed, the word A 1 is loaded into the register 116 .
At the end of the first iteration, the register 110 contains the operand B. The register 111 contains an intermediate result that corresponds to the m*k most significant bits of the operation A 0 *B+C 1,0 C 0 . A 0 corresponds to the k least significant bits of A, C 1,0 corresponds to the k least significant bits of the most significant (k*m) bit word C 1 of the operand C. C 0 corresponds to the least significant m*k bit word of the operand C. The register 112 contains, in terms of most significant bits, the word S 0,0 , and in terms of least significant bits, the words C 1,m−1 to C 1,1 . The word S 0,0 corresponds to the k least significant bits of the m*k bit word S 0 of the result S of the elementary operation of the invention. The words C 1,m−1 to C 1,1 correspond to the m− 1 most significant k bit words of the most significant m*k bit word C 1 of the operand C. The register 116 contains the word A 1 corresponding to the k bit word having the significance of 1 in the operand A. The flip-flop circuit 162 contains a possible overflow carry value resulting from the iteration.
Computation loop: The loop initialization and the loop iteration that follow are repeated m− 1 times, with j being an index varying form 1 to m− 1 .
Loop initialization: I′ 0 ) The word A j contained in the register 116 is loaded into the register 121 . The register 132 and the circuits 130 and 131 are initialized at 0.
Loop iteration: The steps I 1 to I 4 defined above are performed.
I′ 5 ) While the steps I 1 to I 4 are being performed, the word A j+1 is loaded into the register 116 .
At the end of each loop iteration, the register 110 contains the operand B. The register 111 contains an intermediate result that corresponds to the m*k most significant bits of the operation A j . . . A 0 *B+C 1,j . . . C 1,0 C 0 . . . A j . . . A 0 correspond to the j*k least significant bits of A. C 1,j . . . C 1,0 correspond to j*k least significant bits of the most significant k*m bit word of the operand C. C 0 corresponds to the least significant m*k bit word of the operand C. The register 112 contains, in terms of most significant bits, the words S 0,j to S 0,0 and, in terms of least significant bits, the words C 1,m−1 to C 1,j+1 . The words S 0,j to S 0,0 correspond to the j*k least significant bits of the m*k bit word S 0 of the result S of the elementary operation of the invention. The words C 1,m−1 to C 1,j+1 correspond to the m− 1 −j most significant k bit words of the most significant m*k bit word C 1 of the operand C. The register 116 contains the word A j+1 corresponding to the k bit word having the significance of j+ 1 in the operand A. The flip-flop circuit 162 contains a possible overflow carry value resulting from the previous iteration.
At the end of the last iteration, the result S is contained in the registers 111 and 112 . A possible carry value is stored in the flip-flop circuit 162 . To recover the total result, the data elements contained in the registers 111 and 112 are output by means of the terminals 156 and 157 , and a carry value indicating an overflow of computation, if any, is recovered by the terminal 163 .
If, on the contrary, it is desired to chain a computation, only the contents of the register 112 are output. To perform the chaining of a computation, a word with Bt=m*k more significant bits of the variable to be added is loaded into the register 112 . Then, the more significant word replacing A is presented. The updating of the flip-flop circuit 162 is not performed.
By way of an example, the performance of an operation P field (D, E)N=S is illustrated with the circuit 1 of FIG. 2 using the coprocessor 4 of FIG. 4. D, E, S and N are encoded on p words of Bt bits, with Bt being equal to m*k bits. The operation takes place as follows. The computation loop formed by the succession of following steps is repeated p times. The variable i is an index varying from 0 to p−1, and is incremented for each performance of the loop by the processor 2 .
PX) Computation of X=S i +D i *E. X p . . . X 0 =S i,p−1 . . . S i,0 +D i *E p−1 . . . E 0 , with X j , S i,j and E j being the Bt bit words of X, S i and B. S i is an updated value of S such that S 0 =0 and S p−1 =S in breaking down the computation by the steps PX 1 to PXp.
PX 1 ) X′ 1 X 0 =S i,1 S i,0 +D i *E 0 loads D i into the register 110 , S i,1 into the register 112 , and S i,0 into the register 111 for initializing the flip-flop circuit 162 at 0. The m words of k bits forming E 0 are successively loaded into the register 116 . At the end of the computation, the contents of the register 112 corresponding to X 0 are output.
PX 2 ) X′ 2 X 1 =S i,2 X′ 1 +D i *E 1 loads S i,2 into the register 112 , S i,1 into the register 112 , and successively loads the m words of k bits forming E 1 in the register 116 . At the end of the computation, the contents of the register 112 corresponding to X 1 are output.
Pxp− 1 ) X′ p−1 X p−2 =S i,p−1 X′ p−2 +D i *E p−2 loads S i,p−1 into the register 112 , and successively loads the m words of k bits forming E p−2 in the register 116 . At the end of the computation, the contents of the register 112 corresponding to X p−2 are output.
Pxp) X p X p−1 =X′ p−1 +D i *E p−1 loads 0s into the register 112 , and successively loads the m words of k bits forming E p−1 in the register 116 . At the end of the computation, the contents of the register 112 , which correspond to X p−1 , and the contents of the register 111 , which correspond to Xp, are output. The output of the carry value is unnecessary because it is 0. X′ 1 to X′ p−1 are Bt bit words of intermediate computation that remain in the register 111 of the coprocessor 4 between two computations
PY) Y 0 =(X*J 0 ) mod 2 Bt . Y 0 =(X p . . . X 0 *J 0 ) mod 2 Bt , by the following computation made in the coprocessor 4 . Y′ 1 Y 0 =X 0 *J 0 +0 loads X 0 into the register 110 , and 0s into the registers 111 and 112 . The flip-flop circuit 162 is initialized at 0 and successively loads the m words of k bits forming J 0 into the register 116 . At the end of the computation, the contents of the register 112 corresponding to Y 0 , which are the only data element of interest, are output.
PZ) Z=X+N*Y 0 . Z p . . . . Z 0 =X p . . . X 0 +Y 0 *N p−1 . . . N 0 , with Z j , X j and N j being the Bt bit words of Z, X and N. The computation is broken down by the steps PZ 1 to PZp.
PZ 1 ) Z′ 1 Z 0 =X 1 X 0 +Y 0 *N 0 loads Y 0 into the register 110 , X 1 into the register 112 , and X 0 into the register 111 . The flip-flop circuit 162 is initialized at 0 and successively loads the m words of k bits forming N 0 into the register 116 . At the end of the computation, the contents of the register 112 that correspond to Z 0 are output.
PZ 2 ) Z′ 2 Z 1 =X 2 Z′ 1 +Y 0 *N 1 loads X 2 into the register 112 , and successively loads the m words of k bits forming N 1 in the register 116 . At the end of the computation, the contents of the register 112 , which correspond to Z 1 , are output.
Pzp− 1 ) Z′ p−1 Z p−2 =X p−1 Z′ p−2 +Y 0 *N p−2 loads X p−1 into the register 112 , and successively loads the m words of k bits forming N p−2 in the register 116 . At the end of the computation, the contents of the register 112 , which correspond to Z p−2 , are output.
Pzp) Z p Z p−1 =X p Z′ p−1 +Y 0 *N p−1 loads X p values into the register 112 and successively loads the m words of k bits forming N p−1 in the register 116 . At the end of the computation, the contents of the register 112 corresponding to Z p−1 , and the contents of the register 111 corresponding to Z p are output. The carry value is also output. Z′ 1 to Z′ p are Bt bit words of intermediate computation that remain permanently in the coprocessor 4 .
PS) If the carry value is equal to 0 and if Z\2 Bt is smaller than N, then S i+1 =Z\2 Bt . Otherwise, S i+1 =Z\2 Bt −N, with \ being an integer division.
In the example described above, the invention enables economizing of the p addition of Bt bits, i.e., about p*Bt cycles of the clock signal used for the stringing of the coprocessor 4 . This makes it possible to prevent exchanges of data between the memory 3 and the coprocessor 4 . It will be noted that the operation S=A*B+C is performed with a variable C reconstructed from words of smaller size whose source is different.
Alternative embodiments of the processor 4 of FIG. 4 are possible. It is not necessary to connect the output of the flip-flop circuit 162 to the multiplexer 140 and to the terminal 163 . It is possible, for example, to connect the output of the flip-flop circuit 162 to the control device of the processor 4 (not shown), and connect a third input of the multiplexer to a logic 1. The control device provides either a 0 or 1 as a function of the bit contained in the flip-flop circuit. An overflow indicator controlled by the control device, e.g., a status register, is always capable of being provided to the rest of the circuit 1 . Similarly, the multiplexer 161 is not necessary, but is used to simplify the stringing of the coprocessor 4 . It is possible to load the number 1 into the register 122 to use the multiplication circuit 120 as a wire. Sending a logic 0 is done by the multiplexer 126 . It is also possible to modify the arrangement of the different elements used to perform the computation described in detail above with reference to the different components of the coprocessor 4 used to perform other functions.
FIG. 5 shows an alternative embodiment of the invention. The coprocessor 4 of FIG. 5 comprises four shift registers 210 , 211 , 212 and 240 with a serial input and a serial output. These registers comprise n number of cells, with n=m*k, and n, m and k being integers. A multiplexer 241 comprises two serial inputs and one serial output. The serial output of the multiplexer 241 is connected to the input of the register 240 . A first input of the multiplexer 241 is connected to a first terminal 242 , and a second input of the multiplexer 241 is connected to the output of the register 240 . A multiplexer 213 comprises three serial inputs and one serial output. The serial output of the multiplexer 213 is connected to the input of the register 210 . A first input of the multiplexer 213 is connected to a second input terminal 243 , and a second input of the multiplexer 213 is connected to the output of the register 210 .
The coprocessor 4 further includes a multiplexer 214 comprising two serial inputs and one serial output. The serial output of the multiplexer 214 is connected to the input of the register 211 , and a first input of the multiplexer 214 is connected to a third input terminal 244 . A multiplexer 215 comprises three serial inputs and one serial output. The serial output of the multiplexer 215 is connected to the input of the register 212 . A first input of the multiplexer 215 is connected to a fourth input terminal 245 , and a second input of the multiplexer 215 is connected to the output of the register 212 . Three k cell registers 216 , 217 and 218 comprises one serial input and one parallel output.
A multiplexer 246 comprises two serial inputs and one serial output. The serial output of the multiplexer 246 is connected to the input of the register 217 . A first input of the multiplexer 246 is connected to a fifth input terminal 247 , and a second input of the multiplexer 246 is connected to the output of the register 240 . Two multiplication circuits 219 and 220 comprises one serial input, one parallel input to receive k bits, and one serial output. Two k cell storage registers 221 and 222 comprises one parallel input and one parallel output. The input of the register 221 is connected to the output of the register 216 . The output of the register 221 is connected to the parallel input of the multiplication circuit 219 , and the output of the register 222 is connected to the parallel input of the multiplication circuit 220 .
A multiplexer 223 comprises two parallel inputs and one parallel output. A first input of the multiplexer 223 is connected to the output of the register 216 , and a second input of the multiplexer 223 is connected to the output of the register 218 . The output of the multiplexer 223 is connected to the input of the register 222 . Two multiplexers 224 and 225 each comprises two serial inputs and one serial output. The output of the multiplexer 224 is connected to the input of the register 216 . A first input of the multiplexer 224 is connected to the output of the register 240 . The output of the multiplexer 225 is connected to the serial input of the multiplication circuit 219 , and a first input of the multiplexer 225 is for receiving a logic 0.
A multiplexer 248 comprises four series inputs and one series output. The output of the multiplexer 248 is connected to the series input of the multiplication circuit 220 , and a first input of this multiplexer is for receiving a logic 0. Subtraction circuits 227 , 228 and 229 each comprise two serial inputs and one serial output. A first input of the circuit 227 is connected to the output of the register 210 . The output of the circuit 227 is connected to each of the two inputs of the multiplexers 224 and 225 , to an output terminal 249 , and to a fourth input of the multiplexer 248 . A multiplexer 250 comprises three serial inputs and one serial output. The output of the multiplexer 250 is connected to the first input of the circuit 228 . A first input of the multiplexer 250 is connected to the output of the register 211 . A second input of this multiplexer is for receiving a logic 0, and a third input of this multiplexer is for receiving a logic 1.
Two addition circuits 230 and 231 each comprises two serial inputs and one serial output. A first input of the circuit 230 is connected to the output of the circuit 219 , and a second input of this circuit is connected to the output of the subtraction circuit 228 . The output of the circuit 230 is connected to a second input of the multiplexer 248 . The output of the circuit 231 is connected to a first input of the circuit 229 . A multiplexer 253 comprises three serial inputs and one serial output. The serial output of the multiplexer 253 is connected to a first input of the addition circuit 231 , and a first input of this multiplexer is connected to the output of the addition circuit 230 . The third input of the multiplexer is for receiving a logic 0.
Delay cells 232 , 233 and 234 delay the propagation of binary data by k cycle periods. These cells are typically k bit shift registers having the size of the registers 216 , 217 and 218 . These cells each comprise a serial input and a serial output. The output of the cell 232 is connected firstly to a third input of the multiplexer 248 , and secondly to the input of the cell 233 . The output of the cell 233 is connected to a second input of the circuit 229 . The input of the cell 234 is connected to the output of the addition circuit 230 , and the output of the cell 234 is connected to a second input of the multiplexer 253 . A comparison circuit 235 comprises two serial inputs and two outputs. A first input of the circuit 235 is connected to the output of the circuit 231 , and a second input of the circuit 235 is connected to the output of the circuit 229 .
Two multiplexers 236 and 237 each comprises two serial inputs, one selection input, and one serial output. Each of the first serial inputs of the multiplexers 236 and 237 are for receiving a logic 0. Each of the selection inputs are connected to one of the outputs of the circuit 235 . The output of the multiplexer 236 is connected to a second input of the circuit 227 , and the output of the multiplexer 237 is connected to a second input of the circuit 228 . A multiplexer 238 comprises two serial inputs and one serial output. A first input of the multiplexer 238 is for receiving a logic 1. A second input of the multiplexer 238 is connected to the output of the register 212 . The output of the multiplexer 238 is connected firstly to the input of the cell 232 , and secondly to the second inputs of the multiplexers 236 and 237 .
A demultiplexer 239 comprises a serial input and two serial outputs. The input of the demultiplexer 239 is connected to the output of the circuit 220 , and a first output of the demultiplexer 239 is connected to the input of the register 218 . A delay cell 254 delays the propagation of the binary data elements by k cycle times. These cells are typically k bit shift registers. This cell comprises a serial input and a serial output. The input of the cell 254 is connected to a second output of the demultiplexer 239 . A multiplexer 255 comprises two serial inputs and one serial output. A first input of the multiplexer 255 is connected to the second output of the demultiplexer 239 . A second input of the multiplexer 255 is connected to the output of the cell 254 , and the output of the multiplexer 255 is connected to a second input of the addition circuit 231 .
A multiplexer 256 comprises two serial inputs and one serial output. A first input of the multiplexer 256 is connected to the output of the addition circuit 230 . The output of this multiplexer is connected to the third inputs of the multiplexers 213 and 215 and to a second input of the multiplexer 214 . Two output terminals 257 and 258 are connected respectively to the outputs of the registers 211 and 212 . A multiplexer 260 comprises two serial inputs and one serial output. A first input of the multiplexer 260 is connected to the output of the delay cell 233 , and a second input is for receiving a logic 0. An addition circuit 261 comprises two serial inputs, one computation output, and one carry output. A first input of the addition circuit 261 is connected to the output of the multiplexer 260 . A second input of the addition circuit 261 is connected to the output of the addition circuit 231 . The computation output of the addition circuit 261 is connected to the second input of the multiplexer 256 .
A storage flip-flop circuit 262 comprises one input and one output. The input is connected to the carry output of the addition circuit 261 , and the output of the flip-flop circuit 262 is connected to a device for controlling of the coprocessor 4 (not shown). The delay function of the delay cells 232 and 233 is used to perform modular computations internally, as explained in the referenced U.S. Pat. No. 5,513,133. In the invention, the delay cells 232 and 233 are used as shift registers and shall hereinafter be called registers 232 and 233 .
As shall be discussed below, this exemplary coprocessor 4 made according to the invention could undergo modifications without going beyond the scope of the invention. With regard to the output and input terminals, it is possible to make use of distinct terminals, but they could also be one or more input/output terminals common to several elements of the coprocessor. One advantage of using distinct terminals is that it is possible to receive and/or provide data elements from and/or to elements external to the coprocessor, such as the processor 2 . This reduces the duration of the exchanges between the circuit and the external elements. To perform the operation S=A*B+C, it is necessary to make the subtraction circuits 227 and 228 transparent to the bits received at their first inputs. The second input of the multiplexer 255 is selected permanently so that the data elements produced by the multiplication circuit 220 are provided with a delay of k clock cycles to the addition circuit 231 .
In the following explanations, no account will be taken for the delays caused by the subtraction and addition circuits 227 , 228 , 230 and 231 and 261 , or of any delays caused by the initialization of the different elements of the coprocessor 4 . Those skilled in the art are capable of synchronizing the circuits with one another. The following explanations enable the necessary stringing of the different elements of the coprocessor 4 to carry out the elementary operation of the invention S=A*B+C. A and B are encoded on Bt=m*k bits, with C and S being encoded on 2*Bt=2*m*k bits, and m is an even number.
Initialization: IT 0 ) The m*k bits of the operand A are loaded into the register 240 . A 0 and A 1 are respectively loaded into the registers 221 and 222 through the registers 216 and 217 . A 0 and A 1 are the k bit words with values 0 and 1 of the operand A. The m*k bits of the operand B are loaded into the register 210 . The m*k least significant bits of the operand C, referenced C 0 , are loaded into the register 211 . The m*k most significant bits of the operand C, referenced C 1 , are loaded into the register 212 . The registers 232 and 233 , the delay cell 254 , the addition circuits 230 , 231 and 261 , and the multiplication circuits 219 and 220 are initialized at 0. If it is a first elementary operation, then the flip-flop circuit 262 is initialized at 0.
First iteration: IT 1 ) A 2*k bit shift is made in the registers 210 , 211 , 212 and 232 . The data provided by the register 210 is multiplied by the contents of the register 221 using the circuit 219 , and by the contents of the register 222 using the circuit 220 . The register 210 has its input connected to its output. The data elements provided by the register 211 are added up with the result provided by the circuit 219 using the circuit 230 , and with the result provided by the circuit 220 with a k bit shift using the circuit 231 . The data elements provided by the register 212 are loaded into the registers 232 and 233 . The data elements entering the register 212 are provided by the output of the circuit 231 . The circuit 261 is made transparent by the sending of logic 0s through the multiplexer 260 .
IT 2 ) A (m−2)*k bit shift is made in the registers 210 and 211 . The data elements provided by the register 210 are multiplied by the contents of the register 221 using the circuit 219 , and by the contents of the register 222 using the circuit 220 . The register 210 has its input connected to its output. The data elements provided by the register 211 are added with the result provided by the circuit 219 using the circuit 230 , and with the result provided by the circuit 220 with a k bit shift using the circuit 231 . The data elements entering the register 211 are provided by the output of the circuit 231 . The circuit 261 is made transparent by sending logic 0s through the multiplexer 260 .
IT 3 ) A 1 bit shift is made in the registers 211 , 232 and 233 . A 0 is sent to the circuits 219 and 220 by the multiplexers 225 and 248 . The bit present in the flip-flop circuit 262 is added with the result provided by the circuit 219 using the circuit 230 . This is done by the sending either a 0 or a 1 by the multiplexer 250 as a function of the state of the contents of the flip-flop circuit 262 . The result provided by the circuit 230 is added with the result provided by the circuit 220 using the circuit 231 . The bit provided by the register 233 is added to the result provided by the circuit 231 using the circuit 261 . The data elements entering the register 211 are provided by the output of the circuit 261 .
IT 4 ) A 2*k−1 bit shift is made in the registers 211 , 232 and 233 , 0s are sent to the circuits 219 and 220 by the multiplexers 225 and 248 , and 0s are added with the result provided by the circuit 219 using the circuit 230 . The result provided by the circuit 230 are added with the result provided by the circuit 220 using the circuit 231 . The bits provided by the register 233 are added to the result provided by the circuit 231 using the circuit 261 . The data elements entering the register 211 are provided by the output of the circuit 261 . During the last shift, the carry value present in the circuit 261 is stored in the flip-flop circuit 262 .
IT 5 ) While the steps IT 1 to IT 4 are performed, the words A 2 and A 3 respectively are loaded into the registers 216 and 217 .
At the end of the first iteration, the register 210 contains the operand B. The register 211 contains an intermediate result that corresponds to the m*k most significant bits of the operation A 0 *B+C 1,1 C 1,0 C 0 . A 0 corresponds to the k least significant bits of A. C 1,1 C 1,0 corresponds to the two least significant k bit words of the most significant k*m bit word C 1 of the operand C. C 0 corresponds to the least significant (m*k) bit word of the operand C. The register 212 contains, in terms of most significant bits, the words S 0,1 S 0,0 and, in terms of least significant bits, the words C 1,m−1 to C 1,1 . The words S 0,0 and S 0,1 correspond to the two least significant k-bit words of the (m*k) bit word S 0 of the result S of the elementary operation of the invention. The words C 1,m−1 to C 1,2 correspond to the m−2 most significant k bit words of the most significant (m*k) bit word C 1 of the operand C. The registers 216 and 217 contain the words A 2 and A 3 corresponding to the k bit word having the values 2 and 3 of the operand A. The flip-flop circuit 262 contains any overflow carry value resulting from the iteration.
Computation loop: The loop initialization and the loop iteration that follow are repeated (m/2)−1 times, with j being an index varying from 1 to (m/2)−1.
Loop initialization: IT′ 0 ) The word A 2*j contained in the register 216 is loaded into the register 221 . The word A 2*j+1 contained in the register 217 is loaded into the register 222 . The registers 232 and 233 and the circuits 230 , 231 and 261 are initialized at 0.
Loop iteration: The steps IT 1 to IT 4 defined above are performed. IT′ 5 ) While the steps IT 1 to IT 4 are being performed, the word A 2*j+2 is loaded into the register 216 , and the word A 2*j+3 is loaded into the register 217 .
At the end of each loop iteration, the register 210 contains the operand B. The register 211 contains an intermediate result that corresponds to the m*k most significant bits of the operation A 2*j+1 . . . A 0 *B+C 1,2*j+1 . . . C 1,0 C 0 . A 2*j+1 . . . A 0 corresponds to the (2*j+1)*k least significant bits of A. C 1,2*j+1 . . . C 1,0 corresponds to (2*j+2)*k least significant bits of the most significant k*m bit word of the operand C. C 0 corresponds to the least significant m*k bit word of the operand C. The register 212 contains, in terms of most significant bits, the words S 0,2*j+1 to S 0,0 and, in terms of least significant bits, the words C 1,m−1 to C 1,2*j+2 . The words S 0,j to S 0,0 correspond to the j*k least significant bits of the m*k bit word S 0 of the result S of the elementary operation of the invention. The words C 1,m−1 to C 1,2*j+2 correspond to the m−2−2*j most significant k bit words of the most significant m*k bit word C 1 of the operand C. The registers 216 and 217 contain the words A 2*j+2 and A 2*j+3 corresponding to the k bit words having the significance of 2*j+2 and 2*j+3 of the operand A. The flip-flop circuit 262 contains a overflow carry value, if any, resulting from the iteration.
At the end of the last iteration, the result S is contained in the registers 211 and 212 . A possible carry value is stored in the flip-flop circuit 262 . To recover the total result, the data elements contained in the registers 211 and 212 are output by the terminals 257 and 258 and the carry value, if any, indicating an overflow of computation, is recovered. If it is desired to chain a computation, only the contents of the register 212 are output. To perform the chaining of a computation, a word with Bt=m*k more significant bits of the variable to be added is loaded into the register 112 . Then, the more significant word replacing A is loaded into the register 240 . The updating of the flip-flop circuit 262 is not performed. If the operands are encoded on a number m of k bit words, with m as an odd number, then the operation returns to the case where m is an even number in adding a word formed by k 0s.
By way of an example, the performance of an operation P field (D, E)N=S is obtained with the circuit 1 of FIG. 2 using the processor 4 of FIG. 4. D, E, S and N are encoded on p words of Bt bits, with Bt being equal to m*k bits. The performance takes place as follows. The computation loop formed by the succession of following steps is repeated p times, with i being an index varying from 0 to p− 1 and being incremented for each performance of the loop by the processor 2 .
PX) Computation of X=S i +D i *E. X p . . . X 0 =S i,p−1 . . . S i,0 +D i *E p−1 . . . E 0 , with X j , S i,j and E j being the Bt bit words of X, S i and B. S i is an updated value of S such that S 0 =0 and S p−1 =S breaks down the computation by the steps PX 1 to PXp.
PX 1 ) X′ 1 X 0 =S i,1 S i,0 +D i *E 0 loads D i into the register 210 , S i,1 into the register 212 , and S i,0 into the register 211 . The flip-flop circuit 262 is initialized at 0 and E 0 is loaded into the register 240 . At the end of the computation, the contents of the register 212 corresponding to X 0 are provided at an output.
PX 2 ) X′ 2 X 1 =S i,2 X′ 1 +D i *E 1 loads S i,2 into the register 212 , and E 1 is loaded into the register 240 . At the end of the computation, the contents of the register 212 corresponding to X 1 are provided at an output.
Pxp− 1 ) X′ p−1 X p−2 =S i,p−1 X′ p−2 +D i *E p−2 loads S i,p−1 into the register 212 , and E p−2 is loaded into the register 240 . At the end of the computation, the contents of the register 212 corresponding to X p−2 are provided at an output.
Pxp) X p X p−1 =X′ p−1 +D i *E p− loads 0s into the register 212 , and E p−1 is loaded into the register 240 . At the end of the computation, the contents of the register 212 which correspond to X p−1 , and the contents of the register 211 which correspond to X p are provided at an output. The output of the carry value is unnecessary because it is 0. X′ 1 to X′ p−1 are Bt bit words of intermediate computation that remain in the register 211 of the coprocessor 4 between two computations.
PY) Y 0 =(X*J 0 ) mod 2 Bt . Y 0 =(X p . . . X 0 *J 0 ) mod 2 Bt is provided by the following computation made in the coprocessor 4 . Y′ 1 Y 0 =X 0 *J 0 +0 loads X 0 into the register 210 , and 0 s into the registers 211 and 212 . The flip-flop circuit 262 is initialized at 0 and J 0 is loaded into the register 240 . At the end of the computation, the contents of the register 212 corresponding to Y 0 , which are the only data elements of interest, are provided at an output.
PZ) Z=X+N*Y 0 . Z p . . . Z 0 =X p . . . X 0 +Y 0 *N p−1 . . . N 0 . Z j , X j and N j are the Bt bit words of Z, X and N, and are split up by the steps PZ 1 to PZp.
PZ 1 ) Z′ 1 Z 0 =X 1 X 0 +Y 0 *N 0 loads Y 0 into the register 210 , X 1 into the register 212 , and X 0 into the register 211 . The flip-flop circuit 262 is initialized at 0, and N 0 is loaded into the register 240 . At the end of the computation, the contents of the register 212 that correspond to Z 0 are provided at an output.
PZ 2 ) Z′ 2 Z 1 =X 2 Z′ 1 +Y 0 *N 1 loads X 2 into the register 212 , and loads N 1 into the register 240 . At the end of the computation, the contents of the register 212 , which corresponds to Z 1 , are provided at an output.
Pzp− 1 ) Z′ p−1 Z p−2 =X p−1 Z′ p−2 +Y 0 *N p−2 loads X p−1 into the register 212 , and loads N p−2 into the register 240 . At the end of the computation, the contents of the register 212 , which corresponds to Z p−2 , are provided at an output.
Pzp) Z p Z p−1 =X p Z′ p−1 +Y 0 *N p−1 loads X p values into the register 112 and successively loads the m words of k bits forming N p−1 into the register 240 . At the end of the computation, the contents of the register 212 corresponding to Z p−1 , and the contents of the register 211 corresponding to Z p are provided at an output. The carry value is also provided at the output. Z′ 1 to Z′ p are Bt bit words of intermediate computation that remain permanently in the coprocessor 4 .
PS) If the carry value is equal to 0, and if Z\2 Bt is smaller than N, then S i+1 =Z\2 Bt , else S i+1 =Z\2 Bt −N, with \ being an integer division.
The coprocessor 4 of FIG. 5 enables the performance of the computations about twice as fast as the coprocessor 4 of FIG. 4, and reduces the number of interventions of the processor 2 to manage data exchanges between the memory 3 and the coprocessor 4 . Combinations between the processors of FIGS. 4 and 5 are possible. It is possible, for example, to transpose the register 240 to the coprocessor of FIG. 4 to reduce the number of data exchanges. Conversely, it is also possible to eliminate the register 240 from FIG. 5 . However, this requires the loading, during the iterations, of the k bit words of the operand A.
Many shifts of elements can be done. The delay cell 254 may be placed at output of the multiplication circuit 219 provided that the words of the registers 216 and 217 are reversed. It is also possible to shift the addition circuit 261 to another place in the circuit. The flip-flop circuit 262 should be capable of recovering the carry value of the last of the addition circuits 230 , 231 or 261 . Similarly, the carry value should not necessarily be inserted into the first of the addition circuits, but in place of the least significant m*k bit word that has been added. It is also possible to use addition circuits having more than two inputs. It is then necessary to store the carry value of the last of the addition circuits used, and insert the carry value in the place of the least significant word added. The sizes of the operands may be different from one another. It is always possible to return to a size of m*k bits or carry out a number of iterations as a function of the size of the operands. | The computation time of modular operations on large-format data is improved by using a computation circuit integrated as a modular arithmetic coprocessor. The computation circuit carries out an S=A*B+C type operation, with S and C encoded on 2*Bt bits, and A and B encoded on Bt bits. To carry out this operation, a storage flip-flop circuit enables the storage of a possible overflow carry value at the end of an elementary computation, and reinserts this carry value during the following computation. | 6 |
FIELD OF THE INVENTION
[0001] The present invention refers to the construction of pool and, more specifically, to pools made up of standardised dimension modules.
BACKGROUND OF THE STATE OF THE ART
[0002] The growing popularity of pools for recreational, therapeutic and domestic use has resulted in the creation of a plurality of types and models, intended to meet the market's large variety expectations. Among others, the following can be mentioned as the most widely spread:
[0003] concrete pools, lined with tiles, miniature tiles or vinyl linings;
[0004] fibreglass pools, manufactured according to standardised dimensions and shapes;
[0005] mixed type pools, with concrete base (bottom) and blocks, clay bricks or metallic sheets, usually waterproofed with vinyl lining or fibreglass skin.
[0006] However, constructing pools of the above mentioned types is a relatively complex, slow and expensive process, since, in addition to requiring specialised labour, they have disadvantages inherent to their nature.
[0007] In fact, it is known that concrete structures require the manufacture of moulds that, once used, are disposed of, resulting in a substantial waste of material.
[0008] The fibreglass pools, although they do not have this inconvenience, they require digging a hole in the ground with the proper dimensions, as well as the provision of a concrete support bottom.
[0009] Additionally, both concrete and fibreglass pools cannot be moved to another location, and can they have their dimensions (length, width, shape, depth) altered, having no choice but to live with the original dimensions forever. In the case of a pool built at a certain time for small children to use, for example, it is impossible to increase the depth when these children grow.
[0010] Conventional pools have even other inconveniences, such as the need of special techniques to install underwater lighting (that must be planned during the construction), not being possible to alter the number or position of the lights once the construction has ended.
[0011] The above mentioned inconveniences have resulted in the search of solutions based on modular techniques, in order to make their costs more accessible, as well as reducing assembly time and making it easier. That trend is exemplified by the patent documents U.S. Pat. No. 3,798,857, U.S. Pat. No. 3,820,174 and U.S. Pat. No. 4,047,340, which describe techniques based on the use of standardised modules.
[0012] However, the inventions described in the above mentioned documents have inconveniences that limit their usefulness, as is shown below. The document U.S. Pat. No. 3,798,857 describes a pool which walls are made up by steel sheets modules, equipped with couplings between the vertical borders of the adjacent modules, whose assembly results in the pool's sidewall, according to FIG. 1 . Nevertheless, the illustrated pool has to be embedded into the ground, therefore, requiring as occurs with fibreglass pools—the digging of a hole for its construction.
[0013] In addition, the invention does not take into account the bottom of the pool, which requires specialized and, therefore, costly labour. The same labour is needed too manufacture the concrete blocks that provide support to the walls' anchor beams. As well as that inconvenience, the execution time is long, because of the time necessary for the concrete to harden.
[0014] The document U.S. Pat. No. 3,820,174 describes a pool whose walls are made up by steel sheet modules, complemented by a trellised structure, as is shown in FIGS. 2 and 3 . The objective of this invention is to provide a structural array for assembling the ladder's handrails, as well as the support of a concrete deck or pavement surrounding the pool. As in the previous example, the bottom of the pool requires specialized labour, which is also necessary to lay the concrete pavement, these operations that involve the delay necessary for the concrete to harden.
[0015] Patent U.S. Pat. No. 4,047,340 describes a pool which walls are made up by modular plate shaped elements that have, in their vertical borders, groove and tongue joints, those plates being supported by horizontal thrust provided by “X” shaped pre-moulded parts, as shown in FIGS. 4 and 5 . The array shown requires the use of a concrete bottom (referenced as 90 in FIG. 5 ) to support the wall modules 32 , on which they lean, as well as the module internal borders of the deck 20 . The distal end of the latter is supported by one of the arms 50 of the “X” shaped part, which bottom arm 50 d leans on a metallic bracket 80 that is secured to the ground or—according to the document—a concrete base, not shown in the figure, this base is necessary due to the fact that the stress, resulting from the water's thrust on the walls, are unloaded on to this bracket. In the object of this patent the same considerations regarding the delay introduced in the time of construction due to the time necessary for the concrete to harden, are also applicable.
[0016] The three examples of the state of the arte described above also suffer common inconveniences, of which one of the most evident consists of the fact that the pools have fixed depths, since the walls are constituted by predefined size modules. Another serious inconvenience of these models is in the possibility of the occurrence of structural damages in the case of differential pressure of the ground on which the pool lies.
[0017] In fact, in the objects described in the documents U.S. Pat. No. 3,798,857 and U.S. Pat. No. 4,047,340, any deformation of the ground, on which the brackets or concrete blocks lie, will result in the deformation of the pool walls. Additionally, the differential pressure on the soil on which the bottom lies will produce stress that could result in the appearance of cracks with probable fissures lining and consequent infiltrations that speed up the wear and tear process of the pools.
OBJECTIVES OF THE INVENTION
[0018] Due to the above, the first objective of the invention is to provide a constructive design that results in a pool in which the effects of irregularities in the soil compression strength.
[0019] A second objective is to provide a building method that allows an easy and fast assembly of pools whenever possible disposing of specialized labour.
[0020] Another objective is to provide a constructive design that allows the easy disassembly and reassembly of the pool.
[0021] Yet another objective is to provide a constructive design that does not require the use of concrete walls or bottom, blocks or bricks.
[0022] Yet another objective is to provide a constructive design that includes the structure of a deck.
[0023] Another additional objective is to provide a constructive design that allows easily altering the pools dimensions and shape.
[0024] Another objective is to provide a constructive design that allows assembling the pool both under and above the ground level.
BRIEF DESCRIPTION OF THE INVENTION
[0025] The above mentioned objectives, as well as others, are attained by the invention through a constructive design, in which the modules that constitute the bottom and walls are interlinked by semi-permanent connecting means in order to make up a unique and non-deformable structure.
[0026] According to another feature of the invention, said modules are manufactured of steel sheets, which bestows them lightness, portability and easy assembly According to additional feature of the invention, the modules that make up the walls are manufactured of different standardised heights, all having the same horizontal dimension, making it possible to obtain several depths by piling the proper modules.
[0027] According to yet another feature of the invention, the pool's internal lining is of Vinyl, applied once the pool's structure assembly has been finished.
[0028] According to another feature of the invention, the pool's bottom is comprised by a base structure covered by closing modular panels.
[0029] According to another feature of the invention, the deck is comprised by standardised elements and is part of the structure.
[0030] According to another feature of the invention, the pool's assembly disposing the use of soldering or concreting, all of its components being joined to one another by means of standardised dimensions screws and nuts.
[0031] According to another feature of the invention, the set of modules comprises modules with opening for underwater light fittings, proper modules for skimmer and modules for bottom drain.
DESCRIPTION OF THE DRAWINGS
[0032] The other advantages and features of the invention will be easier understood through the description of a preferred embodiment and of the drawings that refer to it, in which:
[0033] FIGS. 1, 2 , 3 , 4 and 5 show pools built according to the known art.
[0034] FIG. 6 shows, through a perspective view, the structure's aspect of a pool built according to the principles of the invention.
[0035] FIG. 7 shows, by means of top views, various combinations of side modular panels corresponding to different depth pools.
[0036] FIG. 8 shows the manufacturing of a typical panel, according to the principles of the invention.
[0037] FIG. 9 shows, by means of a perspective view, details of the assembly of the panels that make up the wall in one of the pool's corners.
[0038] FIG. 10 shows, by means of a perspective view, the features of the wall panels in a corner with an angle that is not of 90°.
[0039] FIG. 11 shows, through a blown up view, the elements that comprised the pool's bottom structure, according to the principles of the invention.
[0040] FIG. 12 shows, by means of a perspective view, part of the pool's bottom structure once assembled.
[0041] FIG. 13 shows, by means of a cross section view, the joint of the side panels with the bottom's structure, according to the principles of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0042] Now, referring in more detail to FIG. 6 , which shows a pool exemplifying the invention, not limiting it, comprises the pool 10 , with rectangular shape and uniform depth, two sidewalls 11 and 12 , two head ends 13 , 14 as well as the bottom 15 , all these elements being constituted by constructive modular panels as described below.
[0043] Since in the example embodiment described the pool has a standard depth of 1 meter, the sides 11 , 12 and the head ends 13 , 14 are comprised by panels 17 overlaid on panels 18 that, in turn, are overlaid on panels 19 . All these panels have the same length, corresponding to a standard module, which can have any convenient measurement, in the present embodiment the value of 1 meter is being adopted. Panels 17 have a useful height of 500 mm, panels 18 the height of 300 mm and panels 19 , 200 mm. Adding these heights the total depth of 1 meter is obtained. The total height of panels 17 is 630 mm, in order to leave a clearance of 130 mm between the water surface and the pool's border.
[0044] Yet according to FIG. 6 , the pool's bottom 15 is made up by panels 16 , hereinafter called “tiles”, which completely line the bottom's surface, and that are supported by a base (not shown in the figure) comprised by an array of standardised dimension, modular, crossed beams.
[0045] Additionally, according to the principles of the invention, all the pool's components have dimensions that allow loading them in pick-ups or small trucks, offering easy and low cost transport.
[0046] In the example embodiment herein described, the dimension of the largest part, corresponding to the beams of the base of the bottom, is only 2 meters. This allows them to be transported in buildings' elevators; substantially reducing vertical transport costs to assemble pools in penthouses.
[0047] FIG. 7 shows some example assortments of different height side panels that allow building pools with various depths. In drawing 7 a, the depth of 1 meter is obtained by overlaying a panel 17 , with useful height of 500 mm, a panel 18 , 300 mm high and a panel 19 , 200 mm high.
[0048] In drawing 7 b, the depth of 1.2 meter results from overlaying a panel 17 of 500 mm, a panel 21 with 400 mm high and a panel 18 of 300 mm.
[0049] FIG. 7 c shows a depth of 1.3 meter obtained by overlaying a panel 17 , two panels 18 and a panel 19 , whilst in FIG. 7 d the depth of 1.5 meter results from overlaying a panel 17 (500 mm), a panel 21 (400 mm) and three panels 19 (200 mm each).
[0050] A general rule adopted to build the pool's walls is using higher panels next to the surface, adopting progressively shorter panels at greater depth.
[0051] It is also noted, in the present embodiment, that the height of panel 17 is greater than 500 mm, the excess 21 corresponds to the clearance between the water's surface 23 and the top of said panel 22 .
[0052] The drawings of FIG. 8 show, in details, how a pool's panel is formed from a metallic sheet 30 . As FIG. 8a shows, the developed sheet comprises a rectangular central portion 31 having stripes 32 , 33 , 34 , 35 contiguous to the sides of said rectangle, and separated from the latter by folding lines 31 a . . . 31 d. These stripes have a standardised width and through holes 36 , all of the same diameter and located at predefined positions according to the standard adopted. Once these rims have been folded in the direction indicated by the arrows 37 , the panel acquires the aspect shown in FIG. 8 b, where the rectangular central portion 31 will make up the pool's sidewall. The hydrostatic pressure 38 is applied on this central portion 31 , producing horizontal and vertical bending stresses. The horizontal rims 32 and 34 , which act as a beam's vanes, absorb the former. The vertical rims 33 and 35 provide the necessary rigidity against the bending stresses on the vertical plan. In addition to the structural role, the said rims provide connecting means with the rest of the wall's adjacent panels.
[0053] FIG. 9 shows a layout of the elements that constitute part of the walls and a pool's rectangular corner, formed by the meeting of said walls at 90 degrees. The first wall that comprises sets 41 and 42 , each one of which formed by piling the modules 17 , 18 and 19 . According to the invention, the vertically adjacent modules are joined through the screw-nut elements 44 - 45 , which traverse the through holes 35 in the juxtaposed horizontal rims, for example in the present case, rim 34 of module 17 with rim 32 of module 18 . Horizontally, the same type modules are joined, i.e., module 17 of set 41 with module 17 of set 42 , and so on, the same elements 44 - 45 providing the permanent joint between said modules.
[0054] FIG. 9 also shows how the joint in a right angle between the first set 43 of the second wall and the first wall of the pool, is structured. According to this figure, rims 33 and 35 of the same type modules make an angle a between them, which, in the present example embodiment, is equal to 90°. The connection between these elements is provided by angle iron 46 , which rims also make an angle α=90°, and whose drilling coincides with the holes of said rims. The same screw-nut elements 44 - 45 are used to provide the connection of said elements.
[0055] It is important to point out that the layout shown is not limited to right angles, the angle between the walls can have different measurements to 90°, such as for example 120°, for hexagonally shaped pools. In this case, the side rims 33 ′ and 35 ′ turned towards the corner between walls will be folded at angles different to 90°, since it is convenient maintain the right angle between the rims of angle iron 46 , in order to preserver the necessary rigidity of the structure. In the present example, the said angles are equal to a 75°, as FIG. 10 shows.
[0056] The pool's floor is constituted by a support structure on which the closing panels called “tiles”, are placed. The structure is comprised by rectangular grid formed longitudinally by the sleepers, having crossbeams placed between them; all these elements are modularly dimensioned de forma modular. FIG. 11 shows, by means of a blown up view, the elements that make up said support structure, comprising:
[0057] sleepers 51 , formed by one or more intermediary modular beams 52 at the central portion, having at both ends the point modular beams 53 ;
[0058] scarves 54 to connect said beams, by way of top joints, formed by short “U” section beams, dimensioned in order to fit in the modular beams;
[0059] modular crossbeams 56 placed between said sleepers by means of angle irons 55 .
[0060] Screws and nuts 44 - 45 (not shown in this figure), of the same type and dimensions used in assembling the walls, connect said structural elements to each other.
[0061] FIG. 12 shows part of the structure assembled on the pool's floor, forming a rectangular grid with the same pitch as module m. This grid supports the floor's smooth tiles 57 , which lean on beams 56 . As shown in figure, said tiles have side rims 57 a that act as vanes providing the necessary rigidity to resist the bending resulting from the hydrostatic pressure on the bottom. In addition to the smooth tiles 57 , special tiles are provided for various functions, such as tile 58 that has a central opening 59 to assemble the bottom's drain.
[0062] FIG. 12 also shows angle irons 61 that constitute the side panel assembling elements, providing the necessary link between the pool's walls and bottom. These angle irons 61 have through holes 62 a on their vertical rims, co-operatively aligned with holes 62 b located on the base structure perimeter beams (crossbeams and sleepers), to which they are attached by means of screws 44 and nuts 45 . According to the schematic cross section view of FIG. 13 , the wall lower, such as, for example, panels 19 , are attached to the horizontal rims of said angle bars, by means of screw-nut sets 44 - 45 and through holes 63 , resulting in the formation of a unique block by said link. Consequently, the horizontal stress applied to said panels by the hydrostatic pressure are unloaded on the floor's structure.
[0063] Although the above description referred to pools, the constructive features of the invention offer a wide range of applications. One of these refers to the building of iced water reservoirs for air conditioning systems in existing buildings, without requiring civil works or structural alterations. In fact, the invention allows assembling a reservoir on existing floors, for example in garages or patios, thermal isolation being provided by polyurethane or polystirene sheets interlaid between the walls and bottom and the vinyl lining.
[0064] Therefore, it is understood that modifications can be introduced by technicians in the subject, keeping within the conceptual limits of the invention, the latter being limited by the list of claims below. | Modular pool constructive design whose walls are constituted by metallic panels ( 17, 18, 19 ), made up by folding metallic sheets, comprising a bottom including a structure that supports a plurality of metallic panels-tiles ( 16 )—said walls ( 11, 12, 13, 14 ) are connected to said bottom's structure, making up a unique and non-deformable structure, all the pool's elements are interlinked by semi-permanent connecting means, such as screws and nuts. The dimensions of the pool's elements allow its easy transport in small vehicles or buildings' elevators. | 4 |
BACKGROUND
1. Field
The disclosed subject matter relates to a vehicle damper and a method of manufacturing the same. More specifically, the disclosed subject matter relates to a rod guide and sealing structure for a vehicle damper and the sealing method therefore.
2. Brief Description of the Related Art
Vehicle dampers are used in conjunction with vehicle suspension systems to absorb unwanted vibrations which occur during operation of the vehicle. In order to absorb this unwanted vibration, vehicle dampers are connected between the sprung mass (the body) and the unsprung mass (the suspension system) of the vehicle. A piston is located within a pressure tube of the vehicle damper and is connected to either the sprung mass or possibly the unsprung mass of the vehicle. The pressure tube is connected to the other of the unsprung mass or sprung mass of the vehicle and is filled with hydraulic fluid. Because the piston has the capability of limiting the flow of hydraulic fluid within the pressure tube when the vehicle damper is compressed or extended, the vehicle damper is able to produce a damping force which counteracts the vibrations which would otherwise be transmitted from the suspension (unsprung mass) to the body (sprung mass) of the vehicle.
A conventional dual tube vehicle damper includes a pressure tube with a piston disposed therein and a reserve tube surrounding the pressure tube. A piston rod is connected to the piston and extends through the upper end of the pressure and reserve tubes. At the lower end of the pressure tube, a base valve is located between the pressure tube and the reserve tube. The base valve controls fluid flow between the working chamber defined by the pressure tube and the reserve chamber defined by the reserve tube. The damping force is created by restricting the flow of fluid through passages in the piston and valve plates which regulate passage of fluid between opposite sides of the piston within the working chamber.
Because the piston rod is located on only one side of the piston, a different amount of fluid is displaced on the compression stroke as opposed to the rebound stroke. The difference in the amount of fluid is termed the rod volume. The rod volume of fluid is pushed out of the pressure tube, through the base valve and into the reserve tube during a compression stroke. During a rebound stroke, the rod volume of fluid flows in the opposite direction from the reserve tube, through the base valve and into the pressure tube.
The piston rod is supported at its lower end by the piston and is slidingly received at the upper end of the vehicle damper by a rod guide. The rod guide thus functions as a slide bearing for the rod. The rod guide properly positions the piston rod within the pressure tube and also acts as a closure member for both the pressure tube and the reserve tube. A small clearance can be formed between the inner periphery of the bearing portion of the rod guide and the outer periphery of the piston rod in order to provide smooth sliding of the piston rod through the rod guide. The small clearance also allows for the hydraulic fluid to lubricate the interface between the piston rod and the rod guide.
In addition to locating the piston rod and closing the pressure and reserve tubes, the rod guide supports and locates a seal assembly which is designed to keep the hydraulic fluid within the vehicle damper and also keep contaminants out of the vehicle damper. The seal assembly normally interfaces between the reserve tube and the rod guide, between the rod guide and the piston rod and possibly between the reserve tube and the piston rod. The seal assembly is designed to keep hydraulic fluid within the vehicle damper as well as keep dirt and other contaminates from entering the vehicle damper. The dirt and contaminants can be present and can adhere to the exposed portion of the piston rod.
There have been numerous seal systems designed and developed for meeting the difficult environmental and sealing requirements for vehicle dampers. While these conventional art seal systems are adequate for their intended purpose, the continued development of vehicle dampers and related seal systems has been directed towards dampers that are made of different materials and have different constructions, requiring different types of seals and seal systems.
One type of vehicle damper and seal system that is currently under continuous development is a monotube type damper. In a monotube type damper, a second reserve tube is not necessary. Instead, a second “floating piston” is provided within the first tube and is located below the working piston. The floating piston divides a working chamber of the monotube that is filled with hydraulic fluid from a lower chamber that can be filled with gas or other easily expandable/contractible fluid. The working piston is connected to a piston rod and moves with respect to the monotube structure by passing through a sealing structure/system located at an upper end of the working chamber above the working piston, similar to the system described above with respect to a dual chamber damper.
A typical monotube damper seal system is shown in FIG. 2A in which a seal system includes an aluminum rod guide 910 connected to an end of a single steel tube 972 . The outer portion of the rod guide 910 is sealed with a surface of the inner tube wall 972 b by O-rings 917 that prevent hydraulic fluid 902 from escaping. Likewise, the inner through hole 911 of the rod guide is sealed at the juncture between the rod guide 910 and the piston rod 941 by a lower inner seal 930 . A lock ring 936 is press fit into an opening in the lower surface 915 of the rod guide 910 to lock the lower inner seal 930 to the rod guide 910 . The rod guide 910 can be locked with respect to the tube 972 via a clinch ring indent in the tube 972 that corresponds to an indent in the rod guide 910 .
The top surface 912 of the rod guide 910 is surrounded by a wall of the bordering tube 972 that extends beyond the rod guide 910 and forms a cup with the top surface 912 of the rod guide. This “cup” shaped portion tends to trap water 980 and other dirt and debris 981 at the top of the rod guide 910 .
As shown in FIG. 3 , the water 980 and debris 981 that are trapped by the tube wall 972 and rod guide 910 at the top of the damper 900 can result in a break down of the seal system between the rod guide 910 and either the tube 972 or the piston rod 941 . The break down occurs when the water 980 and/or debris 981 get in between either the piston rod 941 and rod guide 910 or the rod guide 910 and inner surface 972 b of the tube 972 . The water 980 and/or debris 981 cause the O-ring(s) 917 and/or lower inner seal 930 to deteriorate, resulting in water, debris or hydraulic fluid either entering into the working piston chamber or escaping from the working piston chamber. Over time, this defect can cause deterioration of performance in the damper 900 and possibly failure of the damper 900 .
In some monotube dampers the rod guide 910 is made from aluminum (that can be anodized) while the tube 972 is made from steel (which can be galvanized). Thus, at the juncture between these two structures, galvanic corrosion can also occur, which can cause poor performance or failure of the damper sealing system. For example, galvanic corrosion between the rod guide and the piston rod or between rod guide and the damper tube can result in free play and relative movement between the parts, causing unwanted noise and further deterioration and loss of structural integrity for the damper 900 .
Thus, there has been a long felt need to improve the sealing system in monotube and other types of dampers, to avoid corrosion and deterioration of the seal system, to improve or broaden the tolerance requirements for the parts that make up dampers, and to improve the overall performance and manufacturability of dampers in general.
SUMMARY
The disclosed subject matter relates to a vehicle damper and a method of manufacturing a damper. The vehicle damper can be configured as a suspension damper, and alternatively can be configured as an air spring for the trunk or hood of a vehicle, etc.
In accordance with an aspect of the disclosed subject matter, a vehicle damper is disclosed that can include a damper tube having a first portion and a second portion located along a longitudinal axis of the damper tube. A piston can be located in the damper tube. A piston rod can be attached to the piston at the first portion of the damper tube and can extend from the first portion of the damper tube to the second portion of the damper tube along the longitudinal axis of the damper tube. A rod guide can be located adjacent the piston rod and the second portion of the damper tube and made from a hard material. A working volume can be located between the rod guide and piston and defined by the damper tube. An outer seal can be located between the rod guide and the damper tube and made from a relatively softer material than the rod guide. The outer seal can include an outer seal top surface that faces away from the working volume. The rod guide can include a rod guide top surface that faces away from the working volume. The damper tube can include a damper tube top surface that faces away from the working volume. The working volume can be located at a first longitudinal axis position with respect to a longitudinal axis direction, the rod guide top surface can be located at a second longitudinal axis position with respect to the longitudinal axis direction, the outer seal top surface can be located at a third longitudinal axis position with respect to the longitudinal axis direction, and the damper tube top surface can be located at a fourth longitudinal axis position with respect to the longitudinal axis direction. The second longitudinal axis position of the rod guide top surface can be spaced from the first longitudinal axis position of the working chamber at a second rod guide longitudinal axis distance, the third longitudinal axis position of the outer seal top surface can be spaced from the first longitudinal axis position of the working chamber at a third outer seal longitudinal axis distance, the fourth longitudinal axis position of the damper tube top surface can be spaced from the first longitudinal axis position of the working chamber at a fourth tube top longitudinal axis distance. The fourth tube top longitudinal axis distance can be less than or substantially equal to the second rod guide longitudinal axis distance.
In accordance with another aspect of the disclosed subject matter, the third outer seal longitudinal axis distance can be less than or substantially equal to the second rod guide longitudinal axis distance.
In accordance with yet another aspect of the disclosed subject matter, the rod guide top surface, the outer seal top surface, and the top surface of the tube can be configured to cause liquid to continuously move away from the rod guide and towards the damper tube when the damper is in use.
In accordance with still another aspect of the disclosed subject matter, the rod guide can be made from an aluminum type material and the damper tube is made from a steel type material.
In accordance with another aspect of the disclosed subject matter, the outer seal can include an overhang portion that extends beyond an inner surface of the damper tube in a direction substantially perpendicular to the longitudinal axis of the damper tube.
In accordance with an aspect of the disclosed subject matter, the outer seal top surface can be substantially flush with the rod guide top surface.
In accordance with still another aspect of the disclosed subject matter, the rod guide can be located at an upper portion of the damper and the piston can be located at a lower portion of the damper, and an imaginary line that extends perpendicular to the piston rod and is in contact with an uppermost portion of the rod guide top surface does not intersect the damper tube.
In accordance with another aspect of the disclosed subject matter, the rod guide can be located at an upper portion of the damper and the piston can be located at a lower portion of the damper, and an imaginary line that extends perpendicular to the piston rod and is in contact with an uppermost portion of the outer seal top surface does not intersect the damper tube.
In accordance with yet another aspect of the disclosed subject matter, the damper can be a monotube damper.
In accordance with an aspect of the disclosed subject matter, the damper can be configured as an active (e.g., magneto-rheological) damper or a traditional semi-active or non-active damper.
In accordance with another aspect of the disclosed subject matter, a vehicle damper can include a piston rod having a longitudinal axis extending between an upper portion of the piston rod and a lower portion of the piston rod, a piston attached to the lower portion of the piston rod, a rod guide located adjacent the upper portion of the piston rod and having a top surface located at an uppermost portion of the rod guide, the rod guide made from an aluminum type material, a damper tube located adjacent the piston rod and extending from the upper portion to the lower portion of the piston rod, the damper tube having a top surface at an uppermost portion of the damper tube, and the top surface of the damper tube located substantially co-planar with or lower than the rod guide top surface, an outer seal made of a material that is softer than the material of the rod guide, the outer seal located between the rod guide and the damper tube and including an outer seal top surface at an uppermost portion of the outer seal such that at least the rod guide top surface and the outer seal top surface form an uppermost surface of the damper.
In accordance with still another aspect of the disclosed subject matter, a portion of the uppermost surface of the damper that is furthest away from the piston rod is lower than a portion of the uppermost surface of the damper that is closest to the piston rod.
Still other features and characteristics of the disclosed subject matter will become apparent to those skilled in the art from a reading of the following detailed description of exemplary embodiments constructed in accordance therewith, and taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosed subject matter will become clear from the following description with reference to the accompanying drawings, wherein:
FIG. 1 is a cross-sectional view of an embodiment of a vehicle damper made in accordance with principles of the disclosed subject matter;
FIG. 2A is a cross sectional view of a conventional sealing system for a vehicle damper;
FIG. 2B is a cross sectional view of the sealing system of the vehicle damper shown in FIG. 1 ;
FIG. 3 is a cross sectional view of the conventional sealing system shown in FIG. 2A after deterioration;
FIG. 4 is a cross sectional view of another embodiment of a sealing system for a vehicle damper made in accordance with principles of the disclosed subject matter; and
FIG. 5 is a cross sectional view of another embodiment of a sealing system for a vehicle damper made in accordance with principles of the disclosed subject matter.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
The disclosed subject matter will now be described in more detail with reference to exemplary embodiments of the vehicle damper and method, given only by way of example, and with reference to the accompanying drawings.
The disclosed subject matter relates to a vehicle damper, and more particularly to a sealing system for a vehicle damper. In addition, the disclosed subject matter relates to sealing systems for monotube type vehicle dampers.
FIG. 1 shows a cross section of a vehicle damper 100 that includes a tube 172 that encases both a working piston 40 and a floating piston 50 . The working piston 40 is attached to a piston rod 41 by a lock mechanism 42 . The floating piston 50 is located in the tube 172 below the working piston 40 and separates the working chamber hydraulic fluid 302 from a gas 202 located below the floating piston 50 . A lower cap 174 b encloses the lower end of the tube 172 . A piston rod guide 10 encloses an upper portion of the tube 172 while allowing the piston rod 41 to slide therethrough.
An upper connector 176 a can be provided in an upper cap 174 a located at the upper portion of the tube 172 for connection to a vehicle frame (or vehicle suspension). Likewise, a lower connector 176 b can be provided in the lower cap 174 b located at the lower portion of the tube 172 for connection to a vehicle suspension (or vehicle frame).
The working chamber defined by the piston 40 floating piston 50 and damper tube 172 can be referred to as a working volume. Of course, if there is no floating piston 50 , the working volume can be defined by the piston 40 , damper tube 172 and a surface of the lower cap 174 b (or other structure that contains the hydraulic fluid 302 ). Both the piston rod 41 and damper tube 172 have a longitudinal axis that can be coincident with each other. Typically, the working volume is located lower along the longitudinal axis of either the piston rod 41 or the damper tube 172 than are the rod guide 10 , outer seal 20 or top surface 172 c of the damper tube 172 . The rod guide 10 can be locked to the damper tube 172 with respect to movement in the longitudinal axis direction by a clinch indent 178 in the tube 172 that mates with an indent 18 in a side of the piston rod guide 10 .
FIG. 2B shows a detailed cross sectional view of the seal system for the vehicle damper 100 shown in FIG. 1 . In particular, the rod guide 10 includes an upper outer annular rim 13 into which an upper outer seal 20 is fitted. The rod guide 10 can be made from various hard materials, including metals, ceramics, and even some plastics. For example, the rod guide 10 can be made from aluminium or steel. More specifically, the rod guide can be made from an aluminium type material that includes aluminium, aluminium alloys, anodized aluminium, and the like. Moreover, the aluminium type material can include surface treated aluminium, including aluminium that is anodized and then coated with Teflon or other protective coating.
The upper outer seal 20 can be made of a relatively softer more pliable material (as compared to the material of the rod guide 10 or the damper tube 172 ) for creating the seal between the rod guide 10 and the damper tube 172 . For example, the upper outer seal 20 can be made from rubber, plastic, soft metals, ceramics, etc., including silicon, polyurethane, and other plastics and rubbers. In particular, the outer seal 20 can be made from a low conductivity rubber when used in a magneto-rheological damper or any damper with an aluminum guide and a steel tube. The low conductivity rubber is used to reduce the possibility of galvanic corrosion between the steel and aluminum.
The damper tube 172 can be made from hard materials similar to those from which the rod guide is constructed. Specifically, the damper tube can be made from the aluminium type materials as described above or from steel type materials including steel, steel alloys, galvanized steel, different phase steel materials, and the like.
The outer seal 20 can be configured (in conjunction with the structural configuration of the rod guide 10 and damper tube 172 ) to allow water and other debris to roll off of the top surface 12 of the rod guide 10 . For example, the top surface 22 of the upper outer seal 20 can be located lower than the top surface 12 of the rod guide 10 . In addition, an overhang portion 21 can be provided on the outer seal 20 that lies atop an upper rim or upper surface 172 c of the damper tube 172 so that water and other debris cannot get in between the damper tube 172 and an outer side surface 24 of the outer seal 20 . In addition, the configuration of the outer seal 20 can be slanted or otherwise configured to direct water away from the top surface 12 of the rod guide 10 so that little or no standing water is present on the top surface 12 of the rod guide 10 . An indent can be provided on the inner surface 23 of the outer seal 20 that allows the seal 20 to easily lock with the upper outer annular rim 13 of the rod guide 10 .
A lower inner seal 30 can be locked into an inner lower annular indent 16 in the rod guide 10 by a lock ring 36 . The lower inner seal 30 is configured to seal the through hole 11 that exists in the space between the piston rod 41 and the rod guide 10 . The inner seal 30 can be made from a relatively soft material, such as polyurethane and other types of rubbers or plastics, etc.
The damper 100 shown in FIG. 2B can be a typical damper, but can also be configured as a magneto-rheological damper in which the hydraulic fluid 302 includes magnetic material such that the viscosity of the hydraulic fluid 302 can be changed by applying an electric field to the fluid 302 . For example, an electrical wire core can be provided within the piston rod 41 for producing an electrical field within the hydraulic fluid 302 to provide active control of the damping amount for the vehicle damper 100 .
FIG. 4 shows a cross-sectional view of another embodiment of a vehicle damper 100 with a seal system made in accordance with principles of the disclosed subject matter. In this embodiment, the outer seal 20 and rod guide 10 can be configured such that the outer seal 20 has a top surface 22 that is inclined from the top surface 12 of the rod guide 10 . The top surface 22 of the outer seal 20 can terminate at a position corresponding to the outer surface 172 a of the damper tube 172 . Thus, water and debris travel downwards over the top surface 22 of the outer seal 20 and over the periphery of the rim/top surface 172 c of the damper tube 172 . In this embodiment, the rod guide 10 extends slightly above the annular rim/top surface 172 c . The rod guide 10 can be provided with an extension knob 19 about the outer wall portion 14 that locks with an indent in the inner portion 23 of the outer seal 20 .
FIG. 5 shows a cross-sectional view of another embodiment of a vehicle damper 100 with seal system made in accordance with principles of the disclosed subject matter. In this embodiment, the rod guide 10 , outer seal 20 , and the damper tube 172 can be configured such that the respective top surfaces (i.e., tops surface 12 , top surface 22 , and top surface of annular rim 172 c ) are substantially co-planar.
While there has been described what are at present considered to be exemplary embodiments of the invention, it will be understood that various modifications may be made thereto. For example, the outer seal 20 can be configured to extend across the entire top surface 12 of the rod guide 10 as well as the annular rim 172 c of the tube 172 in order to seal the adjacent portions between the piston rod 41 , rod guide 10 , and tube 172 . In addition, the manner for attaching each of the structures to each other can vary greatly without departing from the spirit and scope of the disclosed subject matter. For example, the knob 19 located at the outer wall surface 14 of the rod guide 10 can instead be configured as an indent that mates with a corresponding knob located on the outer seal 20 . In addition, adhesives, lock rings, or other known attachment structures can be used to attach the upper outer seal 20 to the rod guide 10 and/or tube 172 .
The inner seal 30 is shown as located at a lowermost surface 15 of the rod guide 10 . However, other configurations of the inner seal 30 can be incorporated into a damper 100 of the disclosed subject matter. For example, the inner seal 30 can be provided in a central portion or at a top surface 12 of the rod guide 10 . If provided at the top surface 12 of the rod guide 10 , the inner seal 30 can be configured to drive water and debris away from the piston rod 41 and towards the outer portion of the damper tube 172 . For example, the inner seal 30 can have an upper surface that is inclined downwards and away from the piston rod 41 . Of course, other configurations of the upper surface of the inner seal 30 are contemplated and fall within the scope of the disclosed subject matter, even embodiments in which the inner seal 30 does not direct water or debris away from the piston rod 41 .
The specific configurations of each of the damper structures can also vary without departing from the spirit and scope of the disclosed subject matter. For example, while the tube 172 can have a symmetrical cross-section when viewed along its longitudinal axis, it can also be non-symmetrical. Specifically, the tube can be circular, oval, square, polygonal or other similar symmetrical shape when viewed in cross-section along its longitudinal axis, or it can be non-uniform and non-symmetrical when viewed in cross-section along its longitudinal axis. Thus, the corresponding shape of the piston, rod guide, outer seal and other portions can also be shaped to correspond to the symmetrical or non-symmetrical tube cross section.
In addition, it should be understood that the invention is not only applicable to active, in-active and/or semi-active suspension dampers in a vehicle, but could also be applied to use in dampers such as trunk or hood air springs and other pneumatic or hydraulic cylinder devices used in a vehicle.
While there has been described what are at present considered to be exemplary embodiments of the invention, it will be understood that various modifications may be made thereto, and it is intended that the appended claims cover such modifications as fall within the true spirit and scope of the invention. Any conventional art document referenced above is/are hereby incorporated by reference in its entirety. | A damper for use in vehicle and automotive applications can include a structure for sealing a top portion of the damper such that standing water is prevented from residing adjacent the cylinder/tube, piston rod, gaskets, o-rings, grommets, or other structures located at a top portion of the damper. The structure for sealing the top portion of the damper can include a seal that is located between a rod guide and the damper tube such that water and debris are kept from entering an inner portion of the damper mechanism. | 5 |
FIELD OF THE INVENTION
[0001] The present invention relates to the field of wired communication systems, and, more specifically, to the networking of devices using telephone lines.
BACKGROUND OF THE INVENTION
[0002] FIG. 1 shows the wiring configuration for a prior-art telephone system 10 for a residence or other building, wired with a telephone line 5 . Residence telephone line 5 consists of single wire pair which connects to a junction-box 16 , which in turn connects to a Public Switched Telephone Network (PSTN) 18 via a cable 17 , terminating in a public switch 19 , apparatus which establishes and enables telephony from one telephone to another. The term “analog telephony” herein denotes traditional analog low-frequency audio voice signals typically under 3 KHz, sometimes referred to as “POTS” (“plain old telephone service”), whereas the term “telephony” in general denotes any kind of telephone service, including digital service such as Integrated Services Digital Network (ISDN). The term “high-frequency” herein denotes any frequency substantially above such analog telephony audio frequencies, such as that used for data. ISDN typically uses frequencies not exceeding 100 Khz (typically the energy is concentrated around 40 Khz). The term “telephone line” herein denotes electrically-conducting lines which are intended primarily for the carrying and distribution of analog telephony, and includes, but is not limited to, such lines which may be pre-existing within a building and which may currently provide analog telephony service. The term “telephone device” herein denotes, without limitation, any apparatus for telephony (including both analog telephony and ISDN), as well as any device using telephony signals, such as fax, voice-modem, and so forth.
[0003] Junction box 16 is used to separate the in-home circuitry from the PSTN and is used as a test facility for troubleshooting as well as for wiring new telephone outlets in the home. A plurality of telephones 13 a , 13 b , and 13 c connects to telephone line 5 via a plurality of telephone outlets 11 a , 11 b , 11 c , and 11 d . Each telephone outlet has a connector (often referred to as a “jack”), denoted in FIG. 1 as 12 a , 12 b , 12 c , and 12 d , respectively. Each telephone outlet may be connected to a telephone via a connector (often referred to as a “plug”), denoted in FIG. 1 (for the three telephone illustrated) as 14 a , 14 b , and 14 c , respectively. It is also important to note that lines 5 a , 5 b , 5 c , 5 d , and 5 e are electrically the same paired conductors.
[0004] There is a requirement for using the existing telephone infrastructure for both telephone and data networking. In this way, the task of establishing a new local area network in a home or other building is simplified, because there would be no additional wires to install. U.S. Pat. No. 4,766,402 to Crane (hereinafter referred to as “Crane”) teaches a way to form LAN over two-wire telephone lines, but without the telephone service.
[0005] The concept of frequency domain/division multiplexing (FDM) is well-known in the art, and provides means of splitting the bandwidth carried by a wire into a low-frequency band capable of carrying an analog telephony signal and a high-frequency band capable of carrying data communication or other signals. Such a mechanism is described for example in U.S. Pat. No. 4,785,448 to Reichert et al. (hereinafter referred to as “Reichert”). Also is widely used are xDSL systems, primarily Asymmetric Digital Subscriber Loop (ADSL) systems.
[0006] Relevant prior art in this field is also disclosed in U.S. Pat. No. 5,896,443 to Dichter (hereinafter referred to as “Dichter”). Dichter is the first to suggest a method and apparatus for applying such a technique for residence telephone wiring, enabling simultaneously carrying telephone and data communication signals. The Dichter network is illustrated in FIG. 2 , which shows a network 20 serving both telephones and a local area network. Data Terminal Equipment (DTE) units 24 a , 24 b , and 24 c are connected to the local area network via Data Communication Equipment (DCE) units 23 a , 23 b , and 23 c , respectively. Examples of Data Communication Equipment include modems, line drivers, line receivers, and transceivers. DCE units 23 a , 23 b , and 23 c are respectively connected to high pass filters (HPF) 22 a , 22 b , and 22 c . The HPF's allow the DCE units access to the high-frequency band carried by telephone line 5 . In a first embodiment (not shown in FIG. 2 ), telephones 13 a , 13 b , and 13 c are directly connected to telephone line 5 via connectors 14 a , 14 b , and 14 c , respectively. However, in order to avoid interference to the data network caused by the telephones, a second embodiment is suggested (shown in FIG. 2 ), wherein low pass filters (LPF's) 21 a , 21 b , and 21 c are added to isolate telephones 13 a , 13 b , and 13 c from telephone line 5 . Furthermore, a low pass filter must also be connected to Junction-Box 16 , in order to filter noises induced from or to the PSTN wiring 17 . As is the case in FIG. 1 , it is important to note that lines 5 a , 5 b , 5 c , 5 d , and 5 e are electrically the same paired conductors.
[0007] However, the Dichter network suffers from degraded data communication performance, because of the following drawbacks:
[0008] 1. Induced noise in the band used by the data communication network is distributed throughout the network. The telephone line within a building serves as a long antenna, receiving electromagnetic noise produced from outside the building or by local equipment such as air-conditioning systems, appliances, and so forth. Electrical noise in the frequency band used by the data communication network can be induced in the extremities of telephone line 5 (line 5 c or 5 a in FIG. 2 ) and propagated via telephone line 5 throughout the whole system. This is liable to cause errors in the data transportation.
[0009] 2. The wiring media consists of a single long wire (telephone line 5 ). In order to ensure a proper impedance match to this transmission-line, it is necessary to install terminators at each end of telephone line 5 . One of the advantages of using the telephone infrastructure for a data network, however, is to avoid replacing the internal wiring. Thus, either such terminators must be installed at additional cost, or suffer the performance problems associated with an impedance mismatch.
[0010] 3. In the case where LPF 21 is not fitted to the telephones 13 , each connected telephone appears as a non-terminated stub, and this is liable to cause undesirable signal reflections.
[0011] 4. In one embodiment, LPF 21 is to be attached to each telephone 13 . In such a configuration, an additional modification to the telephone itself is required. This further makes the implementation of such system complex and costly, and defeats the purpose of using an existing telephone line and telephone sets ‘as is’ for a data network.
[0012] 5. The data communication network used in the Dichter network supports only the ‘bus’ type of data communication network, wherein all devices share the same physical media. Such topology suffers from a number of drawbacks, as described in U.S. Pat. No. 5,841,360 to the present inventor, which is incorporated by reference for all purposes as if filly set forth herein. Dichter also discloses drawbacks of the bus topology, including the need for bus mastering and logic to contend with the data packet collision problem. Topologies that are preferable to the bus topology include the Token-Ring (IEEE 803), the PSIC network according to U.S. Pat. No. 5,841,360, and other point-to-point networks known in the art (such as a serial point-to-point ‘daisy chain’ network). Such networks are in most cases superior to ‘bus’ topology systems.
[0013] The above drawbacks affect the data communication performance of the Dichter network, and therefore limit the total distance and the maximum data rate such a network can support. In addition, the Dichter network typically requires a complex and therefore costly transceiver to support the data communication system. While the Reichert network relies on a star topology and does not suffer from these drawbacks of the bus topology, the star topology also has disadvantages. First, the star topology requires a complex and costly hub module, whose capacity limits the capacity of the network. Furthermore, the star configuration requires that there exist wiring from every device on the network to a central location, where the hub module is situated. This may be impractical and/or expensive to achieve, especially in the case where the wiring of an existing telephone system is to be utilized. The Reichert network is intended for use only in offices where a central telephone connection point already exists. Moreover, the Reichert network requires a separate telephone line for each separate telephone device, and this, too, may be impractical and/or expensive to achieve.
[0014] Although the above-mentioned prior-art networks utilize existing in-home telephone lines and feature easy installation and use without any additions or modifications to the telephone line infrastructure (wires, outlets, etc.), they require dedicated, non-standard, and complex DCE's, modems, and filters, and cannot employ standard interfaces. For example, Ethernet (such as IEEE802.3) and other standards are commonly used for personal computers communication in Local Area network (LAN) environments. With prior-art techniques, in order to support communication between computers, each computer must be equipped with an additional modem for communicating over the telephone line. Whether these additional modems are integrated into the computer (e.g. as plug-in or built-in hardware) or are furnished as external units between the computer and the telephone line, additional equipment is required. The prior-art networks therefore incur additional cost, space, installation labor, electricity, and complexity. It would therefore be desirable to provide a network which contains integral therewith the necessary standard interfaces, thereby obviating the need to provide such interfaces in the DTE's.
[0015] There is thus a widely-recognized need for, and it would be highly advantageous to have, a means for implementing a data communication network using existing telephone lines of arbitrary topology, which continues to support analog telephony, while also allowing for improved communication characteristics by supporting a point-to-point topology network.
[0016] Furthermore, there is also a need for, and it would be highly advantageous to have, a means and method for implementing such an in-house data communication network using existing telephone lines, wherein the DTE's (e.g. computers, appliances) can be interconnected solely by using standard interfaces, without the need for modifications or adding external units to the DTE's.
SUMMARY OF THE INVENTION
[0017] It is therefore an object of the present invention to provide a method and apparatus for upgrading an existing telephone line wiring system within a residence or other building, to provide both analog telephony service and a local area data network featuring a serial “daisy chained” or other arbitrary topology.
[0018] To this end, the regular telephone outlets are first replaced with network outlets to allow splitting of the telephone line having two or more conductors into segments such that each segment connecting two network outlets is fully separated from all other segments. Each segment has two ends, to which various devices, other segments, and so forth, may be connected via the network outlets, and are such that the segments can concurrently transport telephony and data communications signals. A network outlet contains a low pass filter, which is connected in series to each end of the segment, thereby forming a low-frequency between the external ports of the low pass filters, utilizing the low-frequency band. Similarly, a network outlet contains a high pass filter, which is connected in series to each end of the segment, thereby forming a high-frequency path between the external ports of the high pass filters, utilizing the high-frequency band The bandwidth carried by the segments is thereby split into non-overlapping frequency bands, and the distinct paths can be inter-connected via the high pass filters and low pass filters as coupling and isolating devices to form different paths. Depending on how the devices and paths are selectively connected, these paths may be simultaneously different for different frequencies. A low-frequency band is allocated to regular telephone service (analog telephony), while a high-frequency band is allocated to the data communication network. In the low-frequency (analog telephony) band, the wiring composed of the coupled low-frequency paths appears as a normal telephone line, in such a way that the low-frequency (analog telephony) band is coupled among all the segments and is accessible to telephone devices at any network outlet, whereas the segments may remain individually isolated in the high-frequency (data) band, so that in this data band the communication media, if desired, can appear to be point-to-point (such as a serialized “daisy chain”) from one network outlet to the next. The term “low pass filter” herein denotes any device that passes signals in the low-frequency (analog telephony) band but blocks signals in the high-frequency (data) band. Conversely, the term “high pass filter” herein denotes any device that passes signals in the high-frequency (data) band but blocks signals in the low-frequency (analog telephony) band. The term “data device” herein denotes any apparatus that handles digital data, including without limitation modems, transceivers, Data Communication Equipment, and Data Terminal Equipment.
[0019] Each network outlet has a standard data interface connector which is coupled to data interface circuitry for establishing a data connection between one or more segments and a data device, such as Data Terminal Equipment, connected to the data interface connector.
[0020] A network according to the present invention allows the telephone devices to be connected as in a normal telephone installation (i.e., in parallel over the telephone lines), but can be configured to virtually any desired topology for data transport and distribution, as determined by the available existing telephone line wiring and without being constrained to any predetermined data network topology. Moreover, such a network offers the potential for the improved data transport and distribution performance of a point-to-point network topology, while still allowing a bus-type data network topology in all or part of the network if desired. This is in contrast to the prior art, which constrains the network topology to a predetermined type.
[0021] Data Terminal Equipment as well as telephone devices can be readily connected to the network outlets using standard interfaces and connectors, thereby allowing a data communications network as well as a telephone system to be easily configured, such that both the data communications network and the telephone system can operate simultaneously without interference between one another.
[0022] A network according to the present invention may be used advantageously when connected to external systems and networks, such as xDSL, ADSL, as well as the Internet.
[0023] In a first embodiment, the high pass filters are connected in such a way to create a virtual ‘bus’ topology for the high-frequency band, allowing for a local area network based on DCE units or transceivers connected to the segments via the high pass filters. In a second embodiment, each segment end is connected to a dedicated modem, hence offering a serial point-to-point daisy chain network. In all embodiments of the present invention, DTE units or other devices connected to the DCE units can communicate over the telephone line without interfering with, or being affected by, simultaneous analog telephony service. Unlike prior-art networks, the topology of a network according to the present invention is not constrained to a particular network topology determined in advance, but can be adapted to the configuration of an existing telephone line installation. Moreover, embodiments of the present invention that feature point-to-point data network topologies exhibit the superior performance characteristics that such topologies offer over the bus network topologies of the prior art, such as the Dichter network and the Crane network.
[0024] Therefore, according to a first aspect of the present invention there is provided a local area network within a building, for transporting data among a plurality of data devices, the local area network including:
[0025] (a) at least two network outlets, each of said network outlets having:
[0026] i) at least one data interface connector and data interface circuitry coupled to said data interface connector and operative to establishing a data connection between a data device and said data interface connector;
[0027] ii) at least one standard telephone connector operative to supporting standard telephony service by connecting a standard telephone device;
[0028] iii) a splitter operative to separating telephony and data communications signals; and
[0029] iv) a coupler operative to combining telephony and data communications signals;
[0030] (b) at least one telephone line segment within the walls of the building, each said telephone line segment connecting at least two of said network outlets and having at least two conductors, said telephone line segment operative to concurrently transporting telephony and data communication signals; and
[0031] (c) at least one modem housed within each of said network outlets for establishing a data connection over said at least one telephone line segment, said at least one modem operative to transmitting and receiving signals over said telephone line segment, and coupled thereto.
[0032] According to a second aspect of the invention there is provided a network outlet for configuring a local area network for the transport of data across telephone lines and for enabling telephony across the telephone lines simultaneous with the transport of data, the network outlet comprising:
[0033] (a) at least one data interface connector and data interface circuitry coupled to said at least one data interface connector and being jointly operative to establishing a data connection between a data device and said at least one data interface connector;
[0034] (b) at least one telephone connector operative to supporting standard telephony service by connecting a standard telephone device thereto;
[0035] (c) a splitter adapted to be coupled to the telephone lines and being operative to separating telephony and data communications signals transported over the telephone lines; and
[0036] (d) a coupler having an output adapted to be coupled to the telephone lines and being operative to combining telephony and data communications signals to be transported over the telephone lines.
[0037] According to a third aspect, the invention provides a method for upgrading an existing telephone system to operate both for telephony and as a local area network for transporting data among a plurality of data devices, the telephone system having a plurality of telephone outlets connected to at least one telephone line within the walls of a building, the method comprising the steps of:
[0038] (a) mechanically removing at least two of the telephone outlets from the walls of the building;
[0039] (b) electrically disconnecting said at least two telephone outlets from the at least one telephone line;
[0040] (c) providing at least two network outlets, each of said network outlets having a data interface connector and data interface circuitry coupled to said data interface connector and operative to establishing a data connection between a data device and said data interface connector;
[0041] (d) electrically connecting said network outlets to the at least one telephone line; and
[0042] (e) mechanically securing said network outlets to the wall.
BRIEF DESCRIPTION OF THE DRAWINGS
[0043] The invention is herein described, by way of non-limiting example only, with reference to the accompanying drawings, wherein:
[0044] FIG. 1 shows a common prior art telephone line wiring configuration for a residence or other building.
[0045] FIG. 2 shows a prior art local area network based on telephone line wiring for a residence or other building.
[0046] FIG. 3 shows modifications to telephone line wiring according to the present invention for a local area network.
[0047] FIG. 4 shows modifications to telephone line wiring according to the present invention, to support regular telephone service operation.
[0048] FIG. 5 shows a splitter according to the present invention.
[0049] FIG. 6 shows a local area network based on telephone lines according to the present invention, wherein the network supports two devices at adjacent network outlets.
[0050] FIG. 7 shows a first embodiment of a local area network based on telephone lines according to the present invention, wherein the network supports two devices at non-adjacent network outlets.
[0051] FIG. 8 shows a second embodiment of a local area network based on telephone lines according to the present invention, wherein the network supports three devices at adjacent network outlets.
[0052] FIG. 9 shows third embodiment of a local area network based on telephone lines according to the present invention, wherein the network is a bus type network.
[0053] FIG. 10 shows a node of local area network based on telephone lines according to the present invention.
[0054] FIG. 11A shows a fourth embodiment of a local area network based on telephone lines according to the present invention.
[0055] FIG. 11B shows an embodiment of the present invention for use with telephone wiring that is not separated into distinct segments.
[0056] FIG. 12 is a flowchart illustrating the sequence of steps in an installation method according to the present invention for upgrading an existing telephone system.
[0057] FIG. 13 illustrates the components of a basic kit according to the present invention for upgrading a telephone system to a local area data network.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0058] The principles and operation of a network according to the present invention may be understood with reference to the drawings and the accompanying description. The drawings and descriptions are conceptual only. In actual practice, a single component can implement one or more functions; alternatively, each function can be implemented by a plurality of components and circuits. In the drawings and descriptions, identical reference numerals indicate those components which are common to different embodiments or configurations.
[0059] The basic concept of the invention is shown in FIG. 3 . A network 30 is based on network outlets 31 a , 31 b , 31 c , and 31 d . The installation of a network supporting both telephony and data communications relates to the installation of such network outlets. Similarly, the upgrade of an existing telephone system relates to replacing the existing telephone outlets with network outlets. In the descriptions which follow, an upgrade of an existing telephone system is assumed, but the procedures can also be applied in a like manner for an initial installation that supports both telephony and data communications.
[0060] A network outlet is physically similar in size, shape, and overall appearance to a standard telephone outlet, so that a network outlet can be substituted for a standard telephone outlet in the building wall. No changes are required in the overall telephone line layout or configuration. The wiring is changed by separating the wires at each network outlet into distinct segments of electrically-conducting media. Thus, each segment connecting two network outlets can be individually accessed from either end. In the prior art Dichter network, the telephone wiring is not changed, and is continuously conductive from junction box 16 throughout the system. According to the present invention, the telephone line is broken into electrically distinct isolated segments 15 a , 15 b , 15 c , 15 d , and 15 e , each of which connects two network outlets. In order to fully access the media, each of connectors 32 a , 32 b , 32 c , and 32 d must support four connections, two in each segment. This modification to the telephone line can be carried out by replacing each of the telephone outlets 31 a , 31 b , 31 c , and 31 d . As will be explained later, the substitutions need be performed only at those places where it is desirable to be able to connect to data network devices. A minimum of two telephone outlets must be replaced with network outlets, enabling data communication between those network outlets only.
[0061] FIG. 4 shows how a network 40 of the present invention continues to support regular telephone service, by the installation of jumpers 41 a , 41 b , 41 c , and 41 d in network outlets 31 a , 31 b , 31 c and 31 d respectively. At each network outlet where they are installed, the jumpers connect both segment ends and allow telephone connection to the combined segment. Installation of a jumper effects a re-connection of the split telephone line at the point of installation. Installation of jumpers at all network outlets would reconstruct the prior art telephone line configuration as shown in FIG. 1 . Such jumpers can be add-ons to the network outlets, integrated within the network outlets, or integrated into a separate module. Alternately, a jumper can be integrated within a telephone set, as part of connector 14 . The term “jumper” herein denotes any device for selectively coupling or isolating the distinct segments in a way that is not specific to the frequency band of the coupled or isolated signals. Jumper 41 can be implemented with a simple electrical connection between the connection points of connector 32 and the external connection of the telephone.
[0062] As described above, jumpers 41 are to be installed in all network outlets which are not required for connection to the data communication network. Those network outlets which are required to support data communication connections, however, will not use jumper 41 but rather a splitter 50 , shown in FIG. 5 . Such a splitter connects to both segments in each network outlet 31 via connector 32 , using a port 54 for a first connection and a port 55 for a second connection. Splitter 50 has two LPF's for maintaining the continuity of the audio/telephone low-frequency band. After low pass filtering by LPF 51 a for the port 54 and LPF 51 b for port 55 , the analog telephony signals are connected together and connected to a telephone connector 53 , which may be a standard telephone connector. Hence, from the telephone signal point of view, the splitter 50 provides the same continuity and telephone access provided by the jumper 41 . On the other hand, the data communication network employs the high-frequency band, access to which is made via HPF's 52 a and 52 b . HPF 52 a is connected to port 54 and HPF 52 b is connected to port 55 . The high pass filtered signals are not passed from port 54 to port 55 , but are kept separate, and are routed to a data interface connector 56 and a data interface connector 57 , respectively, which may be standard data connectors. The term “splitter” herein denotes any device for selectively coupling or isolating the distinct segments that is specific to the frequency band of the coupled or isolated signals. The term “coupler” is used herein in reference to any device used for combining separate signals into a combined signal encompassing the originally-separate signals, including a device such as a splitter used for signal coupling.
[0063] Therefore, when installed in a network outlet, splitter 50 serves two functions. With respect to the low-frequency analog telephony band, splitter 50 establishes a coupling to effect the prior-art configuration shown in FIG. 1 , wherein all telephone devices in the premises are connected virtually in parallel via the telephone line, as if the telephone line were not broken into segments. On the other hand, with respect to the high-frequency data communication network, splitter 50 establishes electrical isolation to effect the configuration shown in FIG. 3 , wherein the segments are separated, and access to each segment end is provided by the network outlets. With the use of splitters, the telephone system and the data communication network are actually decoupled, with each supporting a different topology.
[0064] FIG. 6 shows a first embodiment of a data communication network 60 between two DTE units 24 a and 24 b , connected to adjacent network outlets 31 b and 31 c , which are connected together via a single segment 15 c . Splitters 50 a and 50 b are connected to network outlets 31 b and 31 c via connectors 32 b and 32 c , respectively. As explained above, the splitters allow transparent audio/telephone signal connection. Thus, for analog telephony, the telephone line remains virtually unchanged, allowing access to telephone external connection 17 via junction box 16 for telephones 13 a and 13 c . Likewise, telephone 13 b connected via connector 14 b to a connector 53 a on splitter 50 a , is also connected to the telephone line. In a similar way, an additional telephone can be added to network outlet 31 c by connecting the telephone to connector 53 b on splitter 50 b . It should be clear that connecting a telephone to a network outlet, either via jumper 41 or via splitter 50 does not affect the data communication network.
[0065] Network 60 ( FIG. 6 ) supports data communication by providing a communication path between port 57 a of splitter 50 a and port 56 b of splitter 50 b . Between those ports there exists a point-to-point connection for the high-frequency portion of the signal spectrum, as determined by HPF 52 a and 52 b within splitters 50 ( FIG. 5 ). This path can be used to establish a communication link between DTE units 24 a and 24 b , by means of DCE units 23 a and 23 b , which are respectively connected to ports 57 a and 56 b . The communication between DTE units 24 a and 24 b can be unidirectional, half-duplex, or full-duplex. The only limitation imposed on the communication system is the capability to use the high-frequency portion of the spectrum of segment 15 c . As an example, the implementation of data transmission over a telephone line point-to-point system described in Reichert can also be used in network 60 . Reichert implements both LPF and HPF by means of a transformer with a capacitor connected in the center-tap, as is well-known in the art. Similarly, splitter 50 can be easily implemented by two such circuits, one for each side.
[0066] It should also be apparent that HPF 52 a in splitter 50 a and IPF 52 b in splitter 50 b can be omitted, because neither port 56 a in splitter 50 a nor port 57 b in splitter 50 b is connected.
[0067] Network 60 provides clear advantages over the networks described in the prior art. First, the communication media supports point-to-point connections, which are known to be superior to multi-tap (bus) connections for communication performance. In addition, terminators can be used within each splitter or DCE unit, providing a superior match to the transmission line characteristics. Furthermore, no taps (drops) exists in the media, thereby avoiding impedance matching problems and the reflections that result therefrom.
[0068] Moreover, the data communication system in network 60 is isolated from noises from both the network and the ‘left’ part of the telephone network (Segments 15 a and 15 b ), as well as noises induced from the ‘right’ portion of the network (Segments 15 d and 15 e ). Such isolation is not provided in any prior-art implementation. Dichter suggests installation of a low pass filter in the junction box, which is not a satisfactory solution since the junction box is usually owned by the telephone service provider and cannot always be accessed. Furthermore, safety issues such as isolation, lightning protection, power-cross and other issues are involved in such a modification.
[0069] Implementing splitter 50 by passive components only, such as two transformers and two center-tap capacitors, is also advantageous, since the reliability of the telephone service will not be degraded, even in the case of failure in any DCE unit, and furthermore requires no external power. This accommodates a ‘life-line’ function, which provides for continuous telephone service even in the event of other system malfunction (e.g. electrical failures).
[0070] The splitter 50 can be integrated into network outlet 31 . In such a case, network outlets equipped with splitter 50 will have two types of connectors: One regular telephone connector based on port 53 , and one or two connectors providing access to ports 56 and 57 (a single quadruple-circuit connector or two double-circuit connectors). Alternatively, splitter 50 can be an independent module attached as an add-on to network outlet 31 . In another embodiment, the splitter is included as part of DCE 23 . However, in order for network 60 to operate properly, either jumper 41 or splitter 50 must be employed in network outlet 31 as modified in order to split connector 32 according to the present invention, allowing the retaining of regular telephone service.
[0071] FIG. 7 also shows data communication between two DTE units 24 a and 24 b in a network 70 . However, in the case of network 70 , DTE units 24 a and 24 b are located at network outlets 31 b and 31 d , which are not directly connected, but have an additional network outlet 31 c interposed between. Network outlet 31 c is connected to network outlet 31 b via a segment 15 c , and to network outlet 31 d via a segment 15 d.
[0072] In one embodiment of network 70 , a jumper (not shown, but similar to jumper 41 in FIG. 4 ) is connected to a connector 32 c in network outlet 31 c . The previous discussion regarding the splitting of the signal spectrum also applies here, and allows for data transport between DTE units 24 a and 24 b via the high-frequency portion of the spectrum across segments 15 c and 15 d . When only jumper 41 is connected at network outlet 31 c , the same point-to-point performance as previously discussed can be expected; the only influence on communication performance is from the addition of segment 15 d , which extends the length of the media and hence leads to increased signal attenuation. Some degradation, however, can also be expected when a telephone is connected to jumper 41 at network outlet 31 c . Such degradation can be the result of noise produced by the telephone in the high-frequency data communication band, as well as the result the addition of a tap caused by the telephone connection, which usually has a non-matched termination. Those problems can be overcome by installing a low pass filter in the telephone.
[0073] In a preferred embodiment of network 70 , a splitter 50 b is installed in network outlet 31 c . Splitter 50 b provides the LPF functionality, and allows for connecting a telephone via connector 53 b . However, in order to allow for continuity in data communication, there must be a connection between the circuits in connectors 56 b and 57 b . Such a connection is obtained by a jumper 71 , as shown in FIG. 7 . Installation of splitter 50 b and jumper 71 provides good communication performance, similar to network 60 ( FIG. 6 ). From this discussion of a system wherein there is only one unused network outlet between the network outlets to which the DTE units are connected, it should be clear that the any number of unused network outlets between the network outlets to which the DTE units are connected can be handled in the same manner.
[0074] For the purpose of the foregoing discussions, only two communicating DTE units have been described. However, the present invention can be easily applied to any number of DTE units. FIG. 8 illustrates a network 80 supporting three DTE 20 units 24 a , 24 b , and 24 c , connected thereto via DCE units 23 a , 23 b , and 23 c , respectively. The structure of network 80 is the same as that of network 70 ( FIG. 7 ), with the exception of the substitution of jumper 71 with a jumper 81 . Jumper 81 makes a connection between ports 56 b and 57 b in the same way as does jumper 71 . However, in a manner similar to that of jumper 41 ( FIG. 4 ), jumper 81 further allows for an external connection to the joined circuits, allowing the connection of external unit, such as a DCE unit 23 c . In this way, segments 15 c and 15 d appear electrically-connected for high-frequency signals, and constitute media for a data communication network connecting DTE units 24 a , 24 b , and 24 c . Obviously, this configuration can be adapted to any number of network outlets and DTE units. In fact, any data communication network which supports a ‘bus’ or multi-point connection over two-conductor media, and which also makes use of the higher-frequency part of the spectrum can be used. In addition, the discussion and techniques explained in the Dichter patent are equally applicable here. Some networks, such as Ethernet IEEE 802.3 interface 10BaseT and 100BaseTX, require a four-conductor connection, two conductors (usually single twisted-wire pair) for transmitting, and two conductors (usually another twisted-wire pair) for receiving. As is known in the art, a four-to-two wires converter (commonly known as hybrid) can be used to convert the four wires required into two, thereby allowing network data transport over telephone lines according to the present invention. A network according to the present invention can therefore be an Ethernet network.
[0075] As with jumper 41 ( FIG. 4 ), jumper 81 can be an integral part of splitter 50 , an integral part of DCE 23 , or a separate component.
[0076] In order to simplify the installation and operation of a network, it is beneficial to use the same equipment in all parts of the network. One such embodiment supporting this approach is shown in for a set of three similar network outlets in FIG. 8 , illustrating network 80 . In network 80 , network outlets 31 b , 31 c , and 31 d are similar and are all used as part of the data communication network. Therefore for uniformity, these network outlets are all coupled to splitters 50 a , 50 b , and 50 c respectively, to which jumpers are attached, such as a jumper 81 attached to splitter 50 b (the corresponding jumpers attached to splitter 50 a and splitter 50 c have been omitted from FIG. 8 for clarity), and thus provide connections to local DCE units 23 a , 23 c , and 23 b , respectively. In a preferred embodiment of the present invention, all telephone outlets in the building will be replaced by network outlets which include both splitter 50 and jumper 81 functionalities. Each such network outlet will provide two connectors: one connector coupled to port 53 for a telephone connection, and the other connector coupled to jumper 81 for a DCE connection.
[0077] The terms “standard connector”, “standard telephone connector”, and “standard data connector” are used herein to denote any connectors which are industry-standard or de facto standard connectors. Likewise, the term “standard telephone device” is used herein to denote any telephone device which is a commercial standard or de facto standard telephone device, and the term “standard telephony service” is used herein to denote any commercially-standard or de facto standard telephony.
[0078] In yet another embodiment, DCE 23 and splitter 50 are integrated into the housing of network outlet 31 , thereby offering a direct DTE connection. In a preferred embodiment, a standard DTE interface is employed.
[0079] In most ‘bus’ type networks, it is occasionally required to split the network into sections, and connect the sections via repeaters (to compensate for long cabling), via bridges (to decouple each section from the others), or via routers. This may also be according to the present invention, as illustrated in FIG. 9 for a network 90 , which employs a repeater/bridge/router unit 91 . Unit 91 can perform repeating, bridging, routing, or any other function associated with a split between two or more networks. As illustrated, a splitter 50 b is coupled to a network outlet 31 c , in a manner similar to the other network outlets and splitters of network 90 . However, at splitter 50 b , no jumper is employed. Instead, a repeater/bridge/router unit 91 is connected between port 56 b and port 57 b , thereby providing a connection between separate parts of network 90 . Optionally, unit 91 can also provide an interface to DTE 24 c for access to network 90 .
[0080] As illustrated above, a network outlet can also function as a repeater by the inclusion of the appropriate data interface circuitry. Circuitry implementing modems, and splitters, such as the high pass filters as well as the low pass filters, can function as data interface circuitry.
[0081] FIG. 9 also demonstrates the capability of connecting to external DTE units or networks, via a high pass filter 92 connected to a line 15 a . Alternatively, HPF 92 can be installed in junction box 16 . HPF 92 allows for additional external units to access network 90 . As shown in FIG. 9 , HPF 92 is coupled to a DCE unit 93 , which in turn is connected to a network 94 . In this configuration, the local data communication network in the building becomes part of network 94 . In one embodiment, network 94 offers ADSL service, thereby allowing the DTE units 24 d , 24 a , 24 c , and 24 b within the building to communicate with the ADSL network. The capability of communicating with external DTE units or networks is equally applicable to all other embodiments of the present invention, but for clarity is omitted from the other drawings.
[0082] While the foregoing relates to data communication networks employing bus topology, the present invention can also support networks where the physical layer is distinct within each communication link. Such a network can be a Token-Passing or Token-Ring network according to IEEE 802, or preferably a PSIC network as described in U.S. Pat. No. 5,841,360 to the present inventor, which details the advantages of such a topology. FIG. 10 illustrates a node 100 for implementing such a network. Node 100 employs two modems 103 a and 103 b , which handle the communication physical layer. Modems 103 a and 103 b are independent, and couple to dedicated communication links 104 a and 104 b , respectively. Node 100 also features a DTE interface 101 for connecting to a DTE unit (not shown). A control and logic unit 102 manages the higher OSI layers of the data communication above the physical layer, processing the data to and from a connected DTE and handling the network control. Detailed discussion about such node 100 and the functioning thereof can be found in U.S. Pat. No. 5,841,360 and other sources known in the art.
[0083] FIG. 11 describes a network 110 containing nodes 100 d , 100 a , 100 b , and 100 c coupled directly to splitters 50 d , 50 a , 50 b and 50 c , which in turn are coupled to network outlets 31 a , 31 b , 31 c , and 31 d respectively. Each node 100 has access to the corresponding splitter 50 via two pairs of contacts, one of which is to connector 56 and the other of which is to connector 57 . In his way, for example, node 100 a has independent access to both segment 15 b and segment 15 c . This arrangement allows building a network connecting DTE units 24 d , 24 a , 24 b , and 24 c via nodes 100 d , 100 a , 100 b , and 100 c , respectively.
[0084] For clarity, telephones are omitted from FIGS. 9 and 11 , but it should be clear that telephones can be connected or removed without affecting the data communication network. Telephones can be connected as required via connectors 53 of splitters 50 . In general, according to the present invention, a telephone can be connected without any modifications either to a splitter 50 (as in FIG. 8 ) or to a jumper 41 (as in FIG. 4 ).
[0085] The present invention has been so far described in embodiments in which the telephone wiring segments are split, and which therefore modify the original galvanic continuity of the telephone wiring, as shown in FIG. 3 . Such embodiments require the removal of outlets in order to access the internal wiring. However, the present invention can be applied equally-well to prior-art schemes such as the Dichter network (as illustrated in FIG. 2 ), wherein the continuity of the telephone wiring is not disturbed, and there the wiring is not split into electrically distinct segments.
[0086] Thus, an embodiment of a network utilizing the network outlets of the present invention is shown in FIG. 11B as a network 112 . Generally, the Dichter network of FIG. 2 is employed. However, network outlets 11 a and 11 b (corresponding to network outlets 11 a and 11 d of FIG. 2 ) are modified so that all components are housed therein. In such a case, the splitter/combiner is a single low pass filter 21 and a single high pass filter 22 . High pass filter 22 is coupled to single telephone-line modem/DCE 23 . A single high pass filter, a single low pass filter, and a single DCE are used, since the connection to the telephone line involves a single, point of connection. However, since point-to-point topology is not used in this case, modem 23 is expected to be more complex than in the other described embodiments. Each outlet 111 has standard telephone connector 14 for connecting the telephone set, and standard data connector 113 for the DTE connection. For example, a 10BaseT interface employing an RJ-45 connector can be used for the DTE connection.
[0087] Furthermore, although the present invention has so far been described with a single DTE connected to a single network outlet, multiple DTE units can be connected to a network outlet, as long as the corresponding node or DCE supports the requisite number of connections. Moreover, access to the communication media can be available for plurality of users using multiplexing techniques known in the art. In the case of time domain/division multiplexing (TDM) the whole bandwidth is dedicated to a specific user during a given time interval. In the case of frequency domain/division multiplexing (FDM), a number of users can share the media simultaneously, each using different non-overlapping portions of the frequency spectrum.
[0088] In addition to the described data communication purposes, a network according to the present invention can be used for control (e.g. home automation), sensing, audio, or video applications, and the communication can also utilize analog signals (herein denoted by the term “analog communication”). For example, a video signal can be transmitted in analog form via the network.
[0089] While the present invention has been described in terms of network outlets which have only two connections and therefore can connect only to two other network outlets (i.e., in a serial, or “daisy chain” configuration), the concept can also be extended to three or more connections. In such a case, each additional connecting telephone line must be broken at the network outlet, with connections made to the conductors thereof, in the same manner as has been described and illustrated for two segments. A splitter for such a multi-segment application should use one low pass filter and one high pass filter for each segment connection.
[0090] The present invention has also been described in terms of media having a single pair of wires, but can also be applied for more conductors. For example, ISDN employs two pairs for communication. Each pair can be used individually for a data communication network as described above.
[0091] Also as explained above, a network outlet 31 according to the invention ( FIG. 3 ) has a connector 32 having at least four connection points. As an option, jumper 41 ( FIG. 4 ), splitter 50 ( FIG. 5 ), or splitter 50 with jumper 81 ( FIG. 8 ), low pass filters, high pass filters, or other additional hardware may also be integrated or housed internally within network outlet 31 . Moreover, the network outlet may contain standard connectors for devices, such as DTE units. In one embodiment, only passive components are included within the network outlet. For example, splitter 50 can have two transformers and two capacitors (or an alternative implementation consisting of passive components). In another embodiment, the network outlet may contain active, power-consuming components. Three options can be used for providing power to such circuits:
[0092] 1. Local powering: In this option, supply power is fed locally to each power-consuming network outlet. Such network outlets must be able to support connection for input power.
[0093] 2. Telephone power: In both POTS and ISDN telephone networks, power is carried in the lines with the telephone signals. This power can also be used for powering the network outlet circuits, as long as the total power consumption does not exceed the POTS/ISDN system specifications. Furthermore, in some POTS systems the power consumption is used for OFF-HOOK/ON-HOOK signaling. In such a case, the network power consumption must not interfere with the telephone logic.
[0094] 3. Dedicated power carried in the media: In this option, power for the data communication related components is carried in the communication media.
[0095] For example, power can be distributed using 5 kHz signal. This frequency is beyond the telephone signal bandwidth, and thus does not interfere with the telephone service. The data communication bandwidth, however, be above this 5 kHz frequency, again ensuring that there is no interference between power and signals.
[0096] Upgrading existing telephone lines within a building can be done by the method illustrated in the flowchart of FIG. 12 . At least two telephone outlets must be replaced by network outlets in order to support data communications. For each outlet to be replaced, the steps of FIG. 12 are performed as shown. In a step 122 , the existing telephone outlet is mechanically removed from the wall. Next, in a step 124 , the existing telephone outlet is electrically disconnected from the telephone line. At this point in a step 126 , the existing telephone line is split or formed into two isolated segments. Depending on the existing configuration of the telephone line, this could be done by cutting the telephone line into two segments, by separating two telephone lines which had previously been joined at the existing telephone outlet, or by utilizing an unused wire pair of the existing telephone line as a second segment. Then, in a step 128 , the two segments are electrically connected to a new network outlet, in a manner previously illustrated in FIG. 5 , where one of the segments is connected to connector 54 and the other segment is connected to connector 55 . Note that separating the telephone line into two segments is not necessary in all cases. If only two network outlets are desired, the telephone line does not have to be split, because a single segment suffices to connect the two network outlets. If more than two network outlets are desired, however, the telephone line must be split or formed into more than one segment. Finally, in a step 130 ( FIG. 12 ), the network outlet is mechanically replaced and secured into the wall in place of the original telephone outlet.
[0097] While the above description describes the non-limiting case where two wire segments are connected to the outlet (such as outlets 11 a , 11 b , 11 c and 11 d ), in general it is also possible to connect a single segment or more than two segments to the outlet.
[0098] In order to facilitate the upgrade of existing telephone systems for simultaneous telephony and data communications, the network outlets as described previously can be packaged in kit form with instructions for performing the method described above. As illustrated in FIG. 13 , a basic kit contains two network outlets 132 and 134 with instructions 136 , while supplementary kits need contain only a single network outlet 132 . A network outlet 132 houses two standard data connectors 138 and 140 , and a standard telephone connector 142 , corresponding to connectors 57 , 56 , and 53 , respectively, of FIG. 5 . In addition, network outlet 132 has connectors 144 for electrically connecting to the segment of the telephone line. Connectors 144 correspond to connector 55 of FIG. 5 (connector 54 of FIG. 5 is omitted from FIG. 13 for clarity). Furthermore, network outlet 132 has flanges, such as a flange 146 , for mechanically securing to a standard in-wall junction box. A homeowner could purchase a basic kit according to the present invention to upgrade an existing telephone system to a local area network, and then purchase whatever supplementary kits would be needed to expand the local area network to any degree desired.
[0099] While the invention has been described with respect to a limited number of embodiments, it will be appreciated that many variations, modifications and other applications of the invention may be made. | An outlet for coupling at least one data unit to digital data carried over wiring that simultaneously carry a packet-based serial digital data signal and a power signal over the same conductors. The outlet includes: a wiring connector for connecting to the wiring; a transceiver coupled to the wiring connector for transmitting and receiving packet-based serial digital data over the wiring; a LAN connector coupled to the transceiver for bi-directional packet-based data communication with at least one data unit; a bridge or a router coupled between the transceiver and the LAN connector for passing data bi-directionally between the at least one data unit and the wiring; and a single enclosure housing the above-mentioned components. The enclosure is mountable into a standard wall outlet receptacle or wall outlet opening, and the transceiver and the bridge or router are coupled to the wiring connector to be powered from the power signal. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Nos. 61/576,306, filed on Dec. 15, 2011 and 61/720,844, filed on Oct. 31, 2012. The entire disclosures of the applications referenced above are incorporated herein by reference.
FIELD
[0002] The present disclosure relates to radio frequency (RF) transmitters, and more particularly to RF power detection circuit for RF transmitters.
BACKGROUND
[0003] The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent the work is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
[0004] Some radio frequency (RF) transmitters require accurate control of transmitted output power. For example, many RF transmitters need to comply with FCC regulations and wireless standards. Control of output power can be accomplished using an open loop or closed loop control system. In open loop control systems, the RF transmitter relies on accurate gain steps within the transmitter. In closed loop control systems, output power is measured and gain is adjusted accordingly.
[0005] An RF power detection circuit is an integral part of any RF transmitter closed-loop power-control system. The RF power detection circuit measures absolute transmitted power. This measurement is preferably independent of variation in temperature, device characteristics due to process spread, and load/antenna impedance.
[0006] Some RF power detection circuits assume a resistance value of an output load such as an antenna, measure output voltage and calculate output power based the output voltage squared divided by the resistance value. However, the resistance value of the load such as the antenna may vary during operation. For example, the resistance value of the antenna may be affected when the antenna is near or comes in contact with other objects. As can be appreciated, the RF power calculation will be adversely affected due to the difference between the actual resistance value of the antenna and the assumed resistance value.
SUMMARY
[0007] A circuit includes a multiplier circuit including a mixer configured to multiply a first differential input signal and a second differential input signal. The mixer includes a plurality of transistors including control terminals. The control terminals of the plurality of transistors receive a bias signal and the first differential input signal. A bias circuit is configured to generate the bias signal. The bias signal generated by the bias circuit is based on a voltage threshold of one of the plurality of transistors and a product of constant reference current and a bias resistance.
[0008] In other features, the mixer includes a Gilbert cell mixer. The bias circuit is configured to generate the bias signal such that a conversion gain of the mixer is substantially constant regardless of variations in process and temperature. The bias circuit includes a current source configured to generate the constant reference current, a bias resistance having the bias resistance and including one end in communication with the first current source, and a first transistor including a first terminal and a control terminal in communication with one end of the bias resistance. The bias signal is generated at a node between the bias resistance and the current source.
[0009] A method of operating a circuit includes, using a mixer, multiplying a first differential input signal and a second differential input signal, wherein the mixer comprises a plurality of transistors including control terminals. The control terminals of the plurality of transistors receive a bias signal and the first differential input signal. The method further includes generating the bias signal based on a voltage threshold of one of the plurality of transistors and a product of constant reference current and a bias resistance.
[0010] In other features, the mixer includes a Gilbert cell mixer. Generating the bias signal includes generating the bias signal such that a conversion gain of the mixer is substantially constant regardless of variations in process and temperature. The bias signal is generated at a node between a bias resistance and a current source.
[0011] Further areas of applicability of the present disclosure will become apparent from the detailed description, the claims and the drawings. The detailed description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the disclosure.
BRIEF DESCRIPTION OF DRAWINGS
[0012] FIG. 1 is a functional block diagram and electrical schematic of an example of an RF power detection circuit according to the prior art;
[0013] FIG. 2 is a functional block diagram and electrical schematic of an example of a multiplier circuit;
[0014] FIG. 3 is a functional block diagram and electrical schematic of an example of a bias circuit according to the present disclosure;
[0015] FIG. 4 is a functional block diagram and electrical schematic of an example of a multiplier circuit including a bias circuit according to the present disclosure;
[0016] FIG. 5 is a functional block diagram and electrical schematic of another example of a multiplier circuit including a bias circuit according to the present disclosure; and
[0017] FIG. 6 is a functional block diagram and electrical schematic of another example of a multiplier circuit including a bias circuit according to the present disclosure.
DESCRIPTION
[0018] Referring now to FIG. 1 , part of an output circuit 10 of a prior art transmitter is shown. The output circuit 10 includes a power amplifier (PA) 20 that receives a radio frequency (RF) signal to be amplified and transmitted. The PA 20 outputs an amplified RF signal to a primary side of a transformer 24 . One end of a secondary side of the transformer 24 is connected to an antenna 26 , which may be arranged on a printed circuit board (PCB). Another end of the secondary side of the transformer 24 is connected to a reference potential such as ground. In this example, the antenna is the load, which has a load impedance.
[0019] The output circuit 10 also includes an RF detection circuit 32 that detects an output power level of the PA 20 . The RF detection circuit 32 includes an amplifier 40 that receives and amplifies inputs to the PA 20 and outputs an amplified signal to first inputs of a multiplier circuit 42 . A voltage divider 44 is connected to outputs of the PA 20 (or to nodes 45 A and 45 B on the secondary side of the transformer 24 ) and outputs signals to second inputs of the multiplier circuit 42 . Outputs of the multiplier circuit 42 are connected to inputs of an amplifier 46 , which has first and second feedback resistances R FB connected to respective inputs and outputs of the amplifier 46 . The amplifier 46 outputs a power detect voltage signal V PD , which is based on detected output power.
[0020] The transmitted RF power is measured by multiplying the output voltage and current of the PA 20 . The result is independent of load/antenna impedance (R) or voltage standing wave ratio (VSWR). The output voltage of the PA 20 is sensed through the voltage divider 44 (k v *VPA). The output current of the PA 20 is replicated by using a scaled down replica PA (k I *I PA ).
[0021] In FIG. 2 , an example of the prior art multiplier circuit 42 is shown. The multiplier circuit 42 includes a mixer 50 , such as a Gilbert cell mixer, including transistors M 1 , M 2 , M 3 , and M 4 . First terminals of transistors M 1 and M 2 receive current I p . First terminals of transistors M 3 and M 4 receive current I n . Control terminals of transistors M 2 and M 3 receive a first bias signal V B and the sensed output voltage V PA (or V B −½V PA ). Control terminals of transistors M 1 and M 4 receive the bias signal V B and the sensed output voltage V PA (or V B +½ V PA ). A second terminal of transistor M 3 is connected to a second terminal of transistor M 1 . A second terminal of transistor M 2 is connected to a second terminal of transistor M 4 .
[0022] The multiplier circuit 42 has a conversion gain G c . The mixer 50 performs V*I multiplication. Transistors M 1 thru M 4 are biased in the linear region. Current I p divides into two parts, I p1 and I p2 . The ratio depends on the admittances of transistors M 1 and M 2 (gds 1 and gds 2 ). Similarly, current I n is also divided into two parts, I n1 and I n2 , depending on gds 3 and gds 4 . While a virtual GND termination is assumed for ease of derivation, it is not necessary.
[0000]
I
p
1
=
g
ds
1
g
ds
1
+
g
ds
2
·
I
p
=
(
V
B
+
1
2
V
PA
-
V
T
)
2
(
V
B
-
V
T
)
·
I
p
I
out
=
I
op
-
I
on
=
V
PA
·
(
I
p
-
I
n
)
2
·
(
V
B
-
V
T
)
[0023] From FIG. 1 , the output (voltage) of the power detection circuit is equal to:
[0000] V PD =k V ·k I ·G c ·( V PA ·I PA )· R FB
[0000] From FIG. 2 , the multiplier conversion gain G c is:
[0000]
G
c
=
1
2
(
V
B
-
V
T
)
[0000] Therefore the output of the power detection circuit is equal to:
[0000]
V
PD
=
k
V
·
k
I
·
(
V
PA
·
I
PA
)
·
R
FB
2
·
(
V
B
-
V
T
)
[0024] The value of the on-chip resistance R FB depends on temperature and process variation (manufacturing). MOS threshold voltage V T also depends on temperature and process variation (manufacturing). k v and k I (PA voltage and current division ratio) can be accomplished using a ratioed Gilbert cell, which is independent of temperature, process and load impedance.
[0025] According to the present disclosure, (V B −V T ) is set equal to I ref *R bias . Resistors R FB and R bias can be implemented as scaled versions of each other, e.g. R FB =A*R bias . The ratio of resistances A remains constant and independent of process and temperature variation, therefore the output of the power detector is:
[0000]
V
PD
=
k
V
·
k
I
·
(
V
PA
·
I
PA
)
·
R
FB
2
·
I
ref
·
R
bias
=
1
I
ref
·
R
FB
R
bias
·
k
V
·
k
I
2
·
(
V
PA
·
I
PA
)
[0026] The constant reference current I ref does not depend on process or temperature. The constant reference current I ref is usually already available on-chip. The constant reference current I ref can be generated by using a combination of a bandgap voltage and an external high-precision resistance.
[0027] Referring now to FIG. 3 , a bias circuit 100 for generating a bias voltage V B =V T +I ref *R bias is shown. The bias circuit 100 includes a current source I ref that is connected to one end of a bias resistance R bias . Another end of the resistance R bias is connected to a first terminal and a control terminal of a transistor M 5 . A second terminal of the transistor M 5 is connected to a reference potential such as ground. Assuming:
[0000] V gs5 =V T +V I ;
[0000] If V dsat5 <<V T ;
[0000] Then V gs5 ≈V T
[0028] This can be done by biasing the transistor M 5 with a very low current density. The transistor M 5 is preferably a scaled version of transistors M 1 -M 4 for best matching.
[0029] Referring now to FIGS. 4 and 5 , an example of the multiplier circuit 200 according to the present disclosure is shown. In FIG. 4 , the multiplier circuit 200 includes a mixer 206 , such as a Gilbert cell, with transistors M 1 , M 2 , M 3 , and M 4 . The sampled voltage V PA is connected to first terminals of capacitances C 1 and C 2 . Second terminals of the capacitances C 1 and C 2 are connected to control terminals of transistors M 1 , M 2 , M 3 , and M 4 and to first terminals of resistances R 1 and R 2 . Second terminals of the resistances R 1 and R 2 provide a bias voltage V B to the bias circuit 100 . First terminals of first and second transistors M 1 and M 2 and third and fourth transistors M 3 and M 4 are connected to I PA . A second terminal of transistor M 3 is connected to a second terminal of transistor M 1 . A second terminal of transistor M 2 is connected to a second terminal of transistor M 4 .
[0030] An amplifier 220 has a non-inverting input connected to the second terminals of the transistors M 1 and M 3 and to one end of a first feedback resistance R FB . The amplifier 220 has an inverting input connected to the second terminals of the transistors M 2 and M 4 and to one end of a second feedback resistance R FB . An inverting output of the amplifier 220 is connected to another end of the first feedback resistance R FB and to a first inverting input of an amplifier 230 . A non-inverting output of the amplifier 220 is connected to another end of the second feedback resistance R FB and to a second inverting input of the amplifier 230 . In FIG. 5 , a common mode input of the amplifier 230 is connected to a second terminal of the transistor M 5 and one end of a common mode feedback resistance R CMFB .
[0031] Transistors M 1 -M 4 are biased with a constant voltage (V gs −V T ). The circuit accommodates a non-zero common-mode input voltage level. I ref *R CMFB sets the common-mode voltage reference. A common-mode feedback amplifier sets V + =V − =V CMREF . Therefore, transistors M 1 -M 4 are still biased with (V gs −V T )=I ref *R bias .
[0032] While the preceding discussion involved a power detector using a passive mixer, the present disclosure can also use an active mixer as well. The active mixer transistors may be biased with a constant overdrive voltage=I ref *R. As can be appreciated, while the foregoing description relates to RF detection circuits, the multiplier circuit can be used in other systems. Additionally, the input does not have to correspond to voltage and current delivered to a load.
[0033] PA load impedance is unknown and can vary with the environment Z L =|Z|·e −jφ ). Knowing the value of load impedance is useful because PA output matching can be optimized to allow the PA to operate most efficiently. PA load impedance can be measured if we have the following two measurements:
[0000]
P
o
=V
PA
*I
PA
[0000]
V
sq
=V
PA
*V
PA
=V
PA
*I
PA
*|Z|*e
−jφ
[0034] |Z| and φ can be solved using these two measurements. The voltage V sq can be generated in multiple ways, one of which is shown in FIG. 6 .
[0035] Referring now to FIG. 6 , the voltage V PA is input to a transconductance amplifier 260 , which receives V PA . The transconductance amplifier 260 transforms a voltage input to a current output. The transconductance amplifier 260 generates an output current G m V PA , which is input to the first terminals of the transistors M 1 and M 2 and transistors M 3 and M 4 instead of I PA as in FIGS. 4 and 5 .
[0036] The foregoing description is merely illustrative in nature and is in no way intended to limit the disclosure, its application, or uses. The broad teachings of the disclosure can be implemented in a variety of forms. Therefore, while this disclosure includes particular examples, the true scope of the disclosure should not be so limited since other modifications will become apparent upon a study of the drawings, the specification, and the following claims. For purposes of clarity, the same reference numbers will be used in the drawings to identify similar elements. As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A or B or C), using a non-exclusive logical OR. It should be understood that one or more steps within a method may be executed in different order (or concurrently) without altering the principles of the present disclosure. | A circuit includes a multiplier circuit including a mixer configured to multiply a first differential input signal and a second differential input signal. The mixer includes a plurality of transistors including control terminals. The control terminals of the plurality of transistors receive a bias signal and the first differential input signal. A bias circuit is configured to generate the bias signal. The bias signal generated by the bias circuit is based on a voltage threshold of one of the plurality of transistors and a product of constant reference current and a bias resistance. | 6 |
The present invention relates to applicators for attaching electrical terminals to conductors and more particularly to such applicators having an open ram and a device for holding the open ram captive to the applicator.
BACKGROUND OF THE INVENTION
Applicators for attaching terminals to electrical conductors are generally received in a larger press or power unit that provides the power and physical motion to actuate the applicator and effect the crimping operation. These applicators include a ram that is guided within an opening in a ram housing and arranged to undergo reciprocating motion along a ram axis. The ram housing is an integral part of a frame and includes a base portion having a crimping anvil attached thereto that mates with upper crimping tooling mounted to the ram. The ram housing and frame are typically cast as a single integral part. A terminal feed mechanism operated by the reciprocating ram is attached to the frame so that it can engage a strip of terminals being fed from a reel and feed them into the crimping station of the applicator in timed relation to movement of the ram. Examples of such an applicator are disclosed in U.S. Pat. Nos. 3,184,950 which issued May 25, 1965 to Sitz and 5,483,739 which issued Jan. 16, 1996 to Smith et al. Both of these patents disclose applicators having closed ram structures wherein the ram housings completely encircle their respective rams when viewed along the ram's axis. That is, each ram housing has a rectangular opening formed by four walls and the ram has four outer walls in sliding engagement with the four walls of the opening. The upper crimping tooling is mounted to one of the outer walls of the ram but necessarily leaving a portion of the outer wall exposed on either side for engagement with the respective wall of the opening. A corresponding groove is formed in the opening wall opposite the tooling to provide clearance. There are several known disadvantages of this closed ram structure such as difficulty in changing the upper crimping tooling and difficulty is accessing the ram for attachment of actuating mechanisms for operating the terminal feed unit or other features such as an insulation stripper. To alleviate these problems, an applicator structure has been developed that leaves several outer surfaces of the ram exposed for more ready access. See, for example, U.S. Pat. No. 5,774,977 , which discloses an applicator having an open ram structure. Since these open rams are very accessible, they are occasionally grasped when manually handling the applicator. Typically, these rams are not held captive to the applicator thereby increasing the likelihood that the applicator will be dropped when it is manually moved by grasping the ram.
What is needed is an applicator with an open ram structure having a device for retaining the ram captive to the applicator frame, yet is easily accessible by the operator for disabling so that the ram can be removed when desired.
SUMMARY OF THE INVENTION
An applicator having an open ram is provided for attaching terminals to electrical conductors. The applicator includes a frame, a tool mounting surface attached to the frame and adapted to receive lower termination tooling, an open ram coupled to the frame and arranged for reciprocating movement along a ram axis in a first direction toward the mounting surface and in a second opposite direction. The ram is adapted to receive upper terminating tooling for mating with the lower terminating tooling for effecting the attaching of the terminals. A first slide portion is attached to the frame and a second slide portion is attached to the ram, wherein the first and second slide portions are mated in sliding engagement for guiding the ram along the ram axis. Retention means is provided for limiting the movement of the ram in the second direction to a predetermined limit so that the ram is held captive to the frame. The retention means includes a shoulder attached to the frame and a projection extending from the ram arranged to interferingly engage the shoulder when the ram reaches the predetermined limit.
DESCRIPTION OF THE FIGURES
FIG. 1 is a front view of a terminal applicator incorporating the teachings of the present invention;
FIG. 2 is a side view of the terminal applicator shown in FIG. 1;
FIG. 3 is an isometric view of the applicator frame shown in FIG. 1;
FIG. 4 is a cross-sectional view taken along the lines 4--4 in FIG. 1; and
FIG. 5 is a cross-sectional view taken along the lines 5--5 in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
There is shown in FIGS. 1 and 2 a terminal applicator 10 having a frame 12, including a base 14, and a ram 16 arranged to undergo reciprocating motion in a first direction toward the base and in a second opposite direction. A terminal feed unit 18 is coupled to the frame and driven by the reciprocating ram to feed a strip of terminals, not shown, along a feed track 20, shown in phantom lines in FIG. 2, to lower crimping tooling 22 that is secured to the base 14 in the usual manner. Upper crimping tooling 24 is attached to and carried by the ram 16, the upper tooling being located between a pair of opposing walls 26 extending from an outer surface 28 of the ram 16. The upper tooling 24 is held in position against the surface 28 by means of a button head screw 30 in the usual manner. The ram 16 has a T-shaped opening 32 for slidingly receiving a similarly shaped way 34 that is attached to or formed integral with the frame 12, as best seen in FIG. 4. The opening 32 and way 34 form mating slide portions. One side of the opening 32 is formed by a gib 36 that is secured to the ram 16 by means of screws 38. The opening 32 and way 34 are sized so that the ram is free to slide along a ram axis 40 without appreciable lateral play. With this arrangement, most of the outer facing surfaces 28, 42, 44, and 46, when viewed axially as shown in FIG. 4, are unconfined and easily accessible for mounting support devices such as a cam 48, shown in FIGS. 1 and 2, for driving the feed unit 18 or other power takeoff devices to drive other attachments, such as a wire stripping unit, not shown. Since the ram 16 is an open ram, that is it is relatively unconfined by the mating slide portion coupling it to the frame 12, it is easily accessible for grasping when manually lifting the applicator 10 in its normal day to day use.
To prevent inadvertent separation of the ram from the frame, in these cases, a ram retention rod 50, which is a screw in the present example, is threaded into a threaded hole 52 formed in the ram 16 so that the hole intersects both the T-shaped opening 32 and one of the outer surfaces of the ram, preferably an outer surface that forms an angle to the surface 28, such as the outer surface 42. Note that the outer surface 42 is formed at about a 90 degree angle to the outer surface 28, against which the upper crimping tooling is secured. This provides easy access to the head 54 of the retaining screw 50 by an operator for removal or installation of the ram, as desired. The end of the screw 50 extends into an elongated opening 58 formed in a face 60 of the way 34. The elongated opening 58 has encircling walls 66 and a longitudinal axis 62 that is substantially parallel to the ram axis 40. The upper end of the encircling walls 66 forms a shoulder 64, as best seen in FIGS. 3 and 5. As the ram 16 reciprocates through its normal stroke of operation starting from its full up position, shown in FIG. 1, to its full down position, not shown, where the upper and lower tooling 24 and 22 are in mated crimping engagement, the rod 56 traverses along the longitudinal axis 62 within the elongated opening 58. In the event that the ram is moved in the second direction upwardly, as viewed in FIG. 1, past its full up position, the rod 56 engages and abuts against the shoulder 64 thereby preventing further upward movement of the ram. This effectively prevents inadvertent separation of the ram 16 from the frame 12. In the event that it is desired to separate the ram from the frame, the screw 50 is simply rotated counterclockwise until the rod 56 is clear of the shoulder 64 of the elongated opening 58. The ram 16 is then free to move upwardly and out of engagement with the way 34.
The ram retention screw 50 and shoulder 64 may take other forms in that the shoulder may be formed in an inner surface of the T-shaped opening 32 of the ram and the retention screw 50 may be threaded into a hole formed in the way 34. Additionally, the shoulder may be simply a projection that is not part of an elongated opening.
An important advantage of the present invention is that the applicator has the benefits of an open ram structure while retaining the ram captive to the applicator frame. Further the retaining device is easily accessible by the operator for disabling so that the ram can be removed when desired. | An applicator (10) for crimping electrical terminals onto conductors is provided with a ram (16) having outer facing surfaces (28, 42, 44, 46) that are unobstructed by the slide (32, 34) coupling the ram to the applicator frame (12). A ram retention device is provided that includes a retention screw (50) extending through the ram (16) and into the slide coupling for engagement with a shoulder (64) to limit movement of the ram (16) and to hold it captive to the frame (12). | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to rupturable pressure relief devices, and more particularly, to rupture disk assemblies which resist momentary pressure surges.
2. Description of the Prior Art
A variety of rupturable pressure relief devices have been developed and used heretofore. Commonly, such devices include a rupture member or disk which is of a particular strength whereby it ruptures when a predetermined fluid pressure is exerted thereon. The rupture disk is most often clamped between a pair of annular supporting members positioned in a pressure relief passageway or conduit connected to a vessel or system being protected from overpressure by the rupture disk.
While rupture disk assemblies comprised of a single rupture disk supported between supporting members are commonly utilized in particular applications, composite rupture disk assemblies comprised of two or more rupturable parts supported between supporting members are also commonly used. An example of a particular type of composite rupture disk assembly is comprised of a perforated rupture member formed of metal or other rigid material with a resilient sealing member positioned adjacent thereto. Other parts such as protection members for the resilient sealing member and additional perforated rupture members are often also included in the composite rupture disk assembly. A composite rupture disk assembly can include means for clamping the various parts together, and the entire assembly is adapted to be clamped between a pair of annular supporting members such as pipe flanges or the like.
The prior art rupture disk assemblies including single rupture disks or composite rupture disks have been highly commercially successful in a variety of overpressure protection applications. However, in applications where the vessel or system being protected is subject to momentary surges in pressure which exceed the predetermined rupture pressure of the rupture disk, less than desirable results often result. For example, when a pressurized liquid, such as liquefied petroleum gas, is transported in a tank truck or tank car, a sudden tank movement or stop causes the pressurized liquid to move within the tank which in turn causes a momentary surge in pressure within the tank. When a heretofore utilized rupture disk assembly is subjected to such a pressure surge and the surge causes a momentarily overpressure condition to be exerted thereon, the rupture disk assembly ruptures even though pressure relief from the vessel or system being protected is not required.
Thus, there is a need for a rupture disk assembly which will resist rupture when an overpressure condition is momentarily caused by a momentary pressure surge within a vessel or system being protected, but when an overpressure condition is reached slowly, the rupture disk assembly ruptures and provides needed pressure relief.
SUMMARY OF THE INVENTION
The present invention provides pressure surge resistant rupture disk assemblies and methods which meet the above described need and overcome the shortcomings of the prior art. A pressure surge resistant rupture disk assembly of the invention is adapted to be sealingly clamped in a pressurized fluid containing passageway which is in turn connected to a vessel or system containing pressurized fluid. The rupture disk assembly is basically comprised of a first rupture member having a predetermined rupture pressure, and a second rupture member having a predetermined rupture pressure which is preferably substantially equal to or lower than the rupture pressure of the first rupture member and having at least one opening therein for allowing a restricted pressurized fluid flow therethrough. The assembly is positioned with the second rupture member facing the pressurized fluid. When a momentary pressure surge which causes a momentary overpressure condition is exerted on the rupture disk assembly, the assembly does not rupture because the overpressure is exerted on both the first and second rupture members simultaneously as a result of the restriction in pressurized fluid flow through the second rupture member and the rupture pressure of the assembly is increased accordingly.
Methods of providing overpressure relief to a vessel or system containing pressurized fluid when the pressure of the fluid slowly rises to an overpressure condition but not providing relief when an overpressure condition is momentarily reached as a result of a surge in pressure are also provided.
It is, therefore, a general object of the present invention to provide momentary pressure surge resistant rupture disk assemblies and methods.
Other and further objects, features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of preferred embodiments which follows when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side cross-sectional view of a rupture disk assembly of the present invention clamped between a pair of annular supporting members.
FIG. 2 is a top view of the rupture disk assembly shown in FIG. 1.
FIG. 3 is a bottom view of the rupture disk assembly of FIG. 1.
FIG. 4 is an exploded perspective view showing the various parts of the rupture disk assembly of FIG. 1.
FIG. 5 is a side cross-sectional view similar to FIG. 1 but showing the rupture disk assembly after rupture has taken place.
FIG. 6 is a side cross-sectional view of an alternate form of rupture disk assembly of the present invention clamped between annular supporting members.
FIG. 7 is a top view of the rupture disk assembly of FIG. 6.
FIG. 8 is a bottom view of the rupture disk assembly of FIG. 6.
FIG. 9 is a side cross-sectional view of another alternate form of rupture disk assembly of this invention.
FIG. 10 is a side cross-sectional view of yet another alternate form of rupture disk assembly of the present invention.
FIG. 11 is a side cross-sectional view of still another alternate form of rupture disk assembly of the present invention.
FIG. 12 is a side cross-sectional view of a further alternate form of the rupture disk assembly of the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings and particularly to FIGS. 1-5, one form of the composite rupture disk assembly of the present invention is illustrated and generally designated by the numeral 10. The assembly 10 is illustrated sealingly clamped between a pair of annular support members in the form of inlet and outlet pipe flanges 12 and 14. Inlet flange 12 is sealingly connected to a conduit 16 which is in turn connected to a vessel or system containing pressurized fluid. Outlet flange 14 is connected to a conduit 18 which leads pressurized fluid relieved by the rupture disk assembly 10 to a location of containment or disposal.
The assembly 10 is comprised of an annular positioning member 20, a first rupture member 22, a resilient sealing member 24, a second rupture member 26, a first flow restricting member 28, a second flow restricting member 30 and a support member 32. A conventional gasket 34 is positioned between the rupture disk assembly 10 and the inlet flange 12 to insure a seal therebetween. The inlet and outlet flanges 12 and 14 are clamped together with the rupture disk assembly 10 and gasket 34 therebetween by a plurality of studs 36 and nuts 38.
As best shown in FIG. 4, the positioning member 20 is formed of a rigid material and includes a central upstanding portion 40 connected to an annular flat flange portion 42. The use of the positioning member 20 in the assembly 10 is optional, but when it is included it functions to position the assembly in the annular supporting members between which it is clamped, e.g., the flanges 12 and 14, and to protect the rupture member 22 from damage during handling and installation.
In the form illustrated, the first rupture member 22 is a substantially circular section of flat rigid material. A plurality of elongated slits 44 are formed in the rupture member 22 which extend radially outwardly from a solid central portion 25 towards the periphery of the member 22. The slits 44 are equally spaced around the member 22 and terminate interiorally of the periphery whereby an annular flat solid flange portion 46 remains in the rupture member 22 and the slits 44 define a plurality of sector shaped portions 48 in the rupture member 22. For ease of manufacturing and to avoid sharp projections, apertures 50 may be provided at each of the ends of the slits 44. However, the apertures 50 are optional and may be omitted. Also, slots may optionally be utilized instead of the slits 44.
Positioned adjacent the first rupture member 22 on the opposite side thereof from the positioning member 20 is a resilient sealing member 24. The sealing member 24 is generally formed of a resilient corrosion resistant plastic material and is of a peripheral size and shape corresponding with the peripheral size and shape of the first rupture member 22.
Positioned adjacent the resilient sealing member 24 on the opposite side thereof from the first rupture member 22 is a second rupture member 26 formed of flat rigid material. In the form shown, the second rupture member 26 is identical to the first rupture member 22 in that it includes a plurality of slits 52 which radiate outwardly from a solid central portion 54 and define an annular flat solid flange portion 55 and a plurality of sector shaped portions 56 in the second rupture member 26. Apertures 57 are provided at the ends of the slits 52. While the predetermined rupture pressures of the first and second rupture members can be different with either one being greater than the other, the second rupture member 26 preferably has a predetermined rupture pressure which is substantially equal to or less than the predetermined rupture pressure of the first rupture member 22.
The first flow restricting member 28 is positioned adjacent the second rupture member 26 on the side thereof opposite from the sealing member 24. In the form illustrated, the first flow restricting member is formed of a resilient plastic material such as that forming the sealing member 24 and a pair of intersecting slits 58 and 60 are disposed in the member 28 at the center thereof.
The second flow restricting member 30 is also formed of resilient plastic material and is positioned adjacent the first flow restricting member 28 on the side thereof opposite from the second rupture member 26. The member 30 include a plurality of radial slits 62 formed therein near the periphery of the member 30. The slits 62 are equally spaced around the member 30.
The support member 32 is a flat circular member formed of rigid material having a diameter greater than the diameters of the members 20, 22, 24, 26, 28 and 30. A peripheral portion of the support member 32 is folded upwardly to form an annular lip 64. Upon assembly of the various parts of the assembly 10, the lip portion 64 is folded over the outer peripheral edges of the members 20, 22, 24, 26, 28 and 30 as illustrated in FIG. 1 whereby the members are rigidly held together. The central flat circular portion of the support member 32 includes a plurality of slots 66 which radiate outwardly for a solid central portion 68 and terminate near the periphery of the member 32. The slots 66 define a plurality of sector shaped portions 69 in the member 32 which are positioned to coincide with the sector shaped portions 48 and 56 defined in the first and second rupture members 22 and 26, respectively. Also, the slits 62 in the second flow restricting member 30 are aligned with the slots 66 in the support member 32.
As mentioned above, the inclusion of the positioning member 20 is optional. Also, the support member 32 can take a variety of forms other than the form illustrated and the various members in the assembly 10 can be clamped or held together in a variety of ways different from that described above. The flanges 12 and 14 include raised face portions which coact with the annular flange portions of the assembly 10. When the positioning member 20 is included, the upstanding portion 40 thereof extends within the annular supporting member 14 to thereby position the assembly 10 within the annular supporting members 12 and 14 during installation.
In operation of the assembly 10, fluid pressure from the vessel or system being protected is exerted on the resilient sealing member 24 of the assembly 10 by way of the conduit 16, the inlet flange 12, the slots 66 of the support member 32, the slits 62 of the second flow restricting member 30, the slits 58 and 60 of the first flow restricting member 28 and the slits 52 and apertures 57 of the second rupture member 26. When the fluid pressure reaches the resilient sealing member 24, the sealing member deforms into contact with the first rupture member 22. If a reverse pressure differential is temporarily exerted on the assembly 10 due to the exertion of pressure by way of the conduit 18 which is greater than the pressure exerted on the assembly 10 by way of the conduit 16, the reverse pressure is communicated to the sealing member 24 by way of the slits 44 and apertures 50 in the first rupture member 22 and the sealing member 24 deforms into contact with the second rupture member 26. In such reverse pressure situations, the support member 32 supports the second rupture member 26 as well as the first and second flow restricting members 28 and 30 and prevents the reverse rupture of the assembly 10.
As indicated, the fluid pressure exerted on the assembly 10 from the pressure vessel or system being protected is exerted on the first rupture member 22 by the sealing member 24. As a result, the first rupture member 22 is placed in tension and when the fluid pressure relatively slowly increases to an overpressure condition and reaches the rupture pressure of the first rupture member 22 whereby the tensile strength of a solid portion of the rupture member 22 between two of the apertures 50 at the inner ends of the slits 44 is exceeded, the rupture member 22 ruptures by first tearing between the two apertures 50 and then tearing between the remaining apertures except for the two which are the farthest apart. Because of manufacturing variances in the lengths of the solid portions between the apertures 50 at the inner ends of the slits 44, all of the solid portions tear except the one having the greatest length and the central portion 25 of the rupture member 22 remains attached to one of the sector shaped portions 48 as shown in FIG. 5. When the rupture member 22 ruptures, the resilient sealing member 24 also ruptures causing pressure to be relieved through the assembly 10. The force of the pressure release, i.e., the flow of pressurized fluid through the assembly 10, causes the second rupture member 26 to rupture, the first and second flow restricting members 28 and 30 to rupture and the support member 32 to rupture, all as shown in FIG. 5. As in the case of the first rupture member 22, the central portion 54 of the second rupture member 26 and the central portion 68 of the support member 32 remain attached. As illustrated in FIG. 5, after rupture and initial pressure release, the composite rupture disk assembly 10 is fully opened with the sector shaped portions 48 of the first rupture member 22, the sector shaped portions 56 of the second rupture member 26 and the sector shaped portions formed by the slots 66 of the support member 32 bent upwardly providing full pressure relief to the pressure vessel or system being protected. Upon rupture, the resilient sealing member 24 and the resilient first and second flow restricting members 28 and 30 also rupture in sector shaped portions substantially similar to the sector shaped portions of the first and second rupture members 22 and 26 and support member 32.
In order to eliminate the trial and error techniques required in manufacturing the first and second rupture members 22 and 26 whereby they have desired predetermined rupture pressures, scores can be formed in the rupture members between two of the apertures at the inner ends of the slits thereof to control the rupture pressure as described in U.S. Pat. No. 4,905,722 issued on Mar. 6, 1990 to Rooker et al. which is incorporated herein by reference.
As will be understood by those skilled in the art, the assembly 10 can also include protection members formed of resilient material positioned between the first rupture member 22 and the sealing member 24 and between the sealing member 24 and the second rupture member 26. Such protection members prevent sharp edges formed in the rupture members 22 and 26 by the slits and apertures therein from abrading and damaging the sealing member 24 during handling and installation and in operation. The use of and examples of such protective members are disclosed in U.S. Pat. No. 2,953,279 issued on Sep. 30, 1960 to Coffman, which is incorporated herein by reference.
The assembly 10 will rupture in the manner described above when the pressure of the pressurized fluid exerted on the assembly 10 rises relatively slowly to an overpressure condition, i.e., a pressure equal to or slightly greater than the predetermined rupture pressure of the first rupture member 22. That is, the pressure increase from a level below the predetermined rupture pressure of the rupture member 22 to a level equal to or slightly greater than such predetermined rupture pressure must be slow enough that the pressure increase is communicated to and independently exerted on the sealing member 24 and first rupture member 22. The pressure increase is communicated to the sealing member 24 and first rupture member 22 by the flow of pressurized fluid through the torturous path provided by the second rupture member 26, the first and second flow restricting members 28 and 30 and the support member 32.
When a momentary pressure surge is experienced in the vessel or system being protected whereby the pressure communicated to the composite rupture disk assembly 10 momentarily exceeds the predetermined rupture pressure of the first rupture member 22 thereof, the flow of pressurized fluid through the assembly 10 is restricted and the overpressure condition will be substantially simultaneously exerted on both the first and second rupture members 22 and 26 whereby the assembly 10 will not rupture. The term "momentary pressure surge" is used herein to mean a surge in pressure to a level above the predetermined rupture pressure of the first rupture member 22 which lasts for a time period less than the time required for the resulting flow of pressurized fluid to reach and independently exert the full pressure increase on the first rupture member 22. The rupture disk assembly 10 does not rupture during such a momentary pressure surge because of the torturous path that the flow of pressurized fluid caused by the pressure surge must follow. That is, because the flow of pressurized fluid to the sealing member 24 is restricted by the relatively small openings in the second rupture member 26, the first and second flow restricting members 28 and 30 and the support member 32, the pressure required to rupture the assembly 10 is greater than that required to rupture the first rupture member 22. During a momentary pressure surge, the rupture pressure of the assembly 10 is approximately doubled because the pressure is communicated to both rupture members substantially simultaneously.
Referring now to FIGS. 6-8, an alternate embodiment of the composite rupture disk assembly of the present invention is illustrated and generally designated by the numeral 70. The assembly 70 is shown in FIG. 6 clamped between inlet and outlet annular supporting members 72 and 74, respectively. The inlet supporting member 72 is connected to a conduit 76 which is in turn connected to the vessel or system being protected, and the outlet supporting member 74 is connected to an outlet conduit 78. In the form shown in FIG. 6, the annular supporting members 72 and 74 are pipe flanges which are clamped together with the composite rupture disk assembly 70 in between by a plurality of studs 80 and nuts 82.
Like the assembly 10 described above, the composite rupture disk assembly 70 includes an annular positioning member 84, a first perforated rupture member 86, a resilient sealing member 88 and a second rupture member 90. However, instead of a pair of flow resisting members and support member, the assembly 70 includes a single flow restricting member 92. The flow restricting member 92 is formed of rigid material and includes a central dome portion 94 and a flat annular flange portion 96. The diameter of the flow restricting member 92 can be greater than the diameters of the other members of the assembly 70 whereby a portion 98 can be folded over the peripheral edges of the other members to clamp the assembly together. The dome portion 94 of the flow restricting member 92 is centrally positioned and has a convex side facing the pressurized fluid and a concave side facing the second rupture member 90.
The first rupture member 86 is identical to the first rupture member 22 of the assembly 10 described above in that it includes a plurality of slits 100 formed therein radiating outwardly from a solid central portion 104 thereof and defining a plurality of sector shaped portions 106 therein. Apertures 102 can optionally be formed in the member 86 at the ends of the slits 100 as shown.
The resilient sealing member 88 of the assembly 70 is identical to the sealing member 24 of the assembly 10 described above, and the second rupture member 90 is identical to the second rupture member 26 of the assembly 10 described above. The second rupture member 90 includes a plurality of slits 108 therein radiating outwardly from a solid central portion 110 and defining a plurality of sector shaped portions therein. Apertures 112 are disposed in the member 90 at the ends of the slits 108.
The flow restricting member 92 includes a centrally positioned opening 114 which is shown in FIG. 8 in the form of a small slot. In addition, the member 92 includes a pair of arcuate slits 118 formed therein which define a hinged circular blow-out area therein. That is, the area 118 between two adjacent ends of the arcuate slits define a hinge which retains the blow-out portion connected to the member 92. The area 120 between the other two adjacent ends of the slits 116 defines a rupture tab which tears when the member 92 ruptures. The ends of the slits 116 can optionally include apertures 122 as illustrated in FIG. 8. As will be understood, the arcuate slits 116 can be formed in the dome portion 94 of the flow restricting member 92 or they can be formed in the annular flat flange portion 96 adjacent to the dome portion 94.
The operation of the composite rupture disk assembly 70 is similar to the operation of the assembly 10 described above except that the flow restriction and time delay in communication of fluid pressure to the first rupture member 86 is brought about by the flow restricting openings in the member 92 in combination with the increased volume of space provided within the assembly 70 by the dome shape of the member 92. That is, during a relatively slow build-up of fluid pressure in the vessel or system being protected, pressurized fluid flows through the slot 114, slits 116 and apertures 122 of the flow restricting member 92 into the space between the concave side of the member 92 and the second rupture member 90. The pressurized fluid then flows through the slits 108 and apertures 112 of the second rupture member 90 to the flexible sealing member 88. When the fluid pressure exerted on the sealing member 88 exceeds the rupture pressure of the first rupture member 86, the first rupture member ruptures followed by the sealing member 88, the second rupture member 90 and the flow restricting member 92. The flow restricting member 92 ruptures by the tearing of the area 120 between the apertures 122 followed by the movement of the circular blow-out portion defined by the slits 116 through the opening in the assembly 70. The blow-out portion remains connected to the flow restricting member 92 by the hinge area 118.
When a momentary pressure surge is experienced in the vessel or system being protected whereby pressure rapidly increases to an overpressure condition and subsides, the composite rupture disk assembly 70 does not rupture. This is because the pressurized fluid flow caused by the surge is restricted by the openings in the flow restricting member 92, i.e., the slot 114, the slits 116 and the apertures 122 in combination with the additional time required for the pressurized fluid to fill the volume between the flow restricting member 92 and the second rupture member 90. Because of the restriction in flow and time delay, the pressure acts on both the first and second rupture members simultaneously whereby the pressure required to rupture the assembly 70 is the sum of their rupture pressures.
Referring now to FIG. 9 yet another alternate form of the composite rupture disk assembly of the present invention is illustrated and designated by the numeral 130. The assembly 130 includes an optional positioning member 132, a perforated rupture member 134, a resilient sealing member 136 and a flow restricting member 138. A peripheral portion of the flow restricting member 138 is utilized to clamp the members together. The assembly 130 operates in the same manner as described above except that the flow restricting member 138 functions both to restrict pressurized fluid flow into the assembly 130 and as a second rupture member. The member 138 includes a single flow restricting opening 140 therein. When a momentary pressure surge is experienced, the pressurized fluid flow into the assembly is restricted whereby a pressure level equal to the rupture pressure of the rupture member 134 and the rupture pressure of the member 138 must be exceeded before rupture of the assembly 130 occurs. Like the assemblies 10 and 70 described above, when the pressure increase is relatively slow, the overpressure condition is communicated to the rupture member 134 alone whereupon it and the other members of the assembly rupture at the predetermined rupture pressure of the rupture member 134.
Referring to FIG. 10, still another alternate embodiment of the composite rupture disk assembly of the present invention is illustrated and generally designated by the numeral 140. The composite rupture disk assembly 140 includes an optional positioning member 142, a first perforated rupture member 144, a resilient sealing member 146, a second perforated rupture member 148 and a flow restricting member 149. The members of the assembly are clamped together by means of a separate clamping member 151 which is folded over the peripheral ends of the other members of the assembly.
The composite rupture disk assembly 140 operate in the same manner as described above. However, the first rupture member 144 includes a central dome portion with the concave side thereof facing the sealing member 146. The dome in the first rupture member 144 provides additional volume within the assembly 140 which increases the time delay in communicating a pressure increase to only the first rupture member 144.
Referring to FIG. 11, still another alternate embodiment of the present invention is shown and generally designated by the numeral 150. The assembly 150 include an optional positioning member 152, a first domed perforated rupture member 154, a resilient sealing member 156, a second domed perforated rupture member 158 and a domed flow restricting member 160 which is utilized to clamp the parts of the assembly 150 together. The domed first and second rupture members 154 and 158 have their concave sides facing the sealing member 156 whereby a space of relatively large volume is formed within the assembly 150.
In operation of the assembly 150, a slow pressure increase causes the pressurized fluid flow through a single opening 162 in the flow restricting member 160, through apertures and slits in the second rupture member 158 and into the space within the assembly 150 against the resilient sealing member 156 whereby it is moved into contact with the concave side of the first rupture member 154. When the pressure communicated to the first rupture member 154 exceeds its predetermined rupture pressure, rupture of the assembly occurs. When a momentary pressure surge takes place, the resulting pressurized fluid flow is restricted and a larger volume is required to exceed the predetermined pressure of the first rupture member 154 alone.
Referring now to FIG. 12, still a further embodiment of the composite rupture disk assembly of the present invention is illustrated and generally designated by the numeral 170. The assembly 170 is comprised of an optional positioning member 172 and a solid rupture disk 174 formed of rigid material which can be flat as shown or include a centrally positioned dome having the convex surface thereof facing the positioning member 172. A combined rupture and flow restricting member 176 is provided which can be flat or include a central dome portion as shown positioned with the concave surface facing the rupture disk 174 and including a pressurized fluid flow restricting opening 178 therein.
In operation, the composite rupture disk assembly 170 operates in the same manner as do the various assemblies described above. That is, when a slow pressure increase to an overpressure condition is experienced, the resulting pressurized fluid flow travels through the opening 178 into the space within the assembly 170 and into contact with the rupture disk 174 whereby the overpressure condition is communicated to the rupture disk 174 alone. As a result, the rupture disk 174 ruptures followed by the rupture of the member 176 providing pressure relief to the vessel or system being protected. When a momentary surge in pressure occurs whereby a momentary overpressure condition is experienced, the resulting pressurized fluid flow is restricted and a pressure approximately equal to the sum of the predetermined rupture pressures of the member 174 and member 176 is required to rupture the assembly 170.
As will be understood by those skilled in the art and as mentioned above, the various embodiments of this invention including a resilient sealing member can also include protection members to prevent abrasion damage to the sealing member. In addition, a variety of different parts and arrangements of such parts can be utilized in accordance with this invention which along with changes to the parts and arrangements described herein will suggest themselves to those skilled in the art. Such different parts and arrangements and changes are encompassed within the spirit of this invention as defined by the appended claims. | The present invention provides a pressure surge resistant rupture disk assembly adapted to be sealingly clamped across a pressurized fluid containing passageway. The assembly basically comprises first and second rupture members having predetermined rupture pressures, the second rupture member facing the pressurized fluid and having a predetermined rupture pressure equal to or lower than the rupture pressure of the first rupture member. At least one opening is provided in the second rupture member for allowing a restricted pressurized fluid flow therethrough. | 5 |
TECHNICAL FIELD
The present invention broadly relates to point-of-sale surveillance systems. More specifically, the present invention relates to a method and apparatus for the capture, storage and retrieval of visual and digitized information in a video surveillance network.
BACKGROUND OF THE INVENTION
Visual surveillance via cameras or closed circuit televisions systems is well known in the art as demonstrated by, for example, U.S. Pat. No. 5,216,502 (Katz). These systems have enabled visual records to be stored on videotape for later analysis. However, because of the amount of information recorded, it is difficult to review all the information and identify patterns, such as patterns of employee theft. Employee theft most often occurs at the point-of-sale, for example, at a cash register or at a bank teller's station. and can be identified by observing transactions that fall outside normal activity.
Current video surveillance systems typically record transaction activity with two types of transaction information: a video signal for visual information and digital data to reflect each transaction as it is entered into the point-of-sale device, such as a cash register or bank teller register. In the past, one method of storing this information has been to overlay the digital data on the video signal and record and store both types of information together as a mixed composite video signal. Representative of such systems are the surveillance systems disclosed in U.S. Pat. No. 4,120,004 (Coutta), U.S. Pat. No. 4,922,339 (Stout), and U.S. Pat. No. 4,991,008 (Nama). Wile this type of combined video record is not easily tampered with, the problem with this method is that there is a tremendous volume of information which must be manually reviewed in order to identify patterns of unwanted or criminal activity.
Another method for storing the visual and digital information has been to use the digital data as the leading information or header for the video signal as described in U.S. Pat. Nos. 4,237,483 and 4,145,715 (Clever patents). This merger of information, however, tends to degrade the quality of the video image and still requires that an operator scan all the information in its entirety to identify problem areas. Use of these system with a plurality of cameras requires additional cabling installed in order to coordinate the operation of all cameras in sync with each other. In addition, because much of the digital information is stored separately from the video images, this information is vulnerable to tampering by dishonest store managers, for example.
A third and more recent method is to store the digital data in the audio portion of the video signal and to mark transactions of interest with an alarm signal in the audio track. One example of such a system is disclosed by U.S. Pat. No. 5,216,502 (Katz). This method reduces the amount of material an operator must scan by allowing the operator to move quickly to those portions of the videotape which are marked by the audio alarm. Nonetheless, this method requires that all transactions of interest be previously marked. If transactions of interest are not marked, the operator still must scan all the transaction to find the transaction of interest. In addition, this third method does not provide any easy way for an operator to identify patterns and trends outside of a relatively small group of preselected conditions which cause an alarm signal to be recorded.
One solution to the problem of viewing irrelevant information is to record only those transactions of interest such as is done by the System 500 or System 1000 sold by Video Controls Limited of 1 Aston Fields Road, Whitehouse Industrial, England or the Sensormatic Electronics Corporation POS/EM system sold by Sensormatic of Deerfield, Beach, Fla. The Video Controls system records user-defined events, such as void transactions, through its closed circuit TV and provides a summary videotape of particular events with the details of the cash register transaction superimposed over the videotape picture. One problem is that the system records only those events that the user predefines as important. Thus, critical transactions which are not of prior interest may be lost. For example, often events, such as void transactions, merely point to a larger pattern of theft. This pattern of theft often is evident only by viewing several entries or transactions prior to the void transaction.
The Sensormatic Electronics Corporation POS/EM system automatically aims a camera at the register once a pre-defined exception to normal cash register transactions is detected in the electronic cash register. The Sensormatics Electronics Corporation POS/EM system then displays the cash register transaction data on the video picture. The problem here is that, because the camera is triggered only after an exception is detected in the electronic cash register data, the camera may not record the actual event leading to the loss. Such a time delay, even a small one, may not record the key activity. Again, separate storage of the visual picture data and digital data opens the system to tampering.
In sum, a multimedia capture and audit system for a video surveillance network that captured all relevant information and stored that information in a tamper-resistant form and offered improved review and audit capabilities would be greatly appreciated.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus for a multimedia capture and audit system for a video surveillance network which provides a tamper resistant and easily reviewable record of each transaction monitored. A mixed composite video signal containing both a visual record and digital record of each transaction is stored as well as a digital record. The digital record and mixed composite video signal for each transaction are correlated through use of a unique system pointer. In the preferred embodiment, the unique system pointer identifies the transaction device and the date and time of the transaction. Use of both a video record and digital record makes it difficult to tamper with the transaction record and discourages unauthorized access. Maintaining a record of each transaction in a digital format provides operators the ability to correlate data in almost unlimited relationships for audit purposes. Use of the unique system pointer makes it easy to identify and view the portion of the mixed composite video signal which corresponds to any digital record.
The multimedia capture and audit system broadly includes means for capturing occurrences of digital transaction data from each of the electronic transaction devices, video memory means for storing the video signals and digital memory means for storing the digital transaction data in a database separately from the video memory means, control means operably coupled to the capture means and each of the memory means for storing, in response to an occurrence of digital transaction data, a mixed composite video signal on the video memory means using a unique system pointer and for storing the digital transaction data and the unique system pointer in the database on the digital memory means and audit means operably coupled to the memory means for auditing the transactions by analyzing the database stored in the digital memory to identify transactions of operator interest and reviewing the mixed composite video signal of the corresponding transaction stored in the video memory means by correlation of the unique system pointer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a schematic diagram of a multimedia surveillance and audit system in a point-of-sale environment in accordance with the present invention;
FIG. 2 depicts a schematic diagram of an alternate embodiment of a multimedia surveillance and audit system with multiple point-of-sale devices;
FIG. 3A depicts a block diagram of the format of digital data as it flows from the node to the system controller;
FIG. 3B depicts a block diagram of the digital data as it flows from the system controller to the digital data storage;
FIG. 3C depicts a block diagram of the stored mixed composite video signal;
FIG. 4 presents a flowchart depicting the overall method of the present invention;
FIG. 5 shows the Main Menu step of FIG. 4 in greater detail;
FIG. 6 shows the Utilities step of FIG. 5 in greater detail;
FIG. 7 shows the Location Select step of FIG. 6 in greater detail;
FIG. 8 shows the Edit Location File step of FIG. 6 in greater detail;
FIG. 9 shows the Format Ticket step of FIG. 6 in greater detail;
FIG. 10 shows the Reference File step of FIG. 9 in greater detail;
FIG. 11 shows the Format File step of FIG. 9 in greater detail;
FIG. 12 shows the Format Header File step of FIG. 9 in greater detail;
FIG. 13 shows the Transaction Analysis step of FIG. 5 in greater detail;
FIG. 14 shows the Exception Analysis step of FIG. 5 in greater detail;
FIG. 15 shows the Communications step of FIG. 5 in greater detail; and
FIG. 16 shows the Trends Analysis step of FIG. 5 in greater detail.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference is now made to the drawings, wherein like reference numerals denote like elements throughout the several views. Referring to FIG. 1, one embodiment of a multimedia capture and audit system 10 broadly includes video input unit 12, electronic transaction device 14, node 16, system controller unit 18, video storage system 20 and audit controller system 21.
In the first embodiment depicted in FIG. 1, the video input unit 12 is a camera generating a camera composite video signal. The video storage system 20 includes a videotape 19, video cassette recorder (VCR) 22 and video display 23. In the preferred embodiment, the VCR is a Panasonic AG 6040 VCR or a Panasonic AG 6730 VCR. Those skilled in the art will understand that the video storage system 20 may be a CD-ROM player and CD-ROM disc that stores a digital optical signal to represent the visual picture of-the transaction.
The electronic transaction device 14 may be a cash register, an automated teller machine (ATM), a bank teller cash drawer, a bar code reader or any other device that generates digital data. It will be understood by those skilled in the art that the device 14 may be a link to another network of devices such that the devices 14 in the other network alternate sending digital data through the node 16. In addition, device 14 may be from various manufacturers, such as, for example, cash registers manufactured by NCR or IBM.
The node 16 is operably attached to device 14 and the system controller unit 18 and includes node processor means 24. In the preferred embodiment, the node processor means 24 is any microcontroller and associated circuitry, such as, for example, an IBM PC '286, '386 or '486 machine or a computer system based on the Intel 8050 series processor, that is capable of converting the native digital data of device 14 into a human readable form and including identifying information as a header.
System controller 18 includes video interface 26, a plurality of video cards 27, system processor 28, random access memory (RAM) (not shown), system clock (not shown) and digital data storage 30. In the first embodiment, system controller 18 is an IBM PC '486 computer system with at least 80 MB of hard drive storage and 2 MB RAM. In the preferred embodiment, video cards 27 are housed in a tower 31 and each of the video cards 27 is operably coupled to a video input unit 12. In the preferred embodiment, each video card 27 processes video signals from a single video input unit 12 and is designed for mounting in a video card tower 31. Those skilled in the art will understand that the particular configuration of system controller 18 may vary. For example, microcomputer systems, other than those manufactured by IBM may be used. The size and type of digital storage device may include larger hard drive systems, tape drive systems or CD-ROM systems.
System controller 18 is operably coupled to video input unit 12 via a video card 27 and is operably coupled to node 16 and video storage system 20. The actual connections are those common in the art, using cables into the respective port of each machine. It will be understood by those skilled in the art that the system controller 18 may be remotely coupled to the node 16 by a variety of mechanisms common in the field, such as, a modem or network link or direct leased telephone line.
Audit controller 21 includes a system processor 28, random access memory (RAM) (not shown), digital data storage 30, user input device 32, monitor 34 and an internal video card 35. In the preferred embodiment, audit controller 21 is an IBM PC '486 computer system with internal VGA card, attached keyboard, color monitor and at least 80 MB of hard drive storage and 2 MB RAM. The user input device 32 may be a touchscreen, light pen or voice microphone. The monitor 34 may be monochrome or may vary in size. Alternately, audit controller 21 also may include a printer as an output device.
In the preferred embodiment, the audit controller 21 is operably coupled to system controller 18 via a modem. Those skilled in the art will understand that audit controller 21 may also be remotely coupled to system controller 18 via a variety of mechanisms common in the field, such as, a network link, direct leased telephone line or satellite communications. Typically, audit controller 21 is located at a district office or centralized store or bank management office at a site remote from system controller 18. It will also be understood by those skilled in the art that system controller 18 and audit controller 21 may be the same computer system or may be housed in the same machine.
In a second embodiment depicted in FIG. 2, the camera composite video signal is generated from a plurality of video input units 12, e.g. cameras, coupled together through a video input switcher 36 to video cards 27. Those skilled in the art will understand that the switcher 36 may also be a dome-type camera control device.
A plurality of electronic transaction devices 14 are operably coupled to node 16, called a "polynode." The polynode 16 may couple a variety of devices 14 of different manufacture or the same manufacture on a single polynode 16. In the current embodiment, the polynode 16 is serially connected to the system controller 18 over an optically isolated serial port that uses a central polling scheme to implement a variety of network topologies. Thus, the polynode 16 may accommodate up to thirty-two different devices 14 or more than thirty-two devices may be coupled to polynode 16 if some or all of the devices 14 act as link devices to other networks.
The video storage system 20 includes a videotape 19, a video cassette recorder (VCR) 22 and video display 23 as in FIG. 1 and a video multiplexer 38 to alternate storage of composite video signals generated by different cameras on the same videotape. Video multiplexer 38 may be of any of a number of different video multiplexer systems as are known in the art, such as Robot MV90 series.
In operation, referring to FIGS. 1, 2 and 3A-C and following the data stream, device 14 generates digital data to record a transaction. A transaction may be defined as a single line of information or may be defined as a group of lines. For example, if device 14 is a cash register, a transaction may be defined as each line on a customer's receipt, such as "1 dz. eggs 0.65" or may be defined as all the information in a ticket. Typically, the ticket is the customer's receipt. For example, in a retail environment, the customer's sales receipt is the ticket. In a banking environment, the deposit or withdrawal or funds transfer record is the ticket. Simultaneously, the entry of this transaction by the employee is recorded visually by video input unit 12 such as an overhead camera.
The digital data from device 14 is sent to the node 16 in the data format native to device 14. The node 16 converts the native or raw digital data into a first digital data format, shown in FIG. 3A. In the first digital data format, the raw digital data is converted to a human readable form, such as ASCII code, a source identifier is added and the data is encrypted for secure transmission to system controller 18. The source identifier, at a minimum, identifies device 14 from which the transaction originated. Alternately, node 16 may be initialized to be in sync with the system clock of system controller 18 and the node 16 may add system date and time information to the source identifier.
Upon receipt of a data transaction from node 16, system controller 18 deciphers the first digital data format and converts the human readable digital data into a predefined common standard format, or second digital data format, shown in FIG. 3B, for storage in a database. Use of a predefined common standard format ensures that although the digital data may be generated by devices 14 of different manufacturers, all the digital data will be organized in a similar fashion. For example, if the devices 14 are cash registers, one type of cash register may organize its transactions with leading zeros before each dollar amount and use the code V for void. Another type of cash register may remove leading zeros before each dollar amount and generate the code VD for voids. The predefined format standardizes the organization and storage of similar information from devices 14 of different manufacturers. The format also includes information about device 14 from which the transaction originated. With this information, any re-display of a particular transaction can be re-converted to reflect the original format of transactions for that device 14. Use of the predefined format improves the accuracy and completeness of reports totaling or summarizing activity for a plurality of devices 14 of different manufacturers. Once such information is stored in the predefined format, the information may be easily accessed for use in an electronic journaling or inventory control system.
The video input device 12 automatically records a visual record of each transaction as a camera composite video signal. The camera composite video signal is sent to a video card 27. The video card 27 also receives a copy of the transaction data in the first digital format which is stored in video RAM (not shown) of video card 27. Video card 27 continuously merges the stored digital transaction data with the corresponding camera composite video signal to create a mixed composite video signal, shown in FIG. 3C, such that if no transaction data is in the video RAM at a given time, the mixed composite video signal carries just the camera composite video signal. The mixed composite video signal combines the camera composite video signal and digital transaction data into a single signal for storage on the video storage system 20.
Once combined, the mixed composite video signal is sent to the video storage system 20 to be saved. The VCR 22 stores the mixed composite video signal on the videotape 19 with a non-displayable date and time stamp generated by the VCR 22. For ease of retrieval of this signal, in the preferred embodiment, system controller 18 initializes VCR 22 at least every 24 hours to correlate the internal VCR clock (not shown) of VCR 22 to the system clock of system controller 18.
To audit or review one or more transactions, audit controller 21 uploads the digital transaction data stored by system controller 18 to its digital data storage 30 and identifies the transaction to be viewed according to user-defined criteria entered via user input device 32. The identified transaction is displayed on monitor 34. Audit controller 21 uses a system pointer to identify the portion of the videotape 19 which stores the desired transaction in a mixed composite video signal. In the preferred embodiment, the system pointer is calculated from the system clock (not shown) of system controller 18. Those skilled in the art will understand that the system pointer may be calculated from other timing mechanisms internal to system controller 18.
In the preferred embodiment, audit controller 21 instructs VCR 22 to locate the portion of videotape 19 in which the date and time stamp generated by VCR 22 for a given camera most nearly matches the date and time stamp stored for that transaction as digital data. That portion of the videotape 19 is then displayed on video display 23. Because a visual record of a transaction occurs over several videotape frames, correlation of the local VCR date and time stamp to the system pointer provides sufficient accuracy to locate a given transaction. Nonetheless, it will be understood that, given a highly accurate VCR clock, the local VCR date and time stamp would have the same values as the system pointer.
It will be understood that a videotape 19 storing a mixed composite signal received from video card 27 can be removed from VCR 22, mailed to a central location and reviewed on a different VCR 22 as is shown operably coupled to audit controller 21 or, the videotape 19 may be accessed by playing on-site, i.e. on VCR 22 which is operably coupled to system controller 18.
One of the primary advantages of the present invention is that storage and retrieval of the mixed composite video signal and digital transaction data separately make it difficult for anyone to tamper with a transaction record. In order to tamper, a dishonest person must alter both a containing a visual record of the transaction with a digital record stored in a mixed composite video signal and a second record of the transaction stored as digital data in a predefined database format. By having both the signal and digital transaction data recorded separately, but uniquely interrelated by a system pointer, the present invention avoids the problems of prior systems that stored true composite signals in that the tremendous volume of video information will not need to be reviewed in order to isolate transactions that are of interest.
Referring to FIG. 2, when there are a plurality of video input units 12, system controller 18 records the particular video input unit 12 generating each camera composite video signal through coordination with the video input switcher 36. When storing a plurality of mixed composite video signals, system controller 18 controls and coordinates the multiplexer 38 and VCR 22 to ensure that each mixed signal is uniquely identifiable on videotape 19.
Referring to FIGS. 4-16 and following an operator's use of a multimedia capture and audit system 10 in accordance with the present invention, an operator first activates the system 10 (step 40) and audit controller 21 performs initialization sequence (step 42), main menu process (step 44), termination process (step 46) and ends (step 48).
During the initialization sequence (step 42), audit controller 21 initializes a pass file containing information identifying the last transactions and reports the user accessed.
Referring to FIG. 5, audit controller 21 initiates the Main Menu process (step 50) by asking the operator to input their choice of functions to perform (step 52 Choose Module). The choice of functions includes, at least, the following: Utilities (step 54), Transaction Analysis (step 56), Exception Analysis (step 58), Communications (step 60), Trends Analysis (step 62) and Exit (step 64). If the operator chooses Exit (step 64), audit controller 21 ends the Main Menu process (step 66) and initiates the Termination process (step 46 of FIG. 4).
Referring to FIG. 6, audit controller 21 initiates Utilities (step 54 of FIG. 5) by asking the operator to input a choice of Utilities functions to perform (steps 68 and 70 Choose Menu Item). The choice of functions includes, at least, the following: Location Select (step 72), Edit Location File (step 74), Format Ticket (step 76), Print Error File (step 78), View Error File (step 80), Delete Error File (step 82), Clipboard (step 84) and Exit (step 86). If the operator chooses Exit (step 86), audit controller 21 ends Utilities process (step 88) and initiates Choose Module step (step 52 of FIG. 5).
Referring to FIG. 7, if the operator chooses the Location Select function (step 72 of FIG. 6), audit controller 21 initiates the Location Select procedure (step 90) and requests that operator select the appropriate location file by choosing the appropriate file name (step 92). The location file contains values representing the correct digital data storage location for files related to transactions occurring on the same device. In the preferred embodiment, the location file contains directory path control information and is used to select the correct directory path to save or read files related to transactions occurring on the same device. For example, the location file includes the directory location path, description of the device(s) 14 in the path, the identifier for the corresponding format file, the name of the device(s), a telephone number, a block size for transfer of the data, a unit number (often used to identify the store location of the device(s)), connection type, such as direct or modem, for transferring data, audit controller 21 connection port identifier for the transfer mechanism such as a modem, the VCR port identifier for the connection to audit controller 21, a camera multiplexer port identifier and a modem command line.
Audit controller 21 accesses the selected location file from digital data storage 30 (step 94) and initializes the location file (step 96) by reading the location file information into its random access memory (step 96). Next, audit controller 21 ends the Location Selection procedure (step 98) and returns to Choose Menu Item step (step 70) of FIG. 6.
Referring to FIG. 8, if the operator chooses Edit Location File function (step 74 of FIG. 6), audit controller 21 initiates Edit Location File procedure (step 100) and requests that operator select the appropriate location file by choosing the appropriate file name (step 102). Audit controller 21 accesses the selected location file from digital data storage 30 and inputs the selected location file into its random access memory (step 104). Next, audit controller 21 displays the location file parameters to the operator and accepts new or changed values for location file parameters within a predefined range of acceptable values (step 106). Once the operator has completed the entry of new or changed values, audit controller 21 saves the edited location file to the hard drive storage 30 (step 108). Audit controller 21 ends the Edit Location File procedure (step 110) and returns to Choose Menu Item step (step 70) of FIG. 6.
Referring to FIG. 9, audit controller 21 initiates Format Ticket (step 76 of FIG. 6) by asking the operator to input a choice of Format Ticket functions to perform (steps 112 and 114 Choose Menu Item). The choice of functions includes, at least, the following: Reference File (step 116), Format File (step 118), Header Format (step 120), Test Reference Format (step 122), Test Any Format (step 124) and Exit (step 126). If the operator chooses Exit (step 126), audit controller 21 ends Start Format Ticket process (step 128) and initiates Choose Menu Item step (step 70 of FIG. 6).
Referring to FIG. 10, if the operator chooses Reference File function (step 116 of FIG. 9), audit controller 21 initiates Reference File procedure (step 130) and requests that operator select the appropriate reference file by choosing the appropriate file name (step 132). The reference file contains values representing sample ticket information. The reference file provides sample ticket information for testing ticket format and for format file development. Audit controller 21 accesses the selected reference file from digital data storage 30 and inputs the selected reference file into its random access memory (step 134). Next, audit controller 21 reads the location file and displays the location information to the operator as part of the reference file (step 136). Audit controller 21 accepts new or changed values for the reference file from the operator within the predefined range of acceptable values (step 138 Edit Reference File). Once the operator has completed the entry of new or changed values, audit controller 21 saves the edited reference file to the hard drive storage 30 (step 140). Audit controller 21 ends the Reference file procedure (step 142) and returns to Choose Menu Item step (step 114) of FIG. 9.
Referring to FIG. 11, if the operator chooses Format File function (step 118 of FIG. 9), audit controller 21 initiates Format File procedure (step 144) by accessing the user-selected format file and corresponding reference file (step 146).
The format file contains values representing information defining the organization of each transaction line and ticket for each type of device. In the preferred embodiment, for example, each text line of a transaction receives a unique identifier such as, ITEM LINE. Each line contains one or more fields and each field is defined by a name, size, offset and type. For example, an line which lists each item a customer purchases may be called ITEM LINE and contain a field called PRICE with a size of six characters (representing 000.00 dollar amounts), offset from the zero character in the line by 50 characters and a numeric type. Additionally, fields may be defined to include data such as price, number of items, text description of an item, time (such as military time), date, fixed text, which may be a field for messages to customers such as "Have a nice day!"
The format file also provides information defining the organization of search information. In the preferred embodiment, the search information, such as, device number, digital storage location of the device file and a list of fields for each line that can be searched, is stored in a predefined header. Use of a predefined header minimizes the time and resources required to search all transactions for the desired transactions.
Once the operator identifies the name of the format file, audit controller 21 accesses the selected format file from digital data storage 30 and inputs the selected format file into its random access memory (step 148). Next, audit controller 21 accesses the user-selected format file and corresponding reference file (step 150). Audit controller 21 displays the values of the format file to the operator and accepts new or changed values for current format file values from the operator within the predefined range of acceptable values (step 152 Edit Format File). Once the operator has completed the entry of new or changed values, audit controller 21 saves the edited format file to the hard drive storage 30 (step 154). Audit controller 21 ends the Format File procedure (step 156) and returns to Choose Menu Item step (step 114) of FIG. 9.
Referring to FIG. 12, if the operator chooses Header Format function (step 120 of FIG. 9), audit controller 21 initiates Header Format procedure (step 160) by accessing the user-selected format file (step 162). The header format is part of the format file and contains information for the organization of search information. In addition, the header format identifies the beginning of each transaction and thus is used in delineating transactions for audit purposes. Once the operator selects the desire format file, audit controller 21 accesses the selected header format from format file in digital data storage 30 and inputs the selected header format file into its random access memory (step 164).
Next, audit controller 21 accesses the corresponding reference file (step 166). Audit controller 21 displays the values of the header format file to the operator on the monitor 34 and accepts new or changed values for current header format file values from the operator within a predefined range of acceptable values (step 168 Edit Header Format File). Once the operator has completed the entry of new or changed values, audit controller 21 saves the edited format file to the hard drive storage 30 (step 170). Audit controller 21 ends the Format File procedure (step 172) and returns to Choose Menu Item step (step 114) of FIG. 9.
Referring to FIG. 9, if the operator chooses the Test Reference Format procedure (step 122 of FIG. 9), audit controller 21 inputs the values from one or more user-selected transactions into the reference format and displays the values on the monitor 34 in the user-defined reference format. The operator then visually checks the displayed values for accuracy. If the displayed values are not accurately formatted on the monitor 34, operator returns to Choose Menu Item (step 114) and then may select Reference File (step 116) to edit the reference file format to display transaction values accurately.
Referring to FIG. 9, if the operator chooses the Test Any Format procedure (step 124 of FIG. 9), audit controller 21 inputs the values corresponding to a user-selected format and displays the values on the monitor 34 in the user-selected format. The user-selected format may be a reference file format, a format file or a header format file. The operator then visually checks the displayed values for accuracy. If the displayed values are not accurately formatted on the monitor 34, operator returns to Choose Menu Item (step 114) and then may select Reference File procedure (step 116), Format File procedure (step 118) or Header Format procedure (120) to edit the selected format to display values accurately.
Referring to FIG. 6, if the operator chooses the Print Error File procedure (step 78), audit controller 21 prints the values stored on an error file to an output device, such as a printer. The error file contains values representing information about problems encountered in performing Communications (step 60 of FIG. 5). In the preferred embodiment, for example, the error file may indicate that a telephone transmission line signal disappeared while data was being transferred between audit controller 21 and a remote computer system, such as system controller 18, with a message such as "No carrier." Once the error file is printed, audit controller 21 returns to Choose Menu Item (step 70) and waits for the operator to select the next procedure.
If the operator chooses the View Error File procedure (step 80 of FIG. 6), audit controller 21 displays the values stored on an error file to the monitor 34. Once the error file has been displayed, audit controller 21 returns to Choose Menu Item (step 70) and waits for the operator to select the next procedure.
Referring to FIG. 6, if the operator chooses the Delete Error File procedure (step 82), audit controller 21 deletes the error file from digital data storage 30, returns to Choose Menu Item (step 70) and waits for the operator to select the next procedure.
If the operator chose the Clipboard procedure (step 84 of FIG. 6), audit controller 21 displays clipboard information on the monitor 34. Clipboard information contains values representing the latest information which an operator has requested to be moved to the clipboard. The clipboard provides volatile memory storage for information as such information is edited. Once the clipboard information is displayed, audit controller 21 waits for the operator to edit or delete clipboard information. Once the operator has finished with clipboard information, audit controller 21 returns to Choose Menu Item (step 70) and waits for the operator to select the next procedure.
Referring to FIG. 13, audit controller 21 starts Transaction Analysis (step 56 of FIG. 5) by initializing the VCR 22 with the current system pointer and information about the transactions and files to be analyzed (steps 174, 176). Next, audit controller 21 tests whether or not the transaction files have been indexed (step 178). If the transaction files have not been indexed, audit controller 21 creates an index for each file and stores the index at the end of the file (step 180).
An index file contains values representing storage information for each transaction. In the preferred embodiment, each record in the index includes identifying information for the device which generated the digital transaction, the camera which recorded the transaction, the digital data storage location of the digital transaction file, video storage location (e.g. which videotape 19) and system pointer for the date and time that the transaction occurred. An index file provides key information to correlate the digital transaction information with the corresponding mixed composite video signal which represents a visual record of the transaction with transaction information incorporated into the video signal.
Once the transaction files are indexed, audit controller 21 locates the closest transaction to the current date and time by matching, as nearly as possible, the date and time of each transaction in the file from the selected device to the current date, time and selected device (step 182). Audit controller 21 scans the index file for transactions recorded from the selected device to locate the closest transaction.
Once the closest transaction is identified, audit controller 21 sends the date and time data from the transaction header information to VCR 22. VCR 22 uses its own internal function to retrieve and display that portion of the stored mixed composite video signal corresponding to the desired system date and time of the desired transaction (step 184). The video signal is displayed on video display 23.
Audit controller 21 formats the transaction file entries according to the information stored in the corresponding format file and displays the transaction on the monitor 34 (step 186).
Audit controller 21 then initiates the next procedure chosen by the operator. The operator indicates which procedure to initiate by entering the criteria for the next desired transaction, exiting to Exception Analysis or exiting Transaction Analysis (steps 188, 192, 196). If the operator exits Transaction Analysis (step 188), audit controller 21 ends Transaction Analysis (step 190) and returns to Choose Module (step 52 of FIG. 5). Once Transaction Analysis (step 56 of FIG. 5) is initiated from Exception Analysis, audit controller 21 automatically displays that portion of the stored mixed composite video signal corresponding to the particular transaction that was last reviewed in Exception Analysis (step 58 of FIG. 5).
If operator enters new search criteria i.e. information about the next transaction to view (step 194), audit controller 21 then returns to locate the desired transaction (steps 192, 194, 182). In the preferred embodiment, search criteria may include only particular transactions, such as voids. The search criteria may include only void transactions occurring at a particular device or occurring when any device is run by a particular operator. Those skilled in the art will understand that the individual search criteria can be combined in any number of operations using the relational operators AND, OR, NOR, NOT and numeric operators >, greater than, , less than and = equal to.
If operator chooses to Exit to Exception Analysis (step 196), audit controller 21 ends Transaction Analysis (step 198) and initiates Exception Analysis (steps 200 and step 58 of FIG. 5).
Referring to FIG. 14, audit controller 21 starts Exception Analysis (step 58 of FIG. 5) initializing the VCR 22 with the current system pointer and information about the transactions and files to be analyzed (steps 202, 204). In the preferred embodiment, exceptions are defined by the user and often include void transactions, transactions with a dollar amount above or below predetermined limits and other transactions that may indicate employee pilfering or theft.
Next, similar to steps 178, 180, 182 of FIG. 13, audit controller 21 tests whether or not the transaction files have been indexed (step 206). If the transaction files have not been indexed, system controller creates an index for each file and stores the index at the end of the file (step 208). Once the transaction files are indexed, audit controller 21 locates the closest transaction to the current date and time by matching, as nearly as possible, the date and time of each transaction in the file from the selected device to the current date, time and selected device (step 210). Audit controller 21 scans the index file for transactions recorded from the selected device to locate the closest transaction.
Once the closest transaction is identified, audit controller 21 sends the date and time data from the transaction header information to VCR 22. VCR 22 uses its own internal function to retrieve and display that portion of the stored mixed composite video signal corresponding to the desired system date and time of the desired transaction (step 221). The video signal is displayed on video display 23.
Audit controller 21 formats the digital transaction file entries according to the information stored in the corresponding format file and displays the digital transaction on the monitor 34 (step 214).
Audit controller 21 then initiates the next procedure chosen by the operator. Operator indicates which procedure to initiate by entering the search criteria for the next desired transaction, exiting Exception Analysis or exiting to Transaction Analysis (steps 220, 216, 224). If the operator exits Exception Analysis (step 216), audit controller 21 ends Exception Analysis (step 218) and returns to Choose Module (step 52 of FIG. 5).
If operator enters new search criteria (step 220), similar to step 192 of FIG. 13, audit controller 21 then returns to locate the desired transaction (steps 220, 222, 210).
If operator chooses to Exit to Transaction Analysis (step 224), audit controller 21 ends Exception Analysis (step 226) and initiates Transaction Analysis (steps 228 and step 56 of FIG. 5).
Referring to FIG. 15, audit controller 21 starts Communication (step 60 of FIG. 5) and initializes the Communication procedure by identifying the files to be transferred so audit functions can be performed (steps 230, 232). Next, audit controller 21 asks the operator to input their choice of Communications functions to perform (step 234 Choose Menu Item). The choice of functions includes, at least, the following: Connect to Remote Site (step 236), Configuration (step 238), Clipboard Utilities (step 240), Batch File (step 242), Communication Utilities (step 244) and Exit (step 246). If the operator chooses Exit (step 246), audit controller 21 ends Communications process (step 248) and initiates Choose Module step (step 52 of FIG. 5).
If the operator chooses Connect to Remote Site (step 236), audit controller 21 accesses the location files for the location to which the operator wishes to transfer data, initiates the connection with the remote computer system and records any errors as the selected files are transferred. In the preferred embodiment, the remote computer system is system controller 18. It will be understood that once the remote connection is made, the operator may also view, archive, purge or monitor the transaction activity of the remote computer system.
If the operator chooses Configuration (step 238), audit controller 21 can configure the archival directory for the transferred files, can specify purging priorities such as purge only exception files, and can upload desired files from the remote computer system, such as system controller 18, to audit controller 21.
If operator chooses Clipboard Utilities (step 240), audit controller 21 can configure how the clipboard stores and manages information.
If operator chooses Batch File (step 242), audit controller 21 accesses user-defined batch files. Batch files include instructions to audit controller 21 for executing batch commands to perform communications functions.
If operator chooses Communication Utilities (step 244), audit controller 21 can create and edit batch files, edit the location file and edit the modem command line as desired to manage remote communications.
Referring to FIG. 16, audit controller 21 starts Trends Analysis (step 62 of FIG. 5) and initializes the Trends Analysis procedure by initializing the VCR 22 with the current system pointer and information about the transactions and files to be analyzed (steps 250, 252). Trends Analysis collects transaction data and groups similar data together to produce totals, averages and percentages for analysis purposes. For example, a store manager may wonder what is the average dollar amount for voided transactions. Trends Analysis can correlate all the transaction data for a given period to, for example, determine the average dollar amount for all voided transactions in the month of May.
Next, audit controller 21 asks by asking the operator to input a choice of Trends Analysis functions to perform (step 254 Choose Menu Item). The choice of functions includes, at least, the following: Reports (step 256), Reports with Trends (step 258), Trends Save (step 260), Graphs (step 262), View Report (step 264), Delete Report (step 266), Print Report (step 268), Edit Utilities (step 270) and Exit (step 272). If the operator chooses Exit (step 272), audit controller 21 ends Trends Analysis process (step 274) and initiates Choose Module step (step 52 of FIG. 5).
If the operator chooses Reports (step 256), audit controller 21 accesses the report form file. A report form file contains information to automatically select predefined files and predefined parameters to generate a desired report. The Report form file references the format file for data conversion, the location file for data selection and the trends file and report output file for results from the reports. In the preferred embodiment, a template file defines the format of a report output file. The template file includes information defining, at least, the text, headings and column definitions for printing or displaying the reports.
After accessing all the data, audit controller 21 generates the report to the report output file and writes the report output file. The report output file holds the results for a report. The operator selects the output device for the report output file. depending on the operator's selection, audit controller 21 writes the report output file to a file on the digital data storage 30 or printer or displays them on the monitor 34.
If the operator chooses Reports with Trends (step 258), audit controller 21 performs the same steps as in Reports (step 256) and also generates a separate compilation of data to indicate trends. Trends accumulate report data over time to show long term changes. The trends file holds the results for a trend report. If operator chooses Trends Save (step 260 of FIG. 16), audit controller 21 saves the trends to the trends file on the hard drive storage 30 and returns to Choose Menu Item step (step 254).
If operator chooses Graphs (step 262), audit controller 21 initializes Graphs procedure by initializing the VCR 22 operably coupled to audit controller 21 with the current system pointer and by accessing information about the last transactions and files the operator accessed. Audit controller 21 compiles the data in the selected transaction and report files to produce various graphs. In the preferred embodiment, bar graph uses user-defined scales and the pointer indicating graph includes references to specific transactions falling outside user-defined limits. In the preferred embodiment, audit controller 21 can display specific transactions on the video display 23 from the VCR 22 upon operator's request.
If the operator chooses the View Report procedure (step 264 of FIG. 16), audit controller 21 displays the values stored in a user-selected report file to the monitor 34. Once the report file has been displayed, audit controller 21 returns to Choose Menu Item (step 254) and waits for the operator to select the next procedure.
Referring to FIG. 16, if the operator chooses the Delete Report procedure (step 266), audit controller 21 deletes ta user-selected report file from digital data storage 30, returns to Choose Menu Item (step 254) and waits for the operator to select the next procedure.
If the operator chooses the Print Report procedure (step 268 of FIG. 16), audit controller 21 prints the values stored on a user-selected report file to an output device, such as a printer. Once the report file is printed, audit controller 21 returns to Choose Menu Item (step 254) and waits for the operator to select the next procedure.
If the operator chooses the Edit Utilities procedure (step 270 of FIG. 16), audit controller 21 accesses either the report form file or template file, whichever the operator chooses, and allows the operator to alter and add to these files. Once the operator has completed the desired functions within the Edit Utilities, audit controller 21 returns to Choose Menu Item (step 254) and waits for the operator to select the next procedure. | A multimedia capture and audit system for a video surveillance network provides a tamper resistant and easily reviewable record of each transaction monitored. The system stores a digital record of each physical transaction registered by an electronic device in a standard predefined database format and stores a separate mixed composite video signal containing both a visual record and digital record of each transaction. The separately stored digital record and mixed composite video signal are correlated through the use of a unique system pointer. In the preferred embodiment, the unique system pointer identifies, at a minimum, the electronic device which registered the physical transaction and the date and time of the transaction. Storage of both a mixed composite video signal and digital record makes it difficult to tamper with the transaction record while maintaining a record of each transaction in a digital format provides operators the ability to compile and analyze data for audit purposes. Use of the unique system pointer makes it easy to identify and view the portion of the mixed composite video signal which corresponds to any digital record that may be flagged as of interest in an audit. | 6 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to the field of apparatus and methods for tracking activity and costs on copiers and multi-function printers (MFPs)
[0003] 2. Description of the Prior Art
[0004] Cost recovery software captures office expenses, such as print, copy, scan and fax activity. In a typical conventional two-phase, asynchronous print tracking system, an office job is sent from a client computer to a server computer, where its existence is detected, and where data about the job is extracted. The extracted data is sent to a central message queue, where the client computer reads the data and graphically notifies the user of the existence of unbilled job activity. Billed job information is preferably written to a central location, where a management interface allows for viewing and reporting of job data.
[0005] As described in U.S. Patent Application 2002/0113995, incorporated herein by reference, an office expense is tracked at the point on the computer or communication network where it occurs, such as a print server, copy machine, fax machine, etc. Using an asynchronous transport mechanism, data about the expense item is routed to the desktop of the user responsible for accounting or controlling the use or cost. Based on rules established in the software, the user is then prompted to allocate the expense to an accounting code, such as a project, client, department, etc.
[0006] An MFP is a unit of office equipment that functions as a photocopier, a networked printer, a fax machine and/or a scanner. It must be understood that any kind of equipment or job function is equivalently included, e.g. telephones, communications equipment, display, or information storage equipment without limitation. Although commonly referred to as “copiers,” MFPs are distinguished from traditional copiers by the variety of tasks they perform. Increasingly, MFP manufacturers (e.g. Canon, Ricoh, Konica-Minolta, Toshiba) are adding capabilities to their MFP products that allow third-party developers to embed and run the third-party software directly on-board the MFP.
[0007] MFP front panels usually resemble traditional copiers with a numeric keypad, a green “copy” button, and other items. In addition, most MFPs include a small computer-like screen as depicted in FIG. 1 . It is on this screen that third-party software routines run or are displayed.
[0008] Prior to the advent of embedded software capability on MFPs 10 as shown on FIG. 1 , the only way to track user activity on such a device for accounting purposes was to wire a hardware device into the accounting harness of the MFP 10 . The accounting harness allows a developer to:
a. Control access to the device (lock and unlock) b. Receive feedback as to the number of pages produced (count “clicks”)
[0011] Third party cost recovery vendors have historically produced hardware/software combinations to interact with the accounting harness and report back to a central database residing on a server.
[0012] Tracking MFP copy activity through the accounting harness is relatively costly, difficult and unsightly, as additional hardware must be purchased. Moreover, most accounting harnesses provide only minimal feedback and are often difficult to configure properly, sometimes requiring special engineering knowledge
[0013] Embedded MFP software allows cost recovery vendors to eliminate hardware and still provide cost accounting (“pure-software” tracking). This results in cost savings to customers and eliminates the need to install and house unsightly hardware components.
[0014] In order for pure-software tracking to be employed, the target MFP 10 must first provide the following:
a. A mechanism (“API”) for third-party vendors to develop and deploy proprietary software to the MFP. Most likely this software will run on the screen portion of the MFP front panel. b. A way for said third-party software to sufficiently conceal, disable or otherwise restrict user access to the MFP. c. Feedback to the third-party software during a copy operation, so that third-party software can count pages. Depending on the sophistication of the MFP 10 , additional feedback information may also be recorded (e.g. color vs. black/white, duplex vs. single-sided pages, etc.). Feedback may be provided by the same API described in paragraph “a,” above, via a separate API, or via the harness described above.
[0018] Most cost recovery vendors employ the same basic workflow in order to capture MFP activity: The conventional steps typically are:
a. User logs in. This can be via network username/password pair, or via a numeric code. b. User provides first-tier billing code (e.g. project, client, etc.) c. User provides second-tier billing code (e.g. phase, matter, etc.) d. User provides additional metadata (billable/non-billable, reason, etc.) e. Copier is unlocked f. User performs copy activity g. User logs out explicitly, or is automatically logged out after a predetermined period of inactivity. Copier is locked. h. Copy tracking hardware and/or software records copy job, consisting of user identification, billing information and metadata, and page count.
[0027] The prior art employs a “pre-billed” model, in which the user is expected to supply all accounting information (e.g. project/phase, client/matter, billable/non-billable) prior to performing work at the copier. Accounting questions are mandatory and responses must be valid in order to proceed. If the customer desires additional accounting information (department, overhead code, task number, etc.), then additional prompts are required.
[0028] Most prior art offers no mechanism for searching through lists of billing codes (project, client, etc), leaving the end user to memorize what are often lengthy numeric codes. Rather than helping the user through the process, most of the prior art simply notifies the user when responses are invalid with a prominent screen notice.
[0029] The pre-billed model found in prior art requires all accounting data is entered by the user before the MFP is unlocked. This model is self-enforcing in that users must respond to all questions (possibly inaccurately) in order to gain access to the MFP. Failure to respond to prompts, or failure to supply valid responses to prompts, results in denial of access to the equipment.
[0030] Cost recovery that employs the traditional workflow described above is highly unpopular. The number of mandatory steps, coupled with the absence of a search mechanism, frustrates end users. Many companies employ an “administrator override” billing code (e.g. “99999”). These override codes often become common knowledge, and users eventually use it in lieu of the correct billing code in order to avoid frustration and lost productivity.
BRIEF SUMMARY OF THE INVENTION
[0031] The illustrated embodiment of the invention is a method of accounting for job activity in a multifunctional device comprising the steps of: providing user identification information associated with use of the multifunctional device; performing a job through use of the multifunctional device without providing any billing information relating to the job; communicating unbilled job information to at least one remote user location associated with the user identification information, the unbilled job information relating to the performed job completed with the use of the multifunctional device and communicated through a computer network without employing any hardware modification of the multifunctional device; and inputting billing data relating to the unbilled job information at the least one remote user location.
[0032] The step of providing user identification information comprises the step of providing a network username/password pair, or a numeric code.
[0033] The step of providing user identification information further comprising the step of unlocking access to the multifunctional device and where the step of performing a job through use of the multifunctional device further comprises the step of logging out of the multifunctional device and locking access to the multifunctional device.
[0034] The step of inputting billing data relating to the unbilled job information at the least one remote user location comprises the step of inputting billing data into a single input screen.
[0035] The step of inputting billing data relating to the unbilled job information at the least one remote user location comprises the step of inputting billing data in parallel into a plurality of data input windows.
[0036] The step of inputting billing data relating to the unbilled job information at the least one remote user location comprises the step of inputting billing data into an input screen which is arranged and configured in at least one configuration according to administrator or user choice.
[0037] The step of inputting billing data in parallel into a plurality of data input windows comprises the step of inputting billing data in at least one input window is a drop-down window with a predetermined list of possible input entries.
[0038] The step of inputting billing data into an input screen which is arranged and configured in at least one configuration according to administrator or user choice comprises the step of selecting which data prompts are visible, which data prompts are required, what are acceptable values for each prompt, and/or what the name of the prompt is.
[0039] The step of inputting billing data relating to the unbilled job information at the least one remote user location comprises the step of inputting billing data for multiple activity types in a single user interface.
[0040] The step of inputting billing data in at least one input window which is a drop-down list with a predetermined list of possible input entries comprises the step of auto-complete searching the predetermined list of possible input entries.
[0041] The step of inputting billing data in at least one input window comprises the step of establishing administrator-set quotas.
[0042] The step of inputting billing data in at least one input window comprises the step of displaying a graphical icon in an unobtrusive location when a given user's unbilled activity count is below quota.
[0043] The step of inputting billing data relating to the unbilled job information in at least one remote user location comprises the step of displaying an input billing data screen topmost on the least one remote user location. The input billing data screen is displayed when the user's unbilled activity count meets or exceeds quota.
[0044] The step of inputting billing data relating to the unbilled job information in at least one remote user location comprises the step of displaying an immovable and unremovable input billing data screen in the center of or at least in a materially obstructive position on the computer screen.
[0045] The illustrated embodiment of the invention also comprises an apparatus or software controlled computer network for performing each of the various embodiments of the method of the invention.
[0046] While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112 are to be accorded full statutory equivalents under 35 USC 112. The invention can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 is a depiction of the input screen and panel of a multifunctional printer or device of the prior art with which the invention is employed.
[0048] FIG. 2 is a block diagram of a computer network in which the method of the invention is employed.
[0049] FIG. 3 is a graphic table illustrating the steps and screen displays employed when an embodiment of the method of the invention is performed.
[0050] FIG. 4 is the data billing client (DBC) screen display of the user's computer in one embodiment of the invention.
[0051] The invention and its various embodiments can now be better understood by turning to the following detailed description of the preferred embodiments which are presented as illustrated examples of the invention defined in the claims. It is expressly understood that the invention as defined by the claims may be broader than the illustrated embodiments described below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0052] The illustrated embodiment a fundamentally different workflow from that described in the prior art. For example, the method of the illustrated embodiment comprises the steps of:
a. At step 20 in FIG. 3 a user logs into server 16 via network 18 as depicted in the block diagram of FIG. 2 . This can be via network username/password pair, or via a numeric code. b. The copier or MFP 10 is unlocked. c. At step 22 in FIG. 3 the user performs copy or job activity at MFP 10 controlling the job functions according to the device protocols. d. The user logs out explicitly on site, or is automatically logged out after a predetermined period of inactivity. Copier or MFP 10 is locked. e. At step 24 of FIG. 3 information about the unbilled MFP activity (e.g. user ID, equipment ID, page count) is routed to the responsible user's desktop 14 via a message queue in server 16 as described in U.S. Patent Application 2002/0113995. f. Upon returning to his desktop computer 14 , the user is presented with a billing interface in step 24 , in which he or she provides accounting information in one or more input fields on a single screen. Additional or fewer input screens or drop down input lists and fields could be included, if needed.
[0059] Hence, the illustrated embodiment of the invention is described as “embedded copy tracking with deferred remote billing.” The illustrated embodiment is best understood by comparison with the traditional prior method as summarized in Table 1.
[0000]
TABLE 1
Traditional
Illustrated Embodiment
User logs in. This can be via network
User logs in. This can be via
username/password pair, or via a
network username/password
numeric code.
pair, or via a numeric code.
User provides first-tier billing code (e.g.
project, client, etc.)
User provides second-tier billing code
(e.g. phase, matter, etc.)
User provides additional metadata
(billable/non-billable, reason, etc.)
Copier is unlocked
Copier is unlocked
User performs copy activity
User performs copy activity
User logs out explicitly, or is
User logs out explicitly, or is
automatically logged out after a
automatically logged out after a
predetermined period of inactivity.
predetermined period of
Copier is locked.
inactivity. Copier is locked.
Copy tracking hardware and/or
Upon returning to his desktop
software records copy job, consisting of
computer, user is presented
user identification, billing information
with a billing interface, in which
and metadata, and page count
he provides accounting
information in a single screen
[0060] In contrast to the “hostage” and “quarantine” enforcement methods described above, the present invention is employed in the system of U.S. Patent Application 2002/0113995, which may be termed a “nag” enforcement method. This enforcement method allows the job to pass unhindered from the client computer to the server, and then to the device where the job is performed.
[0061] A quota, defined by a system administrator, determines how many unbilled jobs can exist for a given user before a mandatory billing interface is displayed. While a given user's unbilled job count is below the quota, the user may recall the billing interface at his or her discretion. The user may thus delay the entry of the required billing information to a convenient time, but cannot avoid entering the information and cannot indefinitely delay the entry of the information to a point where the user may no longer recall the pertinent information. Enforcement is preferably accomplished once the quota is reached by obscuring the computer screen with the billing interface, which cannot be removed or moved. Though other processes on the client computer are not interrupted, the user is essentially unable to use the computer without sufficiently addressing, then dismissing, the billing interface.
[0062] Many of the advantages flow from the separation of detection (phase 1) and billing (phase 2) of print activity, and the use of a quota-based message queue between the separate phases. The “nag” system allows native print processes to flow undisturbed by the requirement to enter billing information. Decoupling detection and billing eliminates onerous enforcement techniques typical of the prior art. It should be noted that in the asynchronous embodiment, the act of writing data about a job to a database preferably takes place when the billing data is supplied; this contrasts with some systems in which the writing of data may or may not occur at or near the time when the job information is extracted and stored. In the asynchronous model, the moment that the factual information concerning a job is extracted it is recorded in a message queue. The user is then prompted to supply additional billing information.
[0063] The nag system is based on the view that job should remain a native process, and takes a “hands-off-the-job-process” approach that makes few if any modifications to the process of performing the job. Thus at the core of the system is an intention to impose the fewest restrictions upon users while maintaining a reliable record of job events for cost allocation and recoupment.
[0064] Consider now the user interface at the desktop 14 . When a user logs in at step 20 in FIG. 3 , that user becomes identified on the computer network 18 . A Desktop Billing Client (DBC) 26 as shown in FIG. 4 is displayed on the screen or display of the computer(s) 14 where the identified user is logged in. DBC 26 is generated by software resident on user computer 14 and is controlled by client billing software modules in server 16 where a cost accounting database is being assembled as described in greater detail in U.S. Patent Application 2002/0113995. The DBC 26 prompts the user to supply accounting information as defined by a system administrator. Unlike the prior art workflow, described above, in which accounting data is entered serially through a sequence of on-screen pages at the MFP, the DBC 26 prompts for all required values in parallel as depicted in the screen display of FIG. 2 . In other words, the billing data may be input, corrected and re-input in any order into the windows 30 - 36 in any order. In the illustrated embodiment unbilled jobs appear in window 28 as collected by server 16 for user desktop 14 . The client or job to be billed is entered by the user into window 30 , the matter or sub-job to be billed in window 32 , the status of the billed charged into window 34 and other comments into window 36 . Windows 30 - 34 are drop down windows as indicated by the down arrow in the right end of the window so that only approved inputs are possible for input. When all the data is entered and deemed correct by the user, the record button 38 is clicked. A help button 40 is provided for assistance whenever needed. It must be understood that the DBC 26 of FIG. 3 is illustrative only and that many other arrangements and inputs could be provided without departing from the scope of the invention.
[0065] The various prompts on the DBC 26 are configured by an administrator. Configurable elements illustratively include:
a. Which data prompts are visible? b. Which data prompts are required? c. What are acceptable values for each prompt? d. What is the name of the prompt (e.g. “Client/Matter”, “Project/Phase”)
[0070] The illustrated embodiment of the invention allows the end user to provide accounting data for a variety of different types of activity. DBC 26 can be arranged and configured by the administrator in a wide variety of ways to meet the accounting needs of the specific situation, including having a different configuration and/or inputs possible for different clients and matters. FIG. 4 , for example, illustrates the DBC 26 prompting the user to account for both an MFP copy job of 80 pages and a subsequent computer print job of 4 pages. The DBC 26 can prompt users from a variety of activities, including:
[0071] a. Print
[0072] b. Copy
[0073] c. Scan
[0074] d. Fax
[0075] e. Three-dimensional printers
[0076] f. Laser cutters
[0077] g. Telephone calls
[0078] h. Computer disk drive storage
[0079] i. Employee time
[0080] This list is not exhaustive and may be arbitrarily altered or expanded to meet the needs of the user's situation, not only in an office, but in any type of setting including order fulfillment, warehousing, manufacturing, routing and other job situations without limitation. No other prior art system supports multiple activity types in a single user interface.
[0081] Certain required information (e.g. billing codes, sub-codes, status) are displayed to the user as “dropdown lists” on windows 30 - 34 . A dropdown list is a user interface element found in computer software that eliminates the possibility of selecting an item not in a predefined list. Hence, unlike the scenario, where a user has supplied an invalid response and receives only a prominent screen notice of invalid entry, the DBC 26 does not allow the user into such a state.
[0082] Further, the primary billing code dropdown list in the DBC 26 implements an “auto-complete” search. In this mechanism, a user is permitted to type letters or numbers into the user interface, and the dropdown list nearly instantly locates the first item matching the typed letters.
[0083] Because the present invention does not require accounting data beforehand, but rather allows users to perform work on the MFP 10 with only one piece of information (a user login), some other enforcement mechanism must be provided to insure proper accounting data input. The DBC 26 enforces the accounting rules at the user's desktop computer 14 by remaining topmost, meaning that it conceals some or all of any other software applications running on the screen. The DBC 26 obscures a sufficient amount of the computer desktop screen to impede use of the computer 14 without first responding to the required prompts of the DBC 26 . Further, the DBC software window cannot be moved to a different location on the screen, closed or dismissed.
[0084] The ability to control MFP access through a single prompt (user ID) and then complete accounting at the user's desktop or from another computer coupled to the network is not available from any known system.
[0085] The illustrated embodiment of the invention significantly improves on the prior art by introducing a system that minimizes memorization and user intervention at the point of work, leading to a smoother workflow and a more user friendly experience. Subsequently, accountability is maintained through a desktop component that at once enforces the system and also prompts the user for required information in parallel.
[0086] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following invention and its various embodiments.
[0087] Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations. A teaching that two elements are combined in a claimed combination is further to be understood as also allowing for a claimed combination in which the two elements are not combined with each other, but may be used alone or combined in other combinations. The excision of any disclosed element of the invention is explicitly contemplated as within the scope of the invention.
[0088] The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.
[0089] The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
[0090] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
[0091] The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptionally equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention. | A method of accounting for job activity in a multifunctional device comprises the steps of: providing user identification information associated with use of the multifunctional device; performing a job through use of the multifunctional device without providing any billing information relating to the job; communicating unbilled job information to at least one remote user location associated with the user identification information, the unbilled job information relating to the performed job completed with the use of the multifunctional device and communicated through a computer network without employing any hardware modification of the multifunctional device; and inputting billing data relating to the unbilled job information at the least one remote user location. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to a ferroelectric thin film and a method for producing the same and relates particularly to a ferroelectric thin film formed on a substrate and a method for producing the same.
BACKGROUND ART
[0002] Conventionally, for an electromechanical transducer for a driving device, a sensor, or the like, a piezoelectric body such as PZT (lead zirconate titanate) is used. Furthermore, in recent years, in response to demands such as for size reduction, an increased packaging density, and cost reduction of apparatuses, there has been an increased use of a MEMS (micro-electro-mechanical systems) device using a Si substrate. In order to apply a piezoelectric body to a MEMS device, it is desirable that the piezoelectric body be reduced in thickness.
[0003] By such thickness reduction, high-precision processing using a semiconductor process technology such as film formation or photolithography is enabled, and thus size reduction and an increased packaging density can be realized. Furthermore, devices can be collectively processed so as to achieve a high packaging density on a large-area wafer, and thus cost reduction can be achieved. Moreover, mechanoelectrical transduction efficiency is improved, and thus there are provided advantages such as improvements in property of a driving device and in sensitivity of a sensor.
[0004] For example, in a case of a thermal sensor, having a MEMS configuration, it is reduced in thermal conductance, so that a measurement sensitivity thereof can be increased, and in a case of an ink-jet head for a printer, nozzles thereof are provided at an increased packaging density, so that high-definition patterning can be performed.
[0005] As a method for forming a film of a piezoelectric body such as PZT on a substrate such as of Si (silicon), there are known chemical methods such as CVD, physical methods such as sputtering and ion plating, and liquid phase growth methods such as a sol-gel method. A film of PZT thus formed exhibits an excellent piezoelectric effect when crystals thereof have a perovskite structure.
[0006] A PZT film formed on an electrode on a Si substrate has, due to a difference in lattice constant from that of crystals of the electrode, a polycrystalline structure in which a plurality of crystals assemble together in the form of columns. It is known that the more of such columnar crystals are grown on the same crystal face in a film thickness direction (the higher an orientation characteristic is), the higher a piezoelectric property of the film is.
[0007] Recent years have seen a demand for a further improved property of a piezoelectric film such as of PZT. As one measure to obtain such an improved piezoelectric property, an impurity is added so that a relative dielectric constant and a piezoelectric property are improved. It is known that, particularly, (Pb 1-X La X )(Zr Y Ti 1-Y ) 1-X/4 O 3 (hereinafter, referred to as PLZT), a substance obtained by substituting Pb located at an A site in a piezoelectric body having a perovskite structure (which is ideally a crystalline structure having a unit cell of a cubic system and composed of a metal A located at each vertex of a cubic crystal, a metal B located at a body center, and oxygen O located at each face center of the cubic crystal, and encompasses distorted cubic crystals such as a tetragonal crystal, an orthorhombic crystal, and a rhombohedral crystal) with La (lanthanum) that is an element having a valence number one number higher than that of Pb has a high relative dielectric constant and a high piezoelectric constant.
[0008] For example, a non-patent document 1 discloses that, in PLZT in the form of bulk ceramics, with a predetermined La added amount (for example, 8%) and a Zr/Ti ratio of 60/40 therein, a high piezoelectric property is obtained.
[0009] In a case, however, where an attempt is made to obtain a thin film of PLZT by film formation, resulting PLZT in the form of a thin film is poorer in crystallinity as compared with PZT and does not provide such a high property as is obtained when in the form of bulk ceramics.
[0010] As a solution to this, a patent document 1 discloses a technique in which a PLT layer free of Zr is formed, and a PLZT layer is formed on the PLT layer. In this technique, by using the PLT layer having good crystallinity as an undercoating layer, crystallinity of PLZT can be improved. Furthermore, a patent document 2 discloses a technique in which, in order to alleviate a lattice mismatch between a buffer layer as a base and a piezoelectric layer main body (PZT), a stepped layer composed of a plurality of layers whose compositions vary in a stepwise manner is provided between them. In this stepped layer, a ratio of Zr/Ti (molar ratio) of each of the layers constituting the stepped layer gradually decreases or increases with increasing distance from the buffer layer in a thickness direction.
LIST OF CITATIONS
Patent Literature
[0011] Patent Document 1: JP-A-H 6-290983
[0012] Patent Document 2: JP-A-2007-42984
Non-patent Literature
[0013] Non-patent Document 1: Gene H. Heartling “Ferroelectric Ceramics: History and Technology”, Journal of American Ceramic Society, 82[4]797-818(1999)
SUMMARY OF THE INVENTION
Technical Problem
[0014] In the configuration described in the patent document 1, however, being originally low in piezoelectric property, PLT forming the undercoating layer is not suitable for use to improve a piezoelectric property of a piezoelectric film as a whole. Furthermore, the patent document 2 is to obtain a crystal of PZT reduced in degree of distortion by alleviating a lattice mismatch with the buffer layer and makes no reference to crystallinity of PLZT.
[0015] In view of the above-described problems, it is an object of the present invention to provide a ferroelectric thin film that is a thin film of a ferroelectric body formed with good crystallinity and exhibits a high piezoelectric property, and a method for producing the ferroelectric thin film.
Solution to the Problem
[0016] In order to achieve the above-described object, the present invention provides a ferroelectric thin film that is a film of a dielectric material having a perovskite structure formed on a base body. The dielectric material is made of a composite oxide obtained by adding, as an additive, a metal material other than Pb, Zr, and Ti to PZT. The thin film includes layers different in Zr/Ti ratio, which are a first layer that has a small compounding percentage of Zr and is formed on the base body and a second layer that has a large compounding percentage of Zr and is formed on the first layer.
[0017] According to this configuration, even in a case of using a dielectric material that varies in level of crystallinity and in piezoelectric property depending on a compounding concentration of an additive, the following is achieved. That is, since a compounding percentage of Zr smaller than a predetermined percentage provides excellent crystallinity and a compounding percentage of Zr as large as the predetermined percentage allows an excellent piezoelectric property to be exhibited, by forming, in combination, a first layer having such a compounding percentage that excellent crystallinity is obtained and a second layer having such a compounding percentage that a high piezoelectric property is obtained, a ferroelectric thin film of a predetermined thickness that exhibits a predetermined piezoelectric property can be formed with good crystallinity. That is, it is possible to obtain a ferroelectric thin film that is a thin film of a ferroelectric body formed with good crystallinity on a base body obtained by forming a lower electrode layer on a substrate, and exhibits a high piezoelectric property.
[0018] Furthermore, the present invention provides a method for producing the ferroelectric thin film configured as above, which includes a piezoelectric film formation step that uses a sputtering-type film forming apparatus that forms a film on a base body by using a dielectric material as a target material and in which, as the target material, target materials having different predetermined values of a Zr/Ti ratio are used to form the first layer on the base body and the second layer on said first layer.
[0019] According to this configuration, film formation is performed by using a target material having such a Zr/Ti ratio that excellent crystallinity is obtained and a target material having such a Zr/Ti ratio that an excellent piezoelectric property is obtained, and thus a film that exhibits a predetermined piezoelectric property can be formed to a predetermined thickness without deterioration in crystallinity, so that it is possible to obtain a method for producing a ferroelectric thin film that is a thin film of a ferroelectric body of a predetermined thickness formed with good crystallinity on a substrate and exhibits a high piezoelectric property.
Advantageous Effects of the Invention
[0020] According to the present invention, it is possible to obtain a ferroelectric thin film that is a thin film of a ferroelectric body formed with good crystallinity and exhibits a high piezoelectric property, and a method for producing the same.
BRIEF DESCRIPTION OF DRAWINGS
[0021] [ FIG. 1 ] is a sectional view showing a layer configuration of a piezoelectric device including a ferroelectric thin film according to the present invention.
[0022] [ FIG. 2 ] is an explanatory view schematically showing a crystalline structure of a ferroelectric body.
[0023] [ FIG. 3 ] is a schematic explanatory view showing a configuration of a film forming apparatus.
[0024] [ FIG. 4 ] is an explanatory view showing a film formation flow having a sequential film formation step together with sectional views corresponding to respective production steps.
[0025] [ FIG. 5 ] is a sectional view showing a crystalline state of a piezoelectric film obtained by the film formation flow shown in FIG. 4 .
[0026] [ FIG. 6 ] is an explanatory view showing a film formation flow having a repetitive film formation step together with sectional views corresponding to respective production steps.
[0027] [ FIG. 7A ] is a graph showing dependence of a Zr/Ti ratio with respect to crystallinity of PLZT.
[0028] [ FIG. 7B ] is a graph showing dependence of a Zr/Ti ratio with respect to crystallinity of PLZT.
[0029] [ FIG. 7C ] is a graph showing dependence of a Zr/Ti ratio with respect to crystallinity of PZT.
[0030] [ FIG. 8A ] is a plan view showing a configuration in which the above-described piezoelectric device is applied to a diaphragm.
[0031] [ FIG. 8B ] is a sectional view taken along a line VIIIB-VIIIB of FIG. 8A .
[0032] [ FIG. 9 ] is a table showing piezoelectric properties of PLZT.
DESCRIPTION OF EMBODIMENTS
[0033] Hereinafter, an embodiment of the present invention will be described with reference to the appended drawings. Furthermore, in the following, like constituent members are denoted by like reference symbols, and detailed descriptions thereof are omitted where appropriate.
[0034] With reference to FIG. 1 , a description is given of a ferroelectric thin film according to this embodiment. FIG. 1 is a sectional schematic view showing a layer configuration of a piezoelectric device including a ferroelectric thin film L 4 , in which a silicon substrate B 1 is used as a substrate, and thereon, a thermally oxidized film (SiO 2 layer) L 1 , a Ti film L 2 , a Pt film L 3 , the ferroelectric thin film L 4 , a Ti film L 5 , and an Au film L 6 are formed in this order.
[0035] The substrate B 1 has a thickness that varies depending on a substrate size (diameter) and is, for example, about 400 to 700 μm. For the purposes of protection and insulation of the substrate B 1 , the thermally oxidized film L 1 is formed by heating the substrate B 1 at about 800 to 1300° C. in an oxygen atmosphere and has a thickness of, for example, about 0.1 μm.
[0036] The Ti film L 2 and the Pt film L 3 are formed in this order by sputtering on the thermally oxidized film L 1 and together constitute a lower electrode layer D 1 . Ti is intended to improve adhesion between SiO 2 and Pt and has a film thickness of, for example, about 0.02 μm. Furthermore, Pt has a thickness of, for example, about 0.1 μm. Materials of the lower electrode layer D 1 are not limited to the above, and, for example, Ir may be used in place of Pt.
[0037] The ferroelectric thin film L 4 is made of PLZT having a perovskite structure including Zr and Ti. The ferroelectric thin film L 4 is formed by sputtering on the lower electrode layer D 1 and has a thickness that varies depending on an intended use thereof and is, preferably, for example, not more than 1 μm for a sensor or a filter and about 3 to 5 μm for an actuator. For this reason, in this embodiment in which an intended application is a driving device for a MEMS actuator, the ferroelectric thin film L 4 is set to be 4 to 5 μm thick. A method for forming the ferroelectric thin film L 4 will be described later in more detail.
[0038] Subsequently, on the ferroelectric thin film L 4 , the Ti film L 5 and the Au film L 6 are formed in this order by sputtering to form an upper electrode layer D 2 . Ti is intended to improve adhesion between PLZT and Au and has a film thickness of, for example, about 0.02 μm. Furthermore, Au has a thickness of, for example, about 0.1 μm.
[0039] The ferroelectric thin film L 4 is made of a composite oxide of multiple elements, such as PLZT having a perovskite structure shown in FIG. 2 . In this embodiment, the ferroelectric thin film L 4 is formed by using a dielectric material that is obtained by adding a predetermined amount of La (lanthanum) to PZT.
[0040] A perovskite structure is, for example, a ternary crystalline structure referred to as ABO 3 , which is shown in the figure. Herein, PLZT, a substance obtained by substituting Pb located at an A site with La (lanthanum) that is an element having a valence number one number higher than that of Pb has a high relative dielectric constant and a high piezoelectric constant.
[0041] As described above, by adding an additive (metal material) other than Pb, Zr, and Ti constituting. PZT at a predetermined concentration to PZT used as a piezoelectric body, a high piezoelectric property is exhibited, and thus, in this embodiment, the ferroelectric thin film L 4 is configured by forming a film of a dielectric material made of a composite oxide of multiple elements, which is obtained by adding La to PZT, on a base body (composed of the substrate B 1 and the lower electrode layer D 1 formed on the substrate B 1 ). Furthermore, the ferroelectric thin film L 4 is configured to have a compounding percentage of each of Zr and Ti (Zr/Ti ratio) varying in a thickness direction of the thin film.
[0042] This is because, when an additive is added to PZT, the smaller a compounding percentage of Zr is, the better resulting crystallinity is, so that a perovskite structure is maintained. Based on this, the ferroelectric thin film L 4 is formed so as to have a compounding percentage of Zr varying in the thickness direction of the film, and thus the ferroelectric thin film L 4 having a high piezoelectric property can be formed without a decrease in crystallinity.
[0043] Furthermore, since it is known that, when a film is formed on an undercoating layer, if the undercoating layer has excellent crystallinity, the film formed thereon is improved in crystallinity, preferably, an undercoating layer on which a ferroelectric thin film containing an additive at a predetermined concentration is formed has excellent crystallinity.
[0044] Next, with reference to FIG. 3 , a description is given of one example of a film forming apparatus that forms the ferroelectric thin film L 4 according to this embodiment. A film forming apparatus 10 is a sputtering-type film forming apparatus, and on a substrate B 1 (for example, a silicon substrate) installed in the film forming apparatus, a layer of a predetermined material is formed by high-frequency magnetron sputtering.
[0045] The film forming apparatus 10 includes, in a vacuum chamber 11 , a substrate heater 12 on which the substrate B 1 is installed and that heats the substrate B 1 , and is provided with an introduction duct 13 for introducing argon (Ar) as a sputtering gas, an introduction duct 14 for introducing oxygen, and an exhaust duct 15 . T 1 and T 2 each denote a PLZT target made of elements Pb, La, Zr, Ti, and O, and the targets T 1 and T 2 have respective predetermined dielectric material ratios (for example, predetermined Zr/Ti ratios). Furthermore, each of M 1 and M 2 denotes a magnet, each of CT 1 and CT 2 denotes a cathode electrode, and each of K 1 and K 2 denotes a high-frequency power source.
[0046] Each of the targets T 1 and T 2 is manufactured in the following manner. That is, powdered materials of PLZT prepared to have a predetermined composition ratio are blended, fired, and pulverized, after which they are filled in a target tray and pressed with a pressing machine.
[0047] Then, the targets T 1 and T 2 are installed on the magnets M 1 and M 2 , respectively. Furthermore, a cover may be placed on each the targets T 1 and T 2 . The magnets M 1 and M 2 and the cathode electrodes CT 1 and CT 2 provided below them, respectively, are insulated from the vacuum chamber 11 by an insulator. Furthermore, the cathode electrodes CT 1 and CT 2 are connected to the high-frequency power sources K 1 and K 2 , respectively.
[0048] Next, the substrate Bl is installed on the substrate heater 12 . Then, air in the vacuum chamber 11 is exhausted therefrom, and the substrate B 1 is heated to 600° C. by the substrate heater 12 . After the heating, valves 13 a and 14 a are opened so that Ar as a sputtering gas and O 2 are introduced at a predetermined ratio into the vacuum chamber 11 through the introduction ducts, and a degree of vacuum is maintained at a predetermined value. From the high-frequency power sources K 1 and K 2 , high-frequency power is supplied to the targets T 1 and T 2 , respectively, so that plasma is generated. At this time, a film formation rate can be adjusted in accordance with a set value regarding high-frequency power, and thus by adjusting high-frequency power to be supplied to each of the targets T 1 and T 2 , concentrations of elements in a PLZT film, namely, compounding concentrations of dielectric materials can be adjusted. Furthermore, shutters SH 1 and SH 2 are opened and closed independently of each other, and thus each of PLZT of the target T 1 and PLZT of the target T 2 can be formed as required on the substrate, i.e. on the base body.
[0049] As described above, a plurality of types of targets different in Zr/Ti ratio are mounted, and thus films originating from the targets can be formed sequentially and concurrently.
[0050] Furthermore, various studies on crystallinity of a thin film of PLZT obtained by adding La (lanthanum) to PZT have found that perovskite crystallinity thereof is poorer on a Zr-rich side and more excellent on a Ti-rich side. In this connection, with reference to FIGS. 7A to 7C , a description is given of actually measured dependence of a Zr/Ti ratio with respect to perovskite crystallinity. Herein, FIG. 7A is a graph showing dependence of a Zr/Ti ratio with respect to crystallinity of PLZT in a case where an La added amount is 7.5%, FIG. 7B is a graph showing dependence of a Zr/Ti ratio with respect to crystallinity of PLZT in a case where an La added amount is 3.3%, and FIG. 7C is a graph showing dependence of a Zr/Ti ratio with respect to crystallinity of PZT in a case where an La added amount is 0%.
[0051] Crystallinity was determined by a conventional known method in which a (θ-2θ) measurement was performed with respect to each of thin films by using an X-ray diffractometer. Furthermore, a peak intensity representing a perovskite structure oriented in a (111) direction is normalized assuming that a value thereof at a maximum value of a Zr/(Zr+Ti) ratio is 1. For the sake of comparison of the peak intensity, all the thin films are set to have a fixed film thickness (60 nm), and as for their orientations, almost no perovskite peaks other than a (111) peak are observed.
[0052] As is understood from FIG. 7A showing a peak intensity ratio in the case where the La added amount is 7.5%, in this case, a portion of the thin film where a Zr compounding percentage is 53% is a crystallinity level boundary portion. That is, it has been found that, with respect to a portion where the Zr/Ti ratio=53:47 as a boundary, excellent crystallinity is obtained in a region of the thin film where the Zr compounding percentage is lower than in this portion. In other words, it has been found that a region of the thin film where the Zr compounding percentage is not more than 53% is a region where excellent crystallinity is obtained.
[0053] Furthermore, in the case where the La added amount is 3.3%, it is understood from a measurement result of a peak intensity ratio shown in FIG. 7B that excellent crystallinity is obtained in a region of the thin film where a Zr compounding percentage is lower than 58 to 59%.
[0054] As described above, it has been revealed that, when La is added to PZT, there exists a predetermined first compounding ratio defining a crystallinity level boundary portion. For example, in a case where an La added amount is 7.5% at which an excellent piezoelectric property is exhibited, the first compounding ratio is a compounding ratio (Zr/Ti ratio=53:47) with a Zr compounding percentage of about 53%.
[0055] Furthermore, it is understood that in the case where the La added amount is 7.5%, the peak intensity varies to a greater degree than in the case where the La added amount is 3.3%. Hence, an increase in amount of an additive leads to an increase in influence of a Zr/Ti ratio, which necessitates a film formation step placing increased emphasis on the predetermined first compounding ratio defining a crystallinity level boundary portion. That is, it is understood that, in order to form a film of PLZT with good crystallinity, preferably, a first layer formed on the base body has a Zr compounding percentage of not more than 53% (0<Zr≦53%).
[0056] As described earlier, since it is known that, when formed on an undercoating layer having good crystallinity, thin films of any types are improved in crystallinity as long as they are similar in their crystalline structures, by providing a first layer having excellent perovskite crystallinity, it becomes possible to easily form a second layer that exhibits an excellent piezoelectric property, so that there can be formed a ferroelectric thin film that, as a whole, exhibits a predetermined piezoelectric property.
[0057] In the case where the La added amount is 0%, which is shown in FIG. 7C , no variation occurs in peak intensity of crystallinity. Thus, in PZT with no La added thereto, making a compounding percentage of Zr vary also allows substantially similar crystallinity to be obtained. When, however, an additive is added in order to obtain an improved piezoelectric property, preferably, a first layer having a Zr compounding percentage lower than the predetermined first compounding ratio defining a crystallinity level boundary portion is provided, and a second layer having such a Zr compounding percentage that an excellent piezoelectric property is exhibited is formed thereon. Thus, preferably, on a first layer having a small compounding percentage of Zr, a second layer having a large compounding percentage of Zr is stacked.
[0058] In a case of PLZT, a value of a Zr/Ti ratio representing a MPB (morphotropic phase boundary) composition providing a high piezoelectric property is generally larger than 52% and up to a maximum of around 65%. Furthermore, an increase in Zr/Ti ratio (an increase in compounding percentage of Zr) might lead to deterioration in crystallinity. According to this embodiment, however, a ferroelectric thin film having a high piezoelectric property can be stably formed without deterioration in crystallinity.
[0059] Since, with the Zr/Ti ratio having such a value that a high piezoelectric property is obtained, Zr is contained at about 65% at the maximum, preferably, in forming the second layer that exhibits an excellent piezoelectric property, the second layer is set to have a compounding ratio of Zr of about 60 to 65%. That is, preferably, there is used a target manufactured at a predetermined second compounding ratio with such a large compounding percentage of Zr that a predetermined piezoelectric property is exhibited.
[0060] For this reason, this embodiment adopts a method for producing a ferroelectric thin film, which includes a piezoelectric film formation step in which, in the aforementioned film forming apparatus 10 , as PLZT target materials, there are used a target material having such a small Zr compounding percentage that excellent crystallinity is obtained and a target material having such a large Zr compounding percentage that a predetermined piezoelectric property is exhibited, namely, target materials having different predetermined values of a Zr/Ti ratio, and on a first layer having a small compounding percentage of Zr, a second layer having a large compounding percentage of Zr is stacked.
[0061] For example, a first PZT target having a Zr compounding percentage of 50% (a Zr/Ti ratio of 50:50) and a second PZT target having a Zr compounding percentage of 60% (a Zr/Ti ratio of 60:40) are prepared and installed on the magnets, respectively. Furthermore, with respect to the first and second PZT targets, the aforementioned cathode electrodes and the high-frequency power sources are installed, respectively. Then, from the high-frequency power sources, high-frequency power is supplied to the predetermined targets, respectively, so that films are formed. By controlling an input value or an input time period regarding the high-frequency power, i.e. by adjusting a film formation rate in accordance with a set value regarding the high-frequency power, each of the films can be formed as required to a predetermined thickness on the substrate.
Example 1
[0062] FIG. 4 shows a film formation flow of Example 1. In Example 1, by using a silicon substrate as a substrate and La as an additive, there is formed a thin film of PLZT that is a composite oxide obtained by adding La to PZT. Furthermore, the film formation flow includes a piezoelectric film formation step in which, by using two types of PLZT targets different in Zr compounding percentage, a first layer having a small compounding percentage of Zr and a second layer having a large compounding percentage of Zr are stacked on each other in a layer stacking direction.
[0063] That is, the piezoelectric film formation step in Example 1 is a sequential film formation step, and this film formation flow is a first film formation flow representing a method for producing a ferroelectric thin film including a piezoelectric film of PLZT obtained by adding La to PZT.
[0064] As shown in FIG. 4 , upon a start of a film formation process of Example 1, first, a thermally oxidized film formation step S 1 of forming a thermally oxidized film on the silicon substrate is executed, followed by execution of a lower electrode formation step S 2 of forming a lower electrode layer D 1 on the thermally oxidized film L 1 , after which a sequential film formation step is executed in which first piezoelectric film formation S 3 of forming a first PLZT layer 41 (first layer) by using a first PLZT target having a small compounding percentage of Zr and second piezoelectric film formation S 4 of forming a second PLZT layer 42 (second layer) by using a second PLZT target having a large compounding percentage of Zr are performed. After the first PLZT layer 41 and the second PLZT layer 42 are stacked on each other in this order to form a piezoelectric film (ferroelectric thin film L 4 A) of a predetermined film thickness, an upper electrode formation step S 5 of forming an upper electrode layer D 2 is performed.
[0065] On a monocrystalline Si wafer having a thickness of about 400 μm, a thermally oxidized film was formed to be 100 nm thick, and on this thermally oxidized film, a Ti adhesive layer (L 2 layer) having a thickness of about 20 nm was formed, on which a Pt electrode layer (L 3 layer) further was formed to be about 100 nm thick. Herein, as a material of the adhesive layer, TiOx may be used instead of Ti. The use of TiOx can prevent a phenomenon in which, when exposed to a high temperature at a later step, for example, at the step of forming a PLZT thin film, the material is diffused into the Pt film to cause hillocks, and can further prevent failures of a piezoelectric thin film such as a leakage current and deterioration in orientation characteristic.
[0066] This Si wafer with Pt (base body) is installed in the earlier described film forming apparatus 10 , and the film formation step is executed under predetermined conditions. Furthermore, respective composition ratios of the targets are set so that, when films originating therefrom are formed on the base body, the film formed by using the first PLZT target has a composition of (Pb 1-X La X )(Zr Y Ti 1-Y ) 1-X/4 O 3 X=0.075 (7.5%), y=0.5 (50%)), and the film formed by using the second PLZT target has a composition of (Pb 1-X La X )(Zr Y Ti 1-Y ) 1-X/4 O 3 (X=0.075 (7.5%), y=0.6 (60%)).
[0067] That is, the first layer formed on the base body is formed by using the first PLZT target having a compounding percentage of Zr smaller than the first compounding ratio defining a crystallinity level boundary portion, and the second layer formed on this first layer is formed by using the second PLZT target that has the second compounding ratio with such a large compounding percentage of Zr that a predetermined piezoelectric property is exhibited. Furthermore, it is likely that re-evaporation of Pb occurs at the time of high-temperature film formation, resulting in the formation of a thin film lacking in Pb. For this reason, preferably, a Pb content in a target depending on a film formation temperature is set to be increased by 10 to 30% with respect to (1-X).
[0068] Then, in the film forming apparatus, the first PLZT layer 41 was formed to be 50 nm (0.05 μm) thick, and subsequently, the second PLZT layer 42 was formed to be 4 μm thick. A thin film thus formed was examined by using an X-ray diffractometer, and as a result, it was confirmed that there was obtained a PLZT thin film composed only of a perovskite layer and oriented mainly in the direction of (111), thus having good crystallinity. By changing film quality of the Pt layer or PLZT film formation conditions, it is also possible to form this PLZT thin film so that it is oriented mainly in a direction of (100).
[0069] With reference to FIG. 5 , a description is given of a configuration of layers of a piezoelectric film (ferroelectric thin film) obtained by the above-described film formation process. As shown in the figure, the piezoelectric film (ferroelectric thin film L 4 A) formed on the lower electrode layer D 1 formed at the substrate B 1 is obtained by forming the second PLZT layer 42 (second layer) on the first PLZT layer 41 (first layer). Furthermore, since the second layer is crystallized on the first layer having excellent crystallinity, a polycrystalline state is brought about in which a plurality of crystal grains L 4 a assemble together in the form of columns, forming a structure in which small columnar crystals perpendicularly extending from the substrate and having a good orientation characteristic are arranged in a concentrated manner. A crystal grain boundary L 4 b is formed between every adjacent ones of the crystal grains L 4 a.
[0070] As described above, this film is a PLZT film having a compounding percentage of Zr varying in a thickness direction thereof as shown by different shading. In this case, preferably, a Zr compounding percentage in the vicinity of the surface of the film is small (not more than the aforementioned first compounding ratio) so that high crystallinity is exhibited, and it is therefore appropriate that the Zr compounding percentage be not more than 53% (0 to 53%) and preferably about 40 to 50% (50% in this embodiment). It has been revealed that, with this configuration adopted, a PLZT initial layer in the vicinity of a lower electrode is a perovskite single-phase film having good crystallinity, which has a composition ratio substantially equivalent to a composition of a target, and thus a PLZT film formed thereon so as to have an increased compounding percentage (60% in this embodiment) of Zr is crystallized in an excellent manner without deterioration in crystallinity, so that a piezoelectric film (ferroelectric thin film L 4 A) can be obtained that maintains an excellent piezoelectric property and exhibits a predetermined piezoelectric property even when it has a thickness t of not less than 4 μm.
[0071] According to the above-described method for producing a ferroelectric thin film, on a first layer having such a small Zr compounding percentage that excellent crystallinity is obtained, a piezoelectric film having a large Zr compounding percentage and thus exhibiting a predetermined piezoelectric property is stacked, so that there can be formed a ferroelectric thin film of a predetermined thickness that, as a whole, exhibits a predetermined piezoelectric property.
Example 2
[0072] FIG. 6 shows a film formation flow of Example 2. In Example 2, by using a silicon substrate as a substrate and La as an additive, there is formed a thin film of PLZT that is a composite oxide obtained by adding La to PZT. Furthermore, similarly to Example 1, the film formation flow includes a piezoelectric film formation step in which, by using two types of PLZT targets different in Zr compounding percentage, a first layer having a small compounding percentage of Zr and a second layer having a large compounding percentage of Zr are stacked on each other in a layer stacking direction. Example 2 is different from Example 1, however, in that the piezoelectric film formation step of this embodiment is not a sequential film formation step but a repetitive film formation step.
[0073] That is, in this embodiment, the first layer having a small compounding percentage of Zr and the second layer having a large compounding percentage of Zr are alternately and repetitively formed. In other words, the piezoelectric film formation step in Example 2 is a repetitive film formation step, and this film formation flow is a second film formation flow representing the method for producing a ferroelectric thin film including a piezoelectric film of PLZT obtained by adding La to PZT.
[0074] As shown in FIG. 6 , upon a start of a film formation process of Example 2, first, a thermally oxidized film formation step S 11 of forming a thermally oxidized film on the silicon substrate is executed, followed by execution of a lower electrode formation step S 12 of forming a lower electrode layer D 1 on the thermally oxidized film L 1 , after which first piezoelectric film formation S 13 of forming a first PLZT layer 41 (first layer) by using a first PLZT target having a small compounding percentage of Zr and second piezoelectric film formation S 14 of forming a second PLZT layer 42 (second layer) by using a second PLZT target having a large compounding percentage of Zr are performed. Moreover, a repetitive film formation step S 16 of sequentially and repetitively performing these steps S 13 and S 14 is executed a preset predetermined number of times. In this manner, the first PLZT layer 41 and the second PLZT layer 42 are repetitively and alternately formed to form a piezoelectric film (ferroelectric thin film L 4 B) of a predetermined film thickness, after which an upper electrode formation step S 17 of forming an upper electrode layer D 2 is performed.
[0075] As described above, the piezoelectric film formation step adopted in Example 2 is the repetitive film formation step S 16 in which film formation is performed by alternately and repetitively performing the first piezoelectric film formation step S 13 of forming the first layer having a small compounding percentage of Zr and the second piezoelectric film formation step S 14 of forming the second layer having a large compounding percentage of Zr. Furthermore, by adjusting the number of times this film formation is repetitively performed, a thickness of a piezoelectric film to be formed can be adjusted. At a repetition time number detection step S 15 of detecting that the film formation has been repetitively performed a predetermined number of times, it is detected that the predetermined number of times of repetition has been reached, after which an upper electrode formation step S 17 is executed.
[0076] For example, the first PLZT layer 41 is formed to be 50 nm (0.05 μm) thick, and then the second PLZT layer 42 is formed to be 1 μm thick. Thereafter, again, the first PLZT layer 41 is formed to be 50 nm (0.05 μm) thick, and then the second PLZT layer 42 is formed to be 1 μm thick. In this manner, the first PLZT layer 41 and the second PLZT layer 42 are sequentially and repetitively formed to be stacked on each other, and thus the ferroelectric thin film L 4 B of a predetermined thickness is produced.
[0077] That is, the ferroelectric thin film L 4 B has, on the second layer formed on the first layer, a stacked layer structure equivalent to a stacked layer structure composed of the first layer and the second layer.
[0078] Also by the ferroelectric thin film L 4 B produced in this manner, the following is achieved. That is, by forming, in combination, a first layer having a compounding percentage of Zr smaller than a predetermined percentage and thus having excellent crystallinity and a second layer having a compounding percentage of Zr as large as the predetermined percentage and thus exhibiting an excellent piezoelectric property, a ferroelectric thin film of a predetermined thickness that exhibits a predetermined piezoelectric property can be formed with good crystallinity.
[0079] With this configuration adopted, before a PLZT film having a large compounding percentage of Zr grows in film thickness to such an extent that crystallinity of a film is decreased, there is again provided an effect by an undercoating layer that is a PLZT layer having a small compounding percentage of Zr and thus having good crystallinity, so that a piezoelectric film (ferroelectric thin film) is formed so as to achieve a good orientation characterisitc and good crystallinity of a PLZT film. That is, according to this embodiment, it is possible to obtain the ferroelectric thin film L 4 B that is a thin film of a ferroelectric body of a predetermined thickness formed with good crystallinity on a base body and exhibits a high piezoelectric property, and a method for producing the same.
[0080] Furthermore, the ferroelectric thin film L 4 A of Example 1 and the ferroelectric thin film L 4 B of Example 2 are both formed to be able to exhibit a high piezoelectric property by addition of La thereto. In this case, La is contained preferably at such a compounding concentration that PLZT exhibits a high piezoelectric property, and thus, in this embodiment, an La compounding concentration is set to 7 to 8%.
[0081] Also in a case of adding an additive such as La, since a first layer formed on a base body preferably has such a compounding concentration of the additive that excellent crystallinity is obtained, preferably, layers different in compounding concentration of the additive are stacked on each other toward a thickness direction of a thin film so that a small additive compounding concentration providing excellent crystallinity and a large additive compounding concentration providing a high piezoelectric property are used in combination. As a method for forming a film so that a compounding concentration of an additive such as La therein varies, for example, as targets to be installed in the aforementioned film forming apparatus 10 , there are used a PZT target manufactured at a predetermined compounding ratio and a target containing La (for example, a target made of lanthanum oxide (La 2 O 3 )), and a film formation rate for each of the targets is adjusted so that an La compounding concentration and a film thickness can be controlled.
[0082] Furthermore, with the above-described configuration, it also is easy to set layers equal in Zr/Ti ratio to be different in additive concentration, and thus film formation can be performed in such a manner that a combination of a Zr/Ti ratio and a compounding concentration of an additive is suitably selected depending on whether a layer to be formed is required to have excellent crystallinity or an excellent piezoelectric property.
[0083] As described above, even in a case of using a dielectric material that varies in level of crystallinity and in piezoelectric property depending on a compounding concentration of an additive, by using, in combination, a compounding concentration providing excellent crystallinity and a compounding concentration providing a high piezoelectric property, it is possible to obtain a ferroelectric thin film that exhibits a predetermined piezoelectric property and is formed to a predetermined thickness without deterioration in crystallinity.
[0084] Furthermore, preferably, a compounding concentration of La is not more than 8%. The reason for setting an upper limit concentration of La to 8% is that, as indicated by piezoelectric properties of PLZT ( FIG. 9 shows a main part thereof) shown in Table III of the aforementioned non-patent document 1 “Gene H. Heartling ‘Ferroelectric Ceramics: History and Technology’, Journal of American Ceramic Society, 82[4]797-818(1999)”, PLZT 8/65/35 having a compounding concentration of 8% has a piezoelectric strain constant (d 33 ) of 682×10 −12 C/N, and PLZT 9/65/35 having a compounding concentration of 9% has a piezoelectric strain constant (d 33 ) of 0 C/N, which explains that 8% is appropriate as an upper limit concentration value.
<Regarding Application Example of Piezoelectric Device>
[0085] FIG. 8A is a plan view showing a configuration in which a piezoelectric device 20 including a ferroelectric thin film manufactured in this embodiment is applied to a diaphragm (vibration plate), and FIG. 8B is a sectional view taken along a line VIIIB-VIIIB of FIG. 8A . A ferroelectric thin film L 4 (piezoelectric film) is disposed on a substrate B 1 in each desired region thereof so as to be two-dimensionally staggered. In a region of the substrate B 1 corresponding to the each region in which the ferroelectric thin film L 4 is formed, a concave portion B 1 a is formed by cutting out a part of the substrate B 1 in a thickness direction thereof in a shape circular in section, leaving a thin plate-shaped region B 1 b at an upper portion of the concave portion B 1 a (a bottom portion side of the concave portion B 1 a ) in the substrate B 1 . A lower electrode layer D 1 and an upper electrode layer D 2 are connected to an external control circuit via unshown wiring.
[0086] By applying an electric signal from the control circuit to each of the lower electrode layer D 1 and the upper electrode layer D 2 sandwiching the predetermined ferroelectric thin film L 4 therebetween, it is possible to drive only the predetermined ferroelectric thin film L 4 . That is, when a predetermined electric field is applied to each of electrodes above and below the ferroelectric thin film L 4 , the ferroelectric thin film L 4 expands and contracts in a lateral direction, and due to a bimetal effect, the piezoelectric film L 4 and the region B 1 b of the substrate B 1 are curved up and down. By utilizing this, a gas or a liquid is filled in the concave portion B 1 a of the substrate B 1 , in which case the piezoelectric device 20 can be used as a pump.
[0087] Furthermore, by detecting a charge amount of the predetermined ferroelectric thin film L 4 via the lower electrode layer D 1 and the upper electrode layer D 2 , it is also possible to detect a deformation amount of the ferroelectric thin film L 4 . That is, when the ferroelectric thin film L 4 is caused to vibrate by sound waves or ultrasonic waves, due to an effect adverse to the above-described effect, an electric field is generated between the electrodes above and below the ferroelectric thin film L 4 , and, at this time, a magnitude of the electric field generated and a frequency of a detection signal are detected, which allows the piezoelectric device 20 to be used also as a sensor.
Other Embodiments
[0088] While the foregoing has described PLZT using La as an additive, an additive used in the present invention is not limited to La and can be any of other types of additives that can exhibit a piezoelectric property. For example, at an A site in a perovskite structure having an ABO 3 configuration, as an additive to be used as a substituent, at least one type of metal material selected from a group consisting of Ba, La, Sr, Bi, Li, Na, Ca, Cd, Mg, and K can be used. Furthermore, at a B site, at least one type of metal material selected from a group consisting of V, Nb, Ta, Cr, Mo, W, Mn, Sc, Co, Cu, In, Sn, Ga, Cd, Fe, and Ni can be used. Furthermore, additives may be contained at both the A site and the B site, respectively.
[0089] As described above, a part of Pb located at an A site of PZT is substituted with a predetermined additive and a part of Zr or Ti located at a B site is substituted with a predetermined additive, so that it is possible to obtain a ferroelectric thin film that exhibits a predetermined piezoelectric property.
[0090] As described above, according to the ferroelectric thin film of the present invention, even in a case of using a dielectric material that varies in level of crystallinity and in piezoelectric property depending on an compounding concentration of an additive, by forming, in combination, a first layer having a compounding percentage of Zr smaller than a predetermined percentage and thus having excellent crystallinity and a second layer having a compounding percentage of Zr as large as the predetermined percentage and thus exhibiting an excellent piezoelectric property, a ferroelectric thin film of a predetermined thickness that exhibits a predetermined piezoelectric property can be formed with good crystallinity.
[0091] That is, it is possible to obtain a ferroelectric thin film that is a thin film of a ferroelectric body of a predetermined thickness formed with good crystallinity on a base body and exhibits a high piezoelectric property.
[0092] This makes it possible to form a thick film for an actuator having a thickness of about 3 to 5 μm with good crystallinity, and thus there can be obtained a ferroelectric thin film that is usable as a driving device for a MEMS actuator.
[0093] Furthermore, according to the method for producing a ferroelectric thin film of the present invention, a first layer having a compounding percentage of Zr smaller than a predetermined percentage and thus having excellent crystallinity and a second layer having a compounding percentage of Zr as large as the predetermined percentage and thus exhibiting an excellent piezoelectric property are formed in combination, so that it is possible to produce a ferroelectric thin film that is a thin film of a ferroelectric body of a predetermined thickness formed with good crystallinity on a base body and exhibits a high piezoelectric property.
INDUSTRIAL APPLICABILITY
[0094] The present invention is applicable to various types of devices such as, for example, an ink-jet head, an ultrasonic sensor, an infrared sensor, and a frequency filter and applicable particularly to devices required to be reduced in size and in thickness.
LIST OF REFERENCE SYMBOLS
[0095] B 1 substrate (silicon substrate)
[0096] L 1 thermally oxidized film
[0097] D 1 lower electrode layer
[0098] D 2 upper electrode layer
[0099] L 4 ferroelectric thin film (piezoelectric film)
[0100] L 4 A ferroelectric thin film (formed by a sequential film formation step)
[0101] L 4 B ferroelectric thin film (formed by a repetitive film formation step)
[0102] S 3 first piezoelectric film formation (sequential film formation step)
[0103] S 4 second piezoelectric film formation (sequential film formation step)
[0104] S 16 repetitive film formation step
[0105] 10 film forming apparatus | In order to obtain a ferroelectric thin film having good crystallinity and realizing high piezoelectric properties, and a production method therefor, provided is a ferroelectric thin film constituting a dielectric material having a perovskite structure that comprises Zr and Ti formed on a substrate, wherein a layer having a Zr ratio that is smaller than a predetermined ratio and having good crystallinity and a layer that realizes good piezoelectric properties and has a Zr ratio that is about as great as the predetermined ratio are combined. A production method is also provided. | 8 |
BACKGROUND OF THE INVENTION
[0001] Cleaning compositions such as light duty cleaning compositions may be used for cleaning a variety of surfaces including animate and inanimate surfaces. Inanimate surfaces include hard surfaces of the sort found in kitchens and bathrooms from sinks and work surfaces to pans and dishes. Such cleaning compositions may be formulated in solid, liquid or gel form and are typically used in liquid form, for example as an aqueous liquid. The compositions generally contain one or more surfactants. Such surfactants may be non-ionic surfactants, anionic surfactants, cationic surfactants or amphoteric surfactants. Surfactants are surface active agents which tend to be amphiphilic molecules capable of interacting with soil to be cleaned from a surface to enable the surface to be cleaned. A wide variety of chemically different surfactants are known for such purposes.
[0002] It is known to provide compositions which are mixtures of different surfactants. However, it is difficult to predict what effect mixing surfactants may have because of a wide variation in the chemical structure of individual surfactants. Complexes between chemically different surfactants can give rise to compositions which are unstable and which may form precipitates, thereby rendering them useless for cleaning purposes.
[0003] The effectiveness of surfactant compositions in cleaning may be assessed by the effect of the surfactant on surface tension and by the ability of the surfactant to generate foam. Cleaning compositions which produce foam tend to be more effective than those which do not. It has been found that high surfactant concentrations in cleaning compositions result in effective cleaning and high foam. However, such compositions may have high production costs in view of the costs of the surfactants. In addition, rinsing of cleaned surfaces results in high concentrations of surfactant being disposed into drainage, which is undesirable in view of the potentially damaging effect on the environment.
[0004] There is therefore a need to provide cleaning compositions which are effective in cleaning, which produce good foam and which do so using lower total amounts of surfactant.
BRIEF SUMMARY OF THE INVENTION
[0005] In a first aspect, the invention provides a cleaning composition comprising a surfactant combination which comprises an amine oxide amphoteric surfactant; a first anionic surfactant comprising a poly(oxyalkylene) alkyl ether sulfate: and a second anionic surfactant comprising an alkyl ethoxy carboxylate.
[0006] It has been found that by using this surfactant combination, a cleaning composition may be produced which is effective in cleaning and has the ability to generate foam using lower amounts of total surfactant than previously used. Because lower total surfactant amounts provide the same cleaning performance this allows the development of cleaning compositions at lower cost. This also means that lower quantities of surfactants are disposed to drainage thereby reducing impact on the environment.
[0007] The amine oxide amphoteric surfactant may comprise an alkyl dimethyl amine oxide surfactant in which the alkyl group typically has from 8 to 18 carbon atoms. Optionally, the alkyl dimethyl amine oxide is lauryl dimethyl amine oxide, myristyl dimethyl amine oxide or a mixture thereof.
[0008] In certain embodiments, the amine oxide amphoteric surfactant is present in an amount of 2 to 20% by weight of the composition. In other embodiments, the amount is at least 2 up to 19, 18, 17, 16, 15, 14, 13, 12, 11, or 10 wt. %. In other embodiments, the amount is at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, or at least 10 up to 20 wt. %. In one embodiment, the amount is 5 to 15 wt. %.
[0009] The poly(oxyalkylene) alkyl ether sulfate may be a poly(oxyethylene) alkyl ether sulfate. The poly(oxyethylene) alkyl ether sulfate may have the following general formula: RO—(CH 2 —CH 2 —O) n —SO 3 —X + in which X + is a counterion such as ammonium and n is zero or an integer. The poly(oxyethylene) alkyl ether sulfate may be present as a mixture of poly(oxyethylene) alkyl ether sulfates with different values for n.
[0010] Optionally, the poly(oxyethylene) alkyl ether sulfate is ammonium poly(oxyethylene) lauryl ether sulfate. Optionally, the average ethoxy content of the poly(oxyethylene) alkyl ether sulfate is about 0.6/mole.
[0011] In certain embodiments, the poly(oxyalkylene) alkyl ether sulfate is present in an amount of 2 to 20% by weight of the composition. In other embodiments, the amount is at least 2 up to 19, 18, 17, 16, 15, 14, 13, 12, 11, or 10 wt. %. In other embodiments, the amount is at least 3, at least 4, at least 5, at least 6, at least 7, at least 8, at least 9, or at least 10 up to 20 wt. %. In one embodiment, the amount is 5 to 15 wt. %.
[0012] The alkyl ethoxycarboxylate may include an alkyl group having from 8 to 18 carbon atoms. The alkyl ethoxycarboxylate may be represented by the following general formula: RO—(CH 2 —CH 2 —O) m CH 2 CO 2 H in which m is zero or an integer. The alkyl ethoxycarboxylate may be present as a mixture of alkyl ethoxycarboxylates with different values for m and different R groups.
[0013] Optionally, the alkyl ethoxycarboxylate is lauryl ether carboxylic acid, myristyl ether carboxylic acid or a mixture thereof. Optionally, the average ethoxy content of the alkyl ethoxycarboxylate is more than 3/mole.
[0014] In certain embodiments, the alkyl ethoxycarboxylate is present in an amount of 1 to 15% by weight of the composition. In other embodiments, the amount is at least 1 up to 14, 13, 12, 11, 10, 9, 8, 7, or 6 wt. %. In other embodiment, the amount is at least 1, at least 2, at least 3, at least 4, or at least 5 up to 15 wt. %. In one embodiment, the amount is 1 to 5 wt. %. In one embodiment, the amount is 1 to 2 wt. %.
[0015] In one arrangement, the cleaning composition comprises a surfactant combination comprising an amine oxide amphoteric surfactant which is a mixture of lauryl dimethyl amine oxide and myristyl dimethyl amine oxide and which includes at least two anionic surfactants which are (a) ammonium poly(oxyethylene) lauryl ether sulfate having an average ethoxy content of around 0.6/mole and (b) a mixture of lauryl ether carboxylic acid and myristyl ether carboxylic acid having an average ethoxy content of more than 3/mole.
[0016] In one arrangement the amine oxide amphoteric surfactant comprises a mixture of lauryl dimethyl amine oxide and myristyl dimethyl amine oxide and the at least two anionic surfactants are (a) ammonium poly(oxyethylene) lauryl ether sulphate having an average ethoxy content of about 0.6/mole and (b) an alkyl ethoxy carboxylate.
[0017] In one arrangement, the amine oxide amphoteric surfactant comprises a mixture of lauryl dimethyl amine oxide and myristyl dimethyl amine oxide and the at least two anionic surfactants are (a) ammonium poly(oxyethylene) lauryl ether sulphate having an average ethoxy content of about 3/mole and (b) an alkyl ethoxy carboxylate.
[0018] Optionally, the weight ratios of anionic surfactant (a) to the amphoteric surfactant is from 1:3 to 3:1, optionally, from 1:2 to 2:1, optionally 1:1.
[0019] Optionally, the amount of anionic surfactant (b) by weight in the surfactant combination is no more than 15%, optionally no more than 12.5%, optionally no more than 10%.
[0020] Optionally, the cleaning composition according to the invention further comprises a hydrotope .
[0021] Optionally, the cleaning composition according to the invention further comprises water. In this way a liquid composition may be formed. Alternatively, a gel composition may be formed.
[0022] The surfactant combination is typically present in an amount of 5 to 30% by weight of the composition. In other embodiments, the amount is 10 to 30%, 10 to 20%, 10 to 17%, 10 to 15%, 15 to 20%, or 15% to 25% by weight.
[0023] In a second aspect, the present invention provides a method of cleaning a surface, which comprises contacting the surface with a composition as described herein.
[0024] In a third aspect, the present invention provides a process for the production of a cleaning composition which comprises combining an amine oxide amphoteric surfactant with at least two anionic surfactants comprising a poly(oxyalkylene) alkyl ether sulfate and an alkyl ethoxy carboxylate so as to form a surfactant combination which comprises the cleaning composition or which is incorporated into the cleaning composition.
[0025] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses.
[0027] The compositions described herein have utility in a broad range of applications including, for example, in consumer product fluids such as dish cleaners, surface cleaners, cleansers and the like. The compositions are highly suitable for cleaning surfaces that are designed for food-contact uses, such as dishes, silverware, glasses and cups. The cleaning compositions of the invention are useful as ultra and regular density dish liquid formulas
[0028] The invention also encompasses methods of cleaning a surface including contacting the surface with a composition of the invention, diluted or undiluted.
Solvents
[0029] The invention in certain embodiments can also include one or more solvents. Typical solvents used in the composition are aqueous soluble, miscible or immiscible. Solvents can include aliphatic and aromatic hydrocarbons, chlorinated hydrocarbons, alcohols, ether compounds, fluorocarbon compounds, and other similar low molecular weight generally volatile liquid materials. Of these, preferred are alkanols; more preferred are ethanol, isopropanol, and propanol; and most preferred is ethanol. In a particularly desirable embodiment, the solvents of the cleaning composition are of alkanols, and more preferably the solvent is ethanol. In various embodiments, the compositions may include solvents in amounts of up to about 6 wt. %, preferably at least about wt. 0.1% by weight of the total composition.
[0030] In certain embodiments, water is not a solvent but when used acts as a diluent or as a dispersing medium for the active materials. In other embodiments, water is a solvent.
[0031] These materials can be used in solution or as a miscible mixture or as a dispersion of the solvent in the aqueous liquid. A solvent or cosolvent can be used to enhance certain soil removal properties of this invention. Cosolvents include alcohols and the mono and di-alkyl ethers of alkylene glycols, dialkylene glycols, trialkylene glycols, etc. Alcohols which are useful as cosolvents in this invention include methanol, ethanol, propanol and isopropanol. Other suitable solvents include the mono and dialkyl ethers of ethylene glycol and diethylene glycol, which have acquired trivial names such as polyglymes, cellosolves, and carbitols. Representative examples of this class of cosolvent include methyl cellosolves, butyl carbitol, dibutyl carbitol, diglyme, triglyme. Nonaqueous liquid solvents can be used for varying compositions of the present invention. These include the higher glycols, polyglycols, polyoxides and glycol ethers.
[0032] Suitable substances are propylene glycol, polyethylene glycol, polypropylene glycol, diethylene glycol monoethyl ether, diethylene glycol monopropyl ether, diethylene glycol monobutyl ether, tripropylene glycol methyl ether, propylene glycol methyl ether (PM), dipropylene glycol methyl ether (DPM), propylene glycol methyl ether acetate (PMA), dipropylene glycol methyl ether acetate (CPMA), propylene glycol n-butyl ether, dipropylene glycol monobutyl ether, ethylene glycol n-butyl ether and ethylene glycol n-propyl ether, and combinations thereof. In certain embodiments, the glycol solvent is propylene glycol n-butyl ether. In certain embodiments, the glycol solvent is dipropylene glycol monobutyl ether.
[0033] Other useful solvents are ethylene oxide/propylene oxide, liquid random copolymer such as Synalox solvent series from Dow Chemical (e.g., Synalox 50-50B). Other suitable solvents are propylene glycol ethers such as PnB, DPnB and TPnB (propylene glycol mono n-butyl ether, dipropylene glycol and tripropylene glycol mono n-butyl ethers sold by Dow Chemical under the trade name Dowanol). Also tripropylene glycol mono methyl ether “Dowanol TPM” from Dow Chemical is suitable.
[0034] The final ingredient in the inventive cleaning compositions is water. The proportion of water in the compositions generally is in the range of about 35% to about 90% or about 50% to 85% by weight of the cleaning composition.
Additional Optional Ingredients
[0035] Examples of additional optional components that can be included in the claning composition include, but are not limited to, hydrotropes, sequestering agents, antibacterial agents, fluorescent whitening agents, photobleaches, fiber lubricants, reducing agents, enzymes, enzyme stabilizing agents, powder finishing agents, builders, bleaches, bleach catalysts, soil release agents, dye transfer inhibitors, buffers, colorants, fragrances, pro-fragrances, rheology modifiers, anti-ashing polymers, soil repellents, water-resistance agents, suspending agents, aesthetic agents, structuring agents, sanitizers, solvents, fabric finishing agents, dye fixatives, fabric conditioning agents, and deodorizers. The proportion of such additional materials, in total will normally not exceed 15% by weight of the detergent composition, and the percentages of illustrative examples of such individual components will be about 5% by weight.
[0036] Process of Manufacture
[0037] The compositions are readily made by simple mixing methods from readily available components.
Methods of Use
[0038] The invention encompasses cleaning compositions useful for cleaning a surface.
[0039] By surfaces, it is meant herein any kind of surfaces typically found in houses like kitchens, bathrooms, or the exterior surfaces of a vehicle, for example, floors, walls, tiles, windows, sinks, showers, shower plastified curtains, wash basins, WCs, dishes and other food contact surfaces, fixtures and fittings and the like made of different materials like ceramic, vinyl, no-wax vinyl, linoleum, melamine, glass, any plastics, plastified wood, metal, especially steel and chrome metal or any painted or varnished or sealed surface and the like. Surfaces also include household appliances including, but not limited to, refrigerators, garbage cans, freezers, washing machines, automatic dryers, ovens, microwave ovens, dishwashers and so on. The present composition is especially efficacious in the cleaning of ceramic, steel, plastic, glass and the exterior painted or otherwise finished surface of a vehicle, for example, a car. The cleaning compositions are also safe on the skin.
[0040] The cleaning composition is applied to the surface, undiluted or diluted, optionally after a pre-rinse step. The cleaning composition can be diluted with water, preferably up to a dilution ratio of 1:20, without significantly affecting its cleaning and antimicrobial efficacies. The composition can be applied using a cloth or sponge onto which the composition has been applied or by pouring the composition over the surface. Alternatively the composition may be applied by spraying the composition onto the surface using a spraying device as described above. The cleaning compositions of the invention can be left to sit on a surface or be wiped or scrubbed on or from the surface.
[0041] Once the composition has been applied to the surface, the surface can then be optionally rinsed, usually with water, and left to dry naturally. Optionally the user can wait in between application of the composition and rinsing in order to allow the composition maximum working time. A particular benefit of the composition is that the surface can be cleaned as described above with minimal rinsing and the surface left to dry naturally without accumulating physiologically harmful deposits, and/or with reduced or no corrosion.
[0042] The following examples illustrate compositions of the invention. Unless otherwise specified, all percentages are by weight. The exemplified compositions are illustrative only and do not limit the scope of the invention. Unless otherwise specified, the proportions in the examples and elsewhere in the specification are by active weight. The active weight of a material is the weight of the material itself excluding water or other materials that may be present in the supplied form of the material.
EXAMPLE
[0043] The following abbreviations are used in the Example:
Ammonium lauryl ether sulfate (ALES) Lauryl/myristyl ether carboxylic acid (ECA) Lauryl/myristyl dimethyl amine oxide (LMDO) EO refers to degree of ethoxylation
[0048] The table below compares the foam forming capabilities of compositions according to the invention compared to a commercial formula. Formulations 1 to 4 each contain ALES 0.6, LMDO and ECA. All of these have an active surfactant amount of 16.9%. The commercial product at 100% has an active surfactant amount of 22.6%, and at 76% concentration, it has a comparable 16.9% active surfactant amount.
[0000]
Compar-
Com-
ative
Com-
mercial
Material
1
2
3
4
ECA only
mercial
at 76%
ECA
11.3
2.95
5.7
2.95
16.9
0
0
ALES 0.6
2.8
11.15
5.6
2.8
0
17.3
13.2
LMDO
2.8
2.8
5.6
11.15
0
4.8
3.7
Water and
Q.S.
Q.S.
Q.S.
Q.S.
Q.S.
Q.S
Q.S.
minors
[0000]
Foam Height
Foam Height
Sample
without milk (mm)
with Milk (mm)
1
515
250
2
510
240
3
490
250
4
485
260
Comparative - ECA only
490
250
Commercial at 76%
460
240
Commercial at 100%
470
260
[0049] From the table above, it can be seen that the inventive combination of surfactants produces more foam (in the absence of milk) at the same surfactant level as the comparative and even when the comparative is at a higher surfactant level. The inventive combinations have the about the same or better performance compared to ECA alone, but the formula with ECA alone is much more expensive than the inventive combination. The inventive combination can provide the level of foaming at a much reduced cost. When milk is present, the compositions are comparable for foam. The testing with milk is indicative of the cleaning performance of the composition. The inclusion of ECA results in the same or slightly better cleaning indication compared to the commercial at the same active ingredient level.
Shake-Foam Test
[0050] 100 ml of a diluted (0.033%) test solution in 150 ppm hardness water at room temperature (23° C.) is filled into a 500 ml graduated cylinder with a stopper. The stoppered cylinder is placed on an agitating machine, which rotates the cylinder for 40 cycles at 30 rpm. The height of the foam in the cylinder is observed. A milk soil is then introduced (about 175 μL) into the cylinder. The cylinder is then inverted 40 times more, and the height after soil addition is recorded as ml of foam.
[0051] As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls.
[0052] Unless otherwise specified, all percentages and amounts expressed herein and elsewhere in the specification should be understood to refer to percentages by weight. The amounts given are based on the active weight of the material. | A cleaning composition comprising a surfactant combination which comprises an amine oxide amphoteric surfactant; a first anionic surfactant comprising a poly(oxyalkylene) alkyl ether sulfate: and a second anionic surfactant comprising an alkyl ethoxy carboxylate. The combination provides increased foaming. | 2 |
BACKGROUND
Field of the Technology
The present invention relates generally to toilet sanitation. In particular, the invention relates to anti-splash devices for conventional toilets in CPC E03D 9/00, sanitary or other accessories for lavatories, and CPC A47K 13/26, mounting devices for seats or covers.
Conventional floor toilets, typically constructed of porcelain or a similar material, are a receptacle having a floor-mounted, bowl-shaped collection basin with a pool of standing water in the basin. A drain is typically placed at the bottom of the basin below the pool of standing water. The interior walls of the basin and the standing water provide an area to receive a stream of urine from a person using the toilet. When the toilet is flushed, water runs down and along the interior walls and the standing water, along with the urine, exits through the drain. Fresh water then replaces the flushed fluids to create another pool of standing water for future use.
The porcelain construction of toilets means that it has hard-surfaced walls. These hard surfaces reflect or deflect some portion of any urine stream directed thereon, splashing droplets of urine away from the point where the urine stream impacts the surface. Further, a urine stream directed into the standing pool of water in the basin will also cause splashing, in this case in the form of a urine-water mixture.
This splash back is a long-recognized problem and can occur regardless of whether the urine stream first contacts the surface of the water or the interior wall of the collection basin.
Several functional solutions to the problem of splash back in conventional toilets have been attempted. Past solutions suffer from having either small targets making use of the solution difficult or prevent the use of the toilet for solid waste making the solution inconvenient. Accordingly, there is a continuing need for an alternative conventional-toilet splash-back device that is convenient, effective, and practical.
BRIEF SUMMARY
The illustrated embodiments of the invention include an apparatus for attenuating reflective splash during the use of a conventional toilet. The apparatus includes a base that includes a plurality of upstanding, retractable baffles. The base, lying against the interior surface of the basin, has an appropriate thickness so that the flow of water down the interior walls of the basin during the flushing process is unobstructed. Additionally, the base, made of a flexible sheet material which is wrapped into a frustoconical form and laid on the interior surface of the toilet bowl, has perforations defined therethrough to prevent the collection of fluid on the surface of the base while still conforming to the contours of the interior surface of the basin. A central opening, defined by the base, exposes the pool of standing water below it and allows for, in addition to the retractable baffles, the operation of the toilet for solid waste without the need to remove the apparatus. The conical shape of the base prevents the base from sliding down into the lower portion of the basin. Rails run along both the upper and lower edges of the base providing rigidity and structure to the base.
In some embodiments, the base does not use the rails along both upper and lower edges. This allows the base to maintain a flexible property and adapt to different toilet-bowl shapes.
In some embodiments, the base has a radial cut through the entirely of the thickness of the base, breaking the continuity of the base, to allow for temporary manipulation of the shape of the base to ease the installation process into the toilet.
In some embodiments, the base is suspended by hooks that attach to the rim of the toilet bowl while continuing to keep the base in close contact with the interior surface of the basin.
In accordance with the present invention, a plurality of hinges are disposed radially on the base. The hinges would rotate such that the baffles, in the non-operative configuration, would lie parallel to the surface of the base or the rails on the upper and lower edges of the base.
In some embodiments, the hinges are disposed in a radial fashion, but offset such that the hinges form a pinwheel-like pattern, or configuration, on the base.
In some embodiments, the hinges are disposed to form concentric circles where the hinges would rotate toward the central opening.
Also in accordance with the present invention, a plurality of upstanding baffles are disposed on top of the plurality of hinges. When the hinges rotate downward, the baffles are placed into a non-operational configuration and when the hinges rotate upward, the baffles are placed into an operational configuration. The plurality of baffles are substantially uniform or approximately equal in height, thickness, and flexibility.
In accordance with some embodiments, the baffles vary in length with a range of approximately 1 inch to 5 inches, thickness with a range of approximately 0.05 inches to 0.25 inches, and distance between baffles within a group of baffles.
In accordance with some embodiments, the distance between one group of baffles and another, has a range of approximately 0.25 inches to 1 inch so that the operation of the hinges do not cause interference with adjacent baffles.
In some embodiments, where the hinges are disposed in concentric circles, the hinges would vary in height with the taller hinges disposed on top of the base closer to the outer edge of the base and the shorter hinges disposed on top of the base closer to the inner edge of the base.
Also in accordance with the present invention, a plurality of stoppers are disposed adjacent to the plurality of hinges such that the stoppers and hinges are paired together. The stopper prevents the hinge from rotating beyond 90 degrees.
Also in accordance with the present invention, a plurality of rods are disposed within the hinges such that a single rod is disposed within a single hinge. The rod is disposed within the hinge such that the length of the rod runs along the length of the hinge. The exposed end of the rod, facing the outer edge of the base, has an eyelet.
Also in accordance with the present invention, a cable is threaded through each eyelet and secured to each eyelet. When the cable is pulled in one direction, the hinges will rotate and position the baffles in a non-operative configuration. When the cable is pulled in an opposing direction, the hinges rotate oppositely and position the baffles in an operative configuration. The operative configuration includes a configuration where the plurality of baffles are rotated from an angular orientation lying flatly along the interior surface of the toilet to an angular orientation elevated above the inner toilet surface. The intended or preferred fully operative configuration is that one where the plurality of baffles are rotated to an angular orientation wherein they extend generally radially into the central opening of the toilet, but any orientation bringing the baffles out of they flat disposition against the inner surface of the toilet will be operative to a degree.
Also in accordance with the present invention, a spring is attached to one end of the cable. The cable, affixed to the base, provides constant tension such that the baffles are normally disposed into a non-operative configuration.
Also in accordance with the present invention, overcoming the tension in the spring pulls the cable so that the baffles rotate into an operative configuration.
In accordance with some embodiments of the present invention, the cable is attached to the toilet seat. When the toilet seat is lifted, the cable is pulled overcoming the tension of the spring and rotating the baffles into the operative configuration. When the toilet seat is lowered, the baffles rotate into the non-operative configuration.
In accordance with some embodiments of the present invention, the trigger mechanism is a foot pedal disposed on the floor adjacent to the toilet. When the pedal is depressed and locked, the cabled is pulled and the baffles rotate into the operative configuration. When the pedal is released, the baffles rotate back into the non-operative configuration.
While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 U.S.C. §112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents, and in the case where the claims are expressly formulated under 35 U.S.C. §112 are to be accorded full statutory equivalents under 35 U.S.C. §112. The disclosure can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of a single hinge with the baffles coupled to the hinge in the operative configuration.
FIG. 2 is a side plan view of a single hinge with the baffles in the operative configuration
FIG. 3 is an isometric view of a single hinge with the baffles in the non-operative configuration.
FIG. 4 is a side plan view of a hinge with the baffles in the non-operative configuration.
FIG. 5 is top perspective view of the apparatus with a plurality of hinges coupled together with their corresponding baffles disposed in the operative configuration.
FIG. 6 is top perspective view of the apparatus with a plurality of hinges coupled together with their corresponding baffles disposed in the non-operative configuration.
FIG. 7 is a top perspective view of the apparatus with a plurality of hinges coupled together with their corresponding baffles disposed in the operative configuration within a conventional floor toilet.
FIG. 8 is a top perspective view of the apparatus with hooks that suspend the apparatus within the toilet.
FIG. 9 is a top perspective view of the base without the upper or lower rails and without the hinges, stoppers, or baffles with the radial cut through the base.
FIG. 10 is an isometric view of the hook that attaches to the toilet seat with the cable adhered to the hook.
FIG. 11 is a top perspective view of the apparatus disposed within a conventional toilet with the hook attached to the toilet seat.
The disclosure and its various embodiments can now be better understood by turning to the following detailed description of the preferred embodiments which are presented as illustrated examples of the embodiments defined in the claims. It is expressly understood that the embodiments as defined by the claims may be broader than the illustrated embodiments described below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates an aspect of one embodiment. Hinge 101 is a rotatable bar from which a plurality of finger-like baffles 102 extend. Baffles 102 may be integral with hinge 101 or each separately connected or attached to hinge 101 . Hinge 101 is rotatable clockwise in FIG. 1 to dispose baffles 102 in a non-operative configuration shown in FIG. 3 and is rotatable counter-clockwise in FIG. 1 to dispose baffles 102 in an operative configuration, which is the configuration shown in FIG. 1 . Hinge 101 may include a rod (not shown) along its length that acts as an axle, adjacent and parallel to stopper 103 . Alternatively, hinge 101 could rotate on a pin (not shown) extending from each end of the stopper 103 . Stopper 103 is a bar with vertically extending flange 100 against which hinge 101 rotates and which serves to stop further counter-clockwise rotation from that shown in FIG. 1 . Stopper 103 prevents hinge 101 from rotating beyond an angular orientation corresponding to the extension of flange 100 as best depicted in the side plan view of FIG. 2 . Hinge 101 and stopper 103 are preferably composed a substantially rigid plastic. In one embodiment baffles 102 are disposed on top of hinge 101 through holes (not shown) on top of the hinge 101 and adhered within the hinge 101 .
Eyelet 104 provides a location where a cable 105 may attach. Eyelet 104 is disposed on or extends from an end of hinge 101 . The cable 105 rotates hinge 101 in either clockwise or counter-clockwise directions depending on the direction of tension of the cable 105 . When the cable 105 pulls from the left in the depiction of FIG. 1 , the baffles 102 are disposed in the non-operational configuration shown in FIGS. 3 and 4 . Due to the offset of eyelet 104 from the pivot point where hinge 101 is rotatably coupled to stopper 103 , the cable 105 pulls from an elevated angle or lever arm relative to the pivot point. This angle allows for the cable 105 to pull the hinge 101 and baffles 102 upward into the operative configuration of FIGS. 1 and 2 . When the cable 105 pulls from the right as depicted in FIG. 1 , the similar but opposite action occurs to dispose hinge 101 and baffles 102 into the nonoperative configuration of FIGS. 3 and 4 . Because the cable 105 is threaded or disposed through a base-mounted eyelet 106 shown in FIG. 5 , the cable 105 pulls on hinge 101 from a depressed angle to allow for the cable 105 to pull the hinge 101 and baffles 102 downward.
A plurality of hinges 101 with their corresponding baffles 102 are assembled to a plurality of upper base rails 107 and lower base rails 108 shown in FIGS. 5 and 6 . Upper and lower base rails 107 , 108 collectively form the base 110 . Each base rail 107 and 108 may be rigidly coupled to its corresponding stopper 103 and to the adjacent base rails 107 , 108 at each opposing end of each base rail 107 , 108 or may be flexibly coupled together by means of conventional flexible couplings (not shown). Therefore, continuing around the base rails 107 , 108 , the cable 105 is laid out concentrically in an in-and-out pattern in the depiction of FIGS. 5 and 6 . The cable 105 lies over the stopper 103 and through the eyelet 104 on the hinge 101 . In the illustrated embodiment of FIGS. 5 and 6 the upper end of hinge 101 is provided with eyelet 104 and upper base rail 107 is similarly provided with a base-mounted eyelet 106 through which cable 105 will be led. Alternatively, lower base rail 108 may have the eyelet 106 disposed thereon or extending thereform when eyelet 104 on hinge 101 is provided on the lower end of hinge 101 . Then the cable 105 is led concentrically in FIGS. 5 and 6 by being threaded throughbase eyelet 106 and this pattern repeats toward the adjacent hinge 101 and baffle 102 .
FIG. 5 illustrates an aspect of one embodiment. Baffles 102 are disposed in the operative configuration. Base 110 comprises a flexible material demonstrating some elasticity and contains perforations through the base to mitigate the collection of fluid on the base surface. Hinges 101 are fastened on the surface of base 110 either through adhesives, screws, or rivets. Central opening 114 exposes the pool of standing water (not shown) in the center of the toilet basin (not shown).
Baffles 102 will typically comprise a flexible material and vary in thickness and in length. Baffles 102 that are too long may cause more splash back due to the proximity of the baffles 102 to the upper rim of the toilet basin. Therefore, baffles 102 or varying lengths may typically be used where longer baffles 102 are disposed lower in the toilet basin and shorter baffles 102 are disposed higher in the toilet basin. Additionally, baffles 102 that are too thick may reduce the effectiveness of splash reduction. Therefore, the thickness of the baffles 102 would likely be smaller than the diameter of a typical urine stream.
During use, the urine stream will likely make contact with one of three different points: the baffles 102 , the surface of the base 110 , and the pool of standing water through the central opening 114 . When the urine stream strikes the water, splash-back is mitigated through the interference of the baffles 102 . As splash occurs, the baffles 102 interrupt the droplets' upward motion. When the urine stream strikes the surface of the base 110 , the reflective droplets are again interrupted by the nearby baffles 102 . Additionally, the perforations in the base 110 will mitigate the amount of the urine stream that makes contact at such an angle that produces droplets that would reflect outward. When the urine stream strikes a baffle 102 , the urine stream is broken apart and a majority of the stream is fanned out. The fanning-out process produces the benefit of decelerating the urine stream as well as causing the urine stream to strike additional baffles 102 which will cause additional deceleration. Additionally, the amount of surface area by which outward-bound droplets form is reduced by the fact that the baffles 102 are cylindrically shaped including a rounded tip 116 .
A larger density of hinges 101 may be used. This would reduce the amount of exposed base surface during the urinating process.
The position of the baffle 102 on each hinge 101 may be placed in a staggered formation to ease the transition to the non-operational configuration. A staggering of the baffles 102 may help the baffles 102 retract more compactly.
FIG. 6 illustrates an aspect of one embodiment. Baffles 102 are disposed in the non-operative configuration. A spring 111 is affixed to one end of the cable 105 . The other end of the spring 111 is affixed to the base 110 . The spring 111 provides a persistent tension pulling the hinges 101 and baffles 102 into the non-operative configuration. Perforations 118 provide a bore through base 110 .
FIG. 7 illustrates an aspect of one embodiment. The apparatus is disposed within toilet 120 with baffles 102 disposed in the operative configuration.
FIG. 8 illustrates an aspect of one embodiment. Hooks 119 provide a suspension mechanism for the apparatus when disposed within the toilet.
FIG. 9 illustrates an aspect of one embodiment. Base 110 comprises of a flexible sheet material with a radial cut through base 110 . Perforations 118 provide a bore through base 110 . Central opening 114 exposes the pool of standing water within the toilet when base 110 is disposed along the inner-toilet surface.
FIG. 10 illustrates an aspect of one embodiment. Hook 125 , comprising of a substantially rigid material, attaches to the toilet seat. Cable 105 is adhered to hook 125 .
FIG. 11 illustrates an aspect of one embodiment. The apparatus is disposed within toilet 120 with baffles 102 in the non-operative configuration. Cable 105 is adhered to hook 125 and hook 125 is attached to the toilet seat of toilet 120 . When the toilet seat is lifted, tension is provided in cable 105 which transitions baffles 102 from the non-operative configuration to the operative configuration shown in FIG. 7 .
Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the embodiments. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the embodiments as defined by the following embodiments and its various embodiments.
Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the embodiments as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the embodiments includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations. A teaching that two elements are combined in a claimed combination is further to be understood as also allowing for a claimed combination in which the two elements are not combined with each other, but may be used alone or combined in other combinations. The excision of any disclosed element of the embodiments is explicitly contemplated as within the scope of the embodiments.
The words used in this specification to describe the various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.
The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptually equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the embodiments. | Described herein is an apparatus mitigating splash-back during the use of a conventional toilet while urinating. The apparatus uses a plurality of upstanding baffles that provide for a large target area mounted on a base with a central opening. Additionally, the baffles rotate into and out of operative configurations, relative to the inner-toilet surface, to allow the use of the toilet for solid waste. The baffles mitigate the effect of splash back as the urine stream makes contact with the baffles and reflects the droplets laterally. Additionally, droplets generated when the urine stream contacts either the base or pool of standing water is mitigated by the baffles intercepting the reflective path back to the user. | 4 |
BACKGROUND
The present invention relates to improvements in container closures and more particularly, but not exclusively, to closures for bottles or like containers. For simplicity, the present invention will be hereinafter described in respect of a bottle closure, but it is to be understood that a closure for any other type of container is envisaged to be within the applications to which the present invention could be put.
In drinking bottle closures, various proposals have been put forward for the controlled access to the bottle contents. In many situations, there is a need to have speedy and efficient access to the bottle contents by means of a straw or the like.
In some past proposals, a drinking straw can have a first substantially vertical position, when drink can be supplied from the bottle and a second, folded over, position resulting from the sliding of the bottle closure, when flow of drink from the bottle is terminated. In one such proposal, the bending over of the straw also results in the straw closing off an air vent connecting with the bottle interior.
Other past proposals have included the well known pop-up type closure where the raising or lowering of a pop-up valve on the top of the closure controls access to the bottle contents.
All the previous proposals for bottle closures have been found to have certain disadvantages relating to their efficiency, complexity and/or cost.
It is, thus, an object of a preferred embodiment of the invention to provide a bottle closure which will overcome or at least obviate disadvantages in bottle closures available to the present time or which at least will provide the public with a useful choice.
Further objects of this invention will become apparent from the following description.
SUMMARY
According to one aspect of the present invention, there is provided a container closure having an access means which, in use, can provide external access to the interior of a container, said access means being adapted to receive in use a drinking straw which straw can have a substantially vertical position for drinking purposes, but can be folded over by a pivotal means as it moves to a closed position, said pivotal means being able to pivot between first and second positions when it opens and closes the access means respectively, said access means having an edge portion over which said drinking straw can be folded, which edge portion acting to nip said drinking straw and substantially stop flow of liquid therethrough from the interior of said container.
In one embodiment, the pivotal means comprises a hood which can pivot about a body portion. In one embodiment, the body portion includes a groove in which the drinking straw can be accommodated as it is folded down as the pivotal means moves to its closed position.
According to a further aspect of the present invention, there is provided a container closure substantially as herein described, with reference to the accompanying drawings. According to a still further aspect of the present invention, there is provided a container including a closure substantially as herein described, and/or with reference to the accompanying drawings.
DRAWINGS
Further aspects of this invention, which should be considered in all its novel aspects, will become apparent from the following description, given by way of example of possible embodiments thereof, and in which reference is made to the accompanying drawings where:
FIG. 1 shows a side view of a closure according to one embodiment of the present invention in its closed position;
FIG. 2 shows the closure of FIG. 1 in its open position;
FIG. 3 shows a cross-sectional view through the closure of the preceding figures in its closed position;
FIG. 4 shows a cross-sectional view of the closure of the preceding figures in its open position;
FIG. 5 shows an isometric view of the closure of the preceding figures in its open position;
FIG. 6 shows an underneath view of the closure of the preceding figures;
FIG. 7 shows a front view of the closure of the preceding figures in its closed position;
FIG. 8 shows a front view of the closure of the preceding figures in its open position; and
FIG. 9 shows an isometric view of a further embodiment of the invention in its open position.
DESCRIPTION
Referring to the accompanying drawings, a closure for a bottle or other container is referenced generally by arrow 1. The closure 1 may be formed from any suitable material and from any suitable technique, although a molded plastic closure has been found to be satisfactory, a plastic surface facilitating the closure being kept clean as is especially necessary when the container is used for containing a liquid drink or food.
The closure 1 is shown with a base portion 2 and the bottom edge portion 3. Extending upwardly from the base portion 2 is a body portion 40 about which a top portion 4 is shown provided. The top portion 4 is shown as including a pair of quadrants 5, 6. Both of the quadrants 5, 6 may have surface decoration 41 to enhance their appearance. One of the quadrants 6 is shown pivotally mounted at 8 to the body portion 40 enabling the quadrant 6 to be lifted by means of lever 7 from its closed position shown in FIG. 1 to its open position shown in FIG. 2. As will be seen in FIGS. 1 and 2 for example, in its closed position, the lever 7 is adjacent the base portion 2 with an opposite edge 9 in a substantially vertical position, whereas in the open position shown in FIG. 2, those positions are effectively reversed. The quadrant 6 in this embodiment functions in the nature of a pivotal hood.
As is shown particularly in FIG. 5 for example, the inner and bottom edge 15 of the quadrant 6 may be contoured so as to provide a controlled sliding relationship with similarly contoured surfaces 11 of the body portion 40. The body portion 40 is shown provided with a groove or channel 16 which can accommodate a straw 20, which as shown in FIGS. 3 and 4, can be folded over 20A as the quadrant 6 moves between its open and closed positions.
As seen particularly in FIGS. 3 and 5 for example, at the top of the groove 16 an upstanding flange or projection 17 is provided over which the folded straw 20 can pass so that the straw 20 is nipped at that place so as to be closed off. This stops or substantially stops the flow of liquid through the straw 20. The lever 7 may be associated with an inner recess 19, see FIGS. 3 and 5 particularly, so that when the quadrant 6 is in its closed position, any residual contents in the straw 20 are able to escape from the closure 1.
As seen in FIG. 4 particularly, the straw 20 is positionable within an access 18 connecting with the interior of the closure 1 and in use with the interior of a container. The access 18 is shown including a tube or bore 28 which can accommodate a straw connector 21. The straw connector 21 is shown provided with a grooved end 22 to facilitate a firm connection with the end of the straw 20. The connector end 22 is shown extending to a flange 23 and a bottom projecting tube 24. A crimping ring 25 may be provided as shown to hold the connector 21 in position.
As seen particularly in the underneath view in FIG. 6, the base portion 2 may be provided with a threaded internal rim 26 having thread 27, which can engage with the container neck.
It will be appreciated that in this embodiment of the invention, with the closure 1 fitted onto a container, the only access to the container interior will be through the straw 20 and the access 21. Thus the applicant has found that separate air vents into the container may not be necessary to enable liquid to be drawn from the container provided the container walls are flexible to enable fluid in the container to effectively be pushed out by compressing the walls. However, some rigidity for the container walls may be required to avoid them imploding as liquid is drawn out through the straw 20.
It is emphasized that while the closure 1 is shown in the drawings as being a discrete member, it could be provided as an integral member forming part of a container.
As will be seen particularly in FIGS. 1 and 2, the other quadrant 5 may merely provide a substantially symmetrical match for the quadrant 6 and may form part of the fixed body portion 40 about which the quadrant 6 can pivot. As seen particularly in FIG. 2, and also in FIG. 4, as the quadrant 6 pivots between its open and closed positions, it will slide over the quadrant 5 and in the open position the edge 9 of the quadrant 6 is shown abutting the bottom edge 10 of the quadrant 5.
As seen particularly in FIGS. 2 and 5, the body portion surfaces 11 may include projections 13 over which the inner surfaces 15 of quadrant 6 can engage thus acting to tend to hold the quadrant 6 in its closed position, although not unduly hindering the lifting of the quadrant 6 over the projections 13 when required.
Referring now to FIG. 9 in a further embodiment, the top face 30 of the base portion 2 is shown provided with a pair of air vents 14, which will provide an air connection with the interior of the closure 1 and the container. These vents 14, more or less can be provided as appropriate, can be closed off when the quadrant 6 is in its closed position by respective pins or projections 12 receivable in a respective vent 14.
Where in the foregoing description reference has been made to specific components or integers of the invention having known equivalents then such equivalents are herein incorporated as if individually set forth. Although this invention has been described by way of example and with reference to possible embodiments thereof it is to be understood that modifications or improvements may be made thereto without departing from the scope of the invention, as defined in the appended claims. | A container closure includes an access, which can receive a drinking straw, which is able to be folded down into a groove by the pivotal movement of member, which closes off the drinking straw by engaging it across an upstanding flange or projection. | 1 |
FIELD OF THE INVENTION
The invention relates generally to real-time reservoir characterization.
BACKGROUND OF THE INVENTION
In the lifecycle of modern production management, permanent downhole gauges (PDG) are used in monitoring well production. A PDG is deployed in the down hole in the well. It measures bottom-hole pressure versus time and the data are transmitted to the surface typically via cable. Because of the alien down-hole environment and the high-recording-frequency, the recorded pressure data is numerous and extremely noisy. Hence, only limited information can be extracted from the data.
FIG. 1 shows the conventional method of dealing with the enormous quantity of high-frequency pressure data recorded from PDG in a reservoir 10 . There are two steps, on the left side of FIG. 1 , step 1 , the production data acquisition process (PDAP) 11 is shown. The PDAP is done automatically as the PDG records pressure continuously. The recorded data is referred as real time (RT) data. RT data can be stored automatically to the server and also be downloaded to the local personal computer (PC). The second step is the production data interpretation process (PDIP) 12 and is shown on the right side of FIG. 1 . Typically, trained technical staff or experts have to perform the PDIP 12 . After obtaining real-time data, the technical staff or experts manually determine the transient areas (build up area and draw down area, for example). The process is called transient detection. Once the transients are detected, the technical staff interprets the detected transients, based on the pressure data within the chosen transient areas and the flow rate history. From this interpretation, the technical staff determines formation parameters such permeability, well bore storage and skin, which will be deemed as inputs for history matching. Finally, the technical staff run model based history matching. By running history matching, the interpreted formation parameters can be improved to meet the pressure response in reservoir scale. In this step, a numerical simulator is applied. But this step cannot be implemented automatically, because the numerical simulation is always time-consuming and real time data is enormous. Finally, the improved parameters will be used to characterize the reservoir and guide the future production.
The present invention provides real time data collection, interpretation and modeling to provide real time characterization of reservoirs and provide accurate prediction of reservoir properties.
SUMMARY OF THE INVENTION
The present invention is a system and method for generating predictions for various parameters in a reservoir. The invention includes receiving input data characterizing the reservoir and determining transient areas. The transient areas are determined by receiving data from the reservoir, transforming the data using discrete wavelet transformation to produce transformed data, removing outliers from the transformed data, identifying and reducing noise from the transformed data and then detecting transient areas in the transformed data. A computer model is produced in response to the transient data and predictions for parameters in the reservoir are determined. These predictions are verified by comparing predictive values with a reservoir model and then the predictions for the various parameters can be used.
Additional objects and advantages of the invention will become apparent to those skilled in the art upon reference to the detailed description taken in conjunction with the provided figures.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention is illustrated by way of example and not intended to be limited by the figures of the accompanying drawings in which like references indicate similar elements and in which:
FIG. 1 is a block diagram of the prior art method of retrieving using data to make predictions for parameters in a reservoir;
FIG. 2 is a block diagram of the method of the present invention;
FIG. 3 is a block diagram of the method of automatically detecting transients used in the present invention;
FIG. 4 is a series of signals showing outlier removal using discrete wavelet transformation, the upper plot showing the raw signal with outliers (scaled 0-200,000), the middle plot showing wavelet coefficients, the lower plot showing the outlier removed signal (scaled 500-9000);
FIG. 5 is a series of signals showing noise reduction from the signal in FIG. 4 , the upper plot showing the raw signal with an overlay of the denoised results, the middle plot showing the denoised results, and the lower plot showing the difference between the two signals indicating the amount of noise reduction;
FIG. 6 is a series of signals transient identification from the signal in FIG. 5 , the upper plot showing the raw (outlier and denoised) signal, the middle plot showing the wavelet coefficients, and the lower plot showing the detection results with drawdown period indicted as zero (0) and buildup periods indicated as one (1);
FIG. 7 is a block diagram of the method of automatically selecting a reservoir model to perform transient analysis;
FIG. 8 is a block diagram of the method of automatically using transient interpretation to model reservoir data and history match this with a previous model
FIG. 9 is block diagram of a computer system used in an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Measurement channels from current permanent downhole gauges (PDG) may include pressures and temperatures. The large volume of data requires significant bandwidth to transmit and to analyze.
FIG. 2 shows how the invention deals with the PDG data automatically from reservoir 10 from production data acquisition process (PDAP) 21 to production data interpretation process (PDIP) 22 . The difference lies in PDIP 22 . First, wavelet based transient detection 30 is introduced to implement automatic transient detection. The transients are interpreted 23 and a fast simulator is applied to implement history matching 24 , which meets the requirements of carrying out reservoir simulation in real time. The above simulator can be semi-analytical or analytical. An example of this is the GREAT as described in U.S. Pat. No. 7,069,148, incorporated by reference herein.
Wavelet based transient detection applies wavelet analysis methods. It covers three steps: Outlier removal which removes the outliers in the signal; Denoising which reduces the noise in the signal; and Transient Detection which detects the transient areas in the signal.
Wavelets were developed in the signal analysis field and present a wide range of applications in the petroleum field such as pressure data denoising and transient identification. Wavelets are associated with scaling functions. Wavelets and the associated scaling functions are basis functions and can be used to represent the signal. One can analyze and reconstruct the signal by analyzing and modifying the wavelet coefficient and scaling coefficients, which is calculated via the discrete wavelet transform (DWT). DWT can decompose the signal to certain decomposition levels, which is defined by the data point of the signal. If the signal has 2 J values, J is defined as the maximum decomposition level. A general introduction to DWT is given by Mallat, “ A Theory for Multiresolution Signal Decomposition: The Wavelet Representation ,” IEEE Trans. Pattern Analysis and Machine Intelligence (July 1989) vol. 11, no. 7, p. 674. A further description is found in PCT/US2008/07042 filed 18 Jul. 2008, incorporated by reference herein.
A data processing method that involves using a low-pass filter and a high-pass filter to decompose the dataset into two subsets is described. A one dimensional vector may be referred to as S obs . The vector S obs may be decomposed using a low-pass filter G to extract a vector C or using a high pass filter H to extract a vector D. The vector C represents the low-frequency, or average, behavior of the signals, while the vector D represents the high frequency behavior of the signals.
Unlike Fourier Transforms, which use periodic waves, Wavelet Transforms use localized waves and are more suitable for transient analysis because different resolutions at different frequencies are possible. The filters H and G mentioned above are derived from Discrete Wavelet Transformations (DWT). DWT is the most appropriate for removing the types of random noise and other distortions in signals generated by formation testers. In some cases, when DWT is not the most appropriate approach to the generation of filters H and G mentioned above, other approaches such as Fourier Transformations may be used.
When a DWT is applied, the vector D described above contains the wavelet coefficients (WC's) and the vector C described above contains the scaling function coefficients (SC's). The basic DWT may be illustrated by the following equations (1) and (2):
D HIGH ( n ) = ∑ k = - ∞ ∞ S ( k ) H ( n - k ) , ( 1 ) C LOW ( n ) = ∑ k = - ∞ ∞ S ( k ) G ( n - k ) . ( 2 )
For efficient DWT, the signal S(k) should contain 2 j data values. A vector S having 2 j values is referred to as vector of level j. The vectors C and D shown above each will contain 2 j-1 values, and, therefore, they are at level j−1. Thus, the DWT shown in equations (1) and (2) decomposes the input signal S(k) by one level. The decomposition can be iterated down to any desired level.
In accordance with embodiments of the invention, specific types of wavelet functions may be chosen according to the types of data to be processed. Commonly used wavelet functions include Haar, Daubechies, Coiflet, Symlet, Meyer, Morlet, and Mexican Hat. In accordance with some embodiments of the invention, the Haar wavelet functions are used to detect discrete events, such as the presence of gas bubbles and the start of pressure transients (such as the start of drawdown and buildup), while the Daubechies wavelets are used to detect trends in the signals because these wavelets can generate smooth reconstructed signals.
For H and G derived from DWT, de-noising algorithms may be chosen to be specific to the wavelets used in the DWT. In accordance with some embodiments of the invention, algorithms based-on local maxima may be used to remove white noise. These algorithms have been described in Mallat and Hwang, “ Singularity Detection and Processing with Wavelets ,” IEEE Trans. Info. Theory (1992) vol. 38, no. 2, p. 617.
In accordance with some embodiments of the invention, threshold-based wavelet shrinkage algorithms may be used for noise reduction. These algorithms are given in David L. Donoho and lain M. Johnstone, “Ideal Spatial Adaptation via Wavelet Shrinkage,” Biometrika, 81(3), 425-455 (1994).
In accordance with some embodiments of the invention, the algorithms that are most appropriate for denoising a signal may be chosen after appropriate statistical techniques (tools) have been applied to identify the structure of the noises. Such statistical tools, for example, may include histograms of the wavelet coefficients which provide understanding of the spread and mean of the noises, and plots of the autocorrelation of the wavelet coefficients, as these provide understanding of the time structure of distortions on the signals.
By running DWT, the wavelet coefficients, which represent the noisy signal, and scaling coefficients, which represent the detailed signal, are gained. By analyzing and filtering the wavelet coefficients for noisy signal and then reconstructing it, the signal can be processed. By applying transient identification methods to the wavelet coefficients of the pressure signal, the transient events (drawdown/buildup) can be detected.
To implement wavelet based transient detection 30 to production data, it is necessary to follow the steps, outlier removal 31 , denoising 32 and transient detection 33 as FIG. 3 shows:
1. Outlier Removal ( 31 , FIG. 2 )
Outliers are common phenomena in the signal domain. They are large-amplitude, short lived distortions to the signals and cause discontinuities in the data stream. But they can be recognized in the wavelet coefficient of the 1 st step of decomposition as FIG. 4 shows. Discrete wavelet transforms (DWT) are used to identify outliers by their “outlying” distributions of the wavelet coefficients (WC's). In the upper plot of FIG. 4 the raw signal is scaled from 0-20,000 and the outliers are shown. There are 8092 (2 13 ) points, so the maximum decomposition level is 13. The wavelet coefficients at decomposition level 12 (shown in middle plot of FIG. 4 ) indicate the position of outliers clearly. By running DWT and the outlier removal method, the outliers are completely removed (lower plot of FIG. 4 ).
2. Denoising ( 32 , FIG. 2 )
Noise is another common phenomenon in signal domain. It has low magnitude and exists at all levels of decomposition. It can be detected at lower levels as the upper plot of FIG. 5 shows. By running DWT and the denoising method, the noise can be largely removed. To facilitate noise identification and removal, embodiments of the invention convert (or transform) measurement data, using a proper transformation function, into a dimension/domain different from the original dimension/domain such that the signals and the noises have different characteristics. For example, time domain data may be converted into frequency domain data, or vice versa, by Fourier Transformation (FT). In the frequency domain, the signals can typically be identified as peaks at discrete frequencies with significant amplitudes, while the noises typically spread all over the frequency range and have relatively low amplitudes. Therefore, the signals and noises that commingle in the time domain may become readily discernable in the frequency domain. Wavelet transforms operate by a similar principle: time domain data is converted to wavelet domain data, then distortions are easily identified and removed.
After the transformation, the noises or distortions are identified and removed (middle plot of FIG. 5 ). One of ordinary skill in the art would appreciate that the exact methods for identifying and removing the noises may depend on the transform functions used. For example, time-series data may be transformed using a discrete wavelet transform to permit the distinction between the signals and noises (or other distortions). After a discrete wavelet transform, the true signals associated with a gradually changing process will manifest themselves as wavelets having coefficients that cluster in a normal distribution. On the other hand, noises or distortions would likely have coefficients that do not belong to the same group as the signals. Therefore, noises and distortions can be identified by their unique distribution of wavelet coefficients. The lower plot of FIG. 5 shows the difference between the upper and middle plots of FIG. 5 and indicates the amount of noise reduction.
3. Transient Detection ( 33 , FIG. 2 )
After removing outliers and reducing noise, it is easy to detect the transient areas with transient detection methods. FIG. 6 shows how the transient areas are detected. Here, 1 and 0 are used as indicators: 1 indicating build up and 0 indicating draw down.
Interpretation of the detected transient is performed automatically. To do this a Neural Network system is used to determine the appropriate reservoir model. Standard techniques well known in the industry are applied to interpret the data in the confines of the model and deliver reservoir parameters. FIG. 7 shows the appropriate reservoir model being selected 71 automatically and the transient analysis 72 being performed after being fed the transient detection data 74 . The output from this is the transient interpretation results 73 . These reservoir parameters 73 are used as the input to the history matching in the next step.
History matching applies a fast simulator starting with the output parameters from the transient interpretation. These parameters are optimized interactively with the complete production history of the reservoir. It is possible to update the reservoir models which are renewed with the coming of real time data.
U.S. Pat. No. 7,069,148, describes the Gas Reservoir Evaluation and Assessment Tool (GREAT) which is a semi-analytical simulation method for reservoir simulation. It is fast and accurate in dealing with complex formation problems. This model is used to predict pressure and other production characteristics of a reservoir.
To implement GREAT based history matching, it is necessary to follow the steps as FIG. 8 shows:
1. Model Construction ( 81 , FIG. 8 ) In this step, the transient interpretation results will be used to construct the GREAT model by incorporating formation geometry, formation fluids, formation production history and computation settings. The model will be used by the GREAT simulator. 2. GREAT Simulation ( 82 , FIG. 8 ) GREAT computes the formation pressure over the whole life of well production and carries out automatic history matching. The output will be the improved formation parameters. These parameters will be used to characterize the formation. The fast speed of the GREAT simulation engine allows these computations to be completed in real time.
The GREAT simulation receives input data pertaining to a reservoir. It then creates a model and matches the predictive model values with real-time data. This is accomplished by calculating the reservoir model predictive values in one dimension associated with a single layer in said reservoir, each of the reservoir model predictive values existing a single point in space in the reservoir and at a single point in time in the reservoir. The next step is to calculate the reservoir model predictive values in one dimension associated with multiple layers in the reservoir, each of the reservoir model predictive values in one dimension existing at a single point in space in the reservoir and at a single point in time in the reservoir. Then GREAT calculates the reservoir model predictive values in three dimensions associated with multiple layers in said reservoir, each of the reservoir model predictive values in each of said multiple layers in three dimensions existing at a single point in space in the reservoir and at a single point in time is the reservoir. Finally GREAT calculates the reservoir model predictive values in three dimensions as a function of time, the values being associated with multiple layers in the reservoir, each of the reservoir model predictive values in each of the multiple layers in three dimensions existing as a single point in space in said reservoir, each of the reservoir model predictive values in the multiple layers in three dimensions existing at any future point in time in said reservoir. The computer model is verified through history matching of the reservoir model predictive values. This is a preferred method of computer modeling although other embodiments are possible.
The efficiency of analytical models is generally judged by accuracy and speed. The novel set of solutions used in the GREAT tool is applicable to multiple wells, which can be vertical as well as horizontal. These wells can be operating as producers or injectors thus being of additional significance to gas well storage. The solutions have been derived by application of successive integral transforms. The application of these new solutions is characterized by stability and speed.
By introducing wavelet analysis methods, which process recorded pressure data by removing outlier and denoising, it is possible to detect the transient areas, which is defined as draw-down area and build-up area. By applying well test methods to the pressure data of transient areas, the useful information, such as permeability, well bore storage and skin, can be derived. Then newly developed analytical simulator is applied to improve the reservoir model by executing history matching.
There is illustrated a computer system 900 for generating a prediction of values in a reservoir in accordance with the present invention. Computer system 900 is intended to represent any type of computerized system capable of implementing the methods of the present invention. For example, computer system 900 may comprise a desktop computer, laptop, workstation, server, PDA, cellular phone, pager, etc.
Data generated by PDG is received and stored by computer system 900 , for example, in storage unit 902 , and/or may be provided to computer system 900 over a network 904 . Storage unit 902 can be any system capable of providing storage for data and information under the present invention. As such, storage unit 902 may reside at a single physical location, comprising one or more types of data storage, or may be distributed across a plurality of physical systems in various forms. In another embodiment, storage unit 902 may be distributed across, for example, a local area network (LAN), wide area network (WAN) or a storage area network (SAN) (not shown).
Network 904 is intended to represent any type of network over which data can be transmitted. For example, network 904 can include the Internet, a wide area network (WAN), a local area network (LAN), a virtual private network (VPN), a WiFi network, or other type of network. To this extent, communication can occur via a direct hardwired connection or via an addressable connection in a client-server (or server-server) environment that may utilize any combination of wireline and/or wireless transmission methods. In the case of the latter, the server and client may utilize conventional network connectivity, such as Token Ring, Ethernet, WiFi or other conventional communications standards. Where the client communicates with the server via the Internet, connectivity could be provided by conventional TCP/IP sockets-based protocol. In this instance, the client would utilize an Internet service provider to establish connectivity to the server.
As shown in FIG. 9 , computer system 900 generally includes a processor 906 , memory 908 , bus 910 , input/output (I/O) interfaces 912 and external devices/resources 914 . Processor 906 may comprise a single processing unit, or may be distributed across one or more processing units in one or more locations, e.g., on a client and server. Memory 908 may comprise any known type of data storage and/or transmission media, including magnetic media, optical media, random access memory (RAM), read-only memory (ROM), etc. Moreover, similar to processor 406 , memory 408 may reside at a single physical location, comprising one or more types of data storage, or be distributed across a plurality of physical systems in various forms.
I/O interfaces 912 may comprise any system for exchanging information to/from an external source. External devices/resources 914 may comprise any known type of external device, including speakers, a CRT, LED screen, handheld device, keyboard, mouse, voice recognition system, speech output system, printer, monitor/display (e.g., display 916 ), facsimile, pager, etc.
Bus 910 provides a communication link between each of the components in computer system 900 , and likewise may comprise any known type of transmission link, including electrical, optical, wireless, etc. In addition, although not shown, additional components, such as cache memory, communication systems, system software, etc., may be incorporated into computer system 900 .
Shown in memory 908 is a prediction system 924 for predicting values in a reservoir from the real time data in accordance with the present invention, which may be provided as computer program product. Prediction system 924 includes a transient detection system 926 for identifying transients, an transient interpretation system 928 for interpreting transients, and model construction system 930 for constructing a model. Memory 908 includes history matching system 932 for matching the predicting models with real time data to further refine the model.
It should be appreciated that the teachings of the present invention could be offered as a business method on a subscription or fee basis. For example, computer system 900 could be created, maintained, supported, and/or deployed by a service provider that offers the functions described herein for customers. It should also be understood that the present invention can be realized in hardware, software, a propagated signal, or any combination thereof. Any kind of computer/server system(s)—or other apparatus adapted for carrying out the methods described herein—is suited. A typical combination of hardware and software could be a general purpose computer system with a computer program that, when loaded and executed, carries out the respective methods described herein. Alternatively, a specific use computer, containing specialized hardware for carrying out one or more of the functional tasks of the invention, could be utilized. The present invention can also be embedded in a computer program product or a propagated signal, which comprises all the respective features enabling the implementation of the methods described herein, and which—when loaded in a computer system—is able to carry out these methods. Computer program, propagated signal, software program, program, or software, in the present context mean any expression, in any language, code or notation, of a set of instructions intended to cause a system having an information processing capability to perform a particular function either directly or after either or both of the following: (a) conversion to another language, code or notation; and/or (b) reproduction in a different material form.
As used herein, it is understood that the terms “program code” and “computer program code” are synonymous and mean any expression, in any language, code or notation, of a set of instructions that cause a computing device having an information processing capability to perform a particular function either directly or after any combination of the following: (a) conversion to another language, code or notation; (b) reproduction in a different material form; and/or (c) decompression. To this extent, program code can be embodied as one or more types of program products, such as an application/software program, component software/a library of functions, an operating system, a basic I/O system/driver for a particular computing and/or IPO device, and the like. Further, it is understood that terms such as “component” and “system” are synonymous as used herein and represent any combination of hardware and/or software capable of performing some function(s).
The block diagrams in the figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods and computer program products according to various embodiments of the present invention. In this regard, each block in the block diagrams may represent a module, segment, or portion of code, which comprises one or more executable instructions for implementing the specified logical function(s). It should also be noted that the functions noted in the blocks may occur out of the order noted in the Figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams can be implemented by special purpose hardware-based systems which perform the specified functions or acts, or combinations of special purpose hardware and computer instructions.
In the instant invention the methods and apparatus of implementing automatic production management and data interpretation are improved by integrating wavelet based transient detection and GREAT based history matching. By using this apparatus, the real time production management can be implemented in automatic manner.
This enables automatic production management process and automatic pressure interpretation. Furthermore, it can incorporate alarming mechanism, which sends alarms or warning messages to the experts in real time.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention. | The present invention is a system and method for generating predictions for various parameters in a reservoir. The invention includes receiving input data characterizing the reservoir and determining transient areas. The transient areas are determined by receiving data from the reservoir, transforming the data using discrete wavelet transformation to produce transformed data, removing outliers from the transformed data, identifying and reducing noise from in the transformed data and then detecting transient areas in the transformed data. A computer model is produced in response to the transient data and predictions for parameters in the reservoir are determined. These predictions are verified by comparing predictive values with a reservoir model and then the predictions for the various parameters can be used. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a color television signal reproducing apparatus, and is directed more particularly to a color television signal reproducing apparatus having a circuit for avoiding erroneous operation of its AGC (automatic gain control) circuit.
2. Description of the Prior Art
In the prior art it is known to provide a VTR in which color video signals are recorded on a magnetic tape in obliquely extending successive tracks thereon and the color video signal for each field interval is recorded in a respective one of the tracks. Upon the reproduction thereof, the successive recorded tracks are sequentially reproduced by two rotary magnetic heads which are alternately switched. With this prior art VTR, when the video signals are sequentially reproduced from the successive recorded tracks by the two rotary heads, it can not be avoided that a transient noise is produced at the time when the two heads ae switched. Thus, when relative jitter variations between the rotary heads and magnetic tape are caused by the positional relation between the transient noise and color burst signal present in the vertical blanking interval of the video signal, a color flicker appears at the upper edge of a reproduced picture on a television receiver or monitor which color flicker may be uncomfortable for a viewer.
SUMMARY OF THE INVENTION
According to an aspect of the present invention, there is provided a video signal reproducing apparatus in which, in order to avoid misoperation during the vertical blanking period of an ACC (automatic color control) circuit in the reproducing circuit for the chrominance signal, the chrominance component of the reproduced color video signal is muted or the signal for controlling the ACC circuit is muted. Desirably, the muting signal is produced by a pulse signal from a phase control signal generator which is provided in association with the head drum of the VTR to indicate the rotary positions of the signal reproducing heads.
Accordingly, it is an object of the present invention to provide a video signal reproducing apparatus which is free of the above described defect inherent in the prior art apparatus.
It is another object of the invention to provide a video signal reproducing apparatus in which the appearance of any color flicker on a monitor television receiver is avoided even if jitter components exist.
It is a further object of the invention to provide a video signal reproducing apparatus in which an ACC circuit in the recording circuit of the VTR is improved in operation so as to eliminate a color flicker.
The above, and other objects, features and advantages of the invention, will become apparent from the following description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic block diagram showing an embodiment of a video signal reproducing apparatus according to the invention;
FIGS. 2A to 2D and FIGS. 3A to 3C are waveform diagrams to which reference will be made in explaining the operation of a prior art VTR and of the embodiment of the invention shown in FIG. 1; and
FIG. 4 is a schematic block diagram showing another embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention will now be described with reference to FIG. 1 as applied to a color VTR of the type having two rotary magnetic heads, by way of example.
In the color video signal producing system of FIG. 1, reference numerals 1A and 1B indicate rotary magnetic heads which are located with an angular spacing therebetween of about 180° and rotated at a speed of 30 r.p.s. The magnetic heads 1A and 1B reproduce a color television signal from a magnetic tape (not shown) which travels about the periphery of a guide drum (not shown) through an angular extent of about 180°. The color television signal is recorded on the magnetic tape in a known manner so that its luminance signal is angle-modulated, for example, frequency-modulated, its chrominance signal is converted into a low band frequency signal, the angle-modulated luminance signal is combined with the frequency converted chrominance signal, and each interval of the resulting combined signal recorded in a respective oblique track on the magnetic tape. The magnetic heads 1A and 1B sequentially contact the magnetic tape for about one field interval to reproduce the color television signals which are then supplied through pre-amplifiers 2A and 2B to a switching circuit 3. The switching circuit 3 serves to pass therethrough one or the other of the signals reproduced by the magnetic heads 1A and 1B as the latter alternately contact the magnetic tape, and is actuated by a switching pulse from a flip-flop 4. In order to produce the switching pulse, there is provided a means for detecting the rotary phases of the magnetic heads 1A and 1B. As the rotary phase detecting means, there may be used a magnetic means or photo-electric means. In the example shown in FIG. 1, two detecting coils 5A and 5B are located on the rotary trace of the magnetic heads 1A and 1B with an angular spacing of 180° between the coils 5A and 5B, and a magnet (not shown) is rotated together with the magnetic heads 1A and 1B past the coils 5A and 5B. Thus, each of the detecting coils 5A and 5B produces a detecting pulse each 1/30 sec. to indicate the rotary phase or position of the magnetic heads 1A and 1B. Since the detecting pulses from the detecting coils 5A and 5B are shifted in phase by 180°, if the flip-flop 4 is triggered with the detecting pulses passed through amplifiers 6A and 6B, the flip-flop 4 may produce the switching pulse whose level changes between two values at the frequency of 60 c.p.s. Accordingly, at any time, the switching circuit 3 passes therethrough the signal being reproduced by the magnetic head which then contacts the tape. The detecting pulses from the detecting coils 5A and 5B are supplied to a servo circuit (not shown) for achieving the usual tracking servo operation during reproduction.
The reproduced signal passed through the switching circuit 3 is fed to high pass and low pass filters 7 and 8 respectively. From the high pass filter 7, is obtained a luminance signal Y FM which is frequency-modulated. This luminance signal Y FM is then supplied through a limiter 9 to a frequency demodulator 10 which produces a luminance signal Y. This luminance signal Y is fed to a low pass filter 11 which eliminates unnecessary signal components from the luminance signal Y and the output signal from the low pass filter 11 is fed to an adding circuit 12. From the low pass filter 8, there is obtained a frequency-converted chrominance signal C l which is supplied to a frequency converter 13. The chrominance signal C l is reconverted to the original frequency of chrominance subcarrier (in the case of the NTSC system, to 3.58 MH z ) by the frequency converter 13. An APC (automatic phase control) circuit 14 is provided in association with the frequency converter 13. The output signal from the frequency converter 13 is supplied to a band pass filter 15 in which unnecessary signal components are eliminated from the output signal of the frequency converter 13. Thus, from the band pass filter 15, is obtained a chrominance signal S C which is supplied to an ACC circuit 16 for removing level variations therein. The output signal from the ACC circuit 16 is then fed to the adding circuit 12 which is also supplied with the luminance signal Y as described above. Thus, the adding circuit 12 provides a composite color television signal including the luminance signal Y and chrominance signal S c and, which is delivered to an output terminal 17 led out from the adding circuit 12.
The ACC circuit 16 is supplied with a control signal which is obtained by extracting a burst signal from the output of ACC circuit 16 by means of a burst gate circuit 18 and detecting the level of the burst signal by a burst detecting circuit 19. The level of the burst signal is in proportion to that of the chrominance signal so that, for example, as the level of the chrominance signal becomes low, the level of the burst signal also becomes low. When the detected output signal of the burst detecting circuit 19 becomes small, the gain of the ACC circuit 16 is increased, whereas, when the detected output signal becomes great, the gain of the ACC circuit 16 is decreased. Thus, the chrominance signal is made constant in level or a so-called ACC operation is carried out. The burst gate circuit 18 is supplied with a burst flag pulse which is produced by delaying, through a delay circuit 21, a horizontal synchronizing signal extracted by a horizontal synchronizing signal separator 20 from the luminace signal passed by the low pass filter 11.
In accordance with this invention, the ACC operation is arrested during the switching from one to the other of the magnetic heads 1A and 1B, and more particularly at the commencement of each of the successive intervals of the color video signal being respectively reproduced by such heads. In the example of the invention shown in FIG. 1, the chrominance signal S C is muted during the commencement of each of the field intervals of the color video signal which are reproduced by the magnetic heads 1A and 1B, by utilizing the switching pulse from the flip-flop 4 which is, in turn, based upon the detecting pulses from coils 5A and 5B indicating the rotary phases of the magnetic heads 1A and 1B. To this end, the switching pulse from the flip-flop 4 is fed to a muting signal circuit M which includes a differentiation circuit 22A, and only the positive differentiated pulse therefrom is fed through a diode 23A as a muting signal to a muting circuit 24. The switching pulse from the flip-flop 4 is also fed in circuit M through a phase inverter 25 to another differentiation circuit 22B and the positive differentiated pulse therefrom is fed through a diode 23B as a muting signal to the muting circuit 24. The output side of the muting circuit 24 is connected to the transmission line of the chrominance signal S C between, for example, the band pass filter 15 and the ACC circuit 16. When the positive differentiated pulse is fed from each of the diodes 22A and 22B to the muting circuit 24, it operates, for example, to ground the chrominance signal transmission line and to cut off the transmission of the chrominance signal S C to the ACC circuit 16.
An error operation of the ACC circuit will now be described with reference to FIGS. 2A-2D for the case where the muting circuit 24 and the circuit M for driving the muting circuit 24 as shown in FIG. 1 are not provided, for example, as in a prior art color VTR of the two head type. Upon an error operation of the ACC circuit, the level of the chrominance signal S C , which is reproduced and then converted, becomes low or high at the initial portion or commencement of one field interval T v or at the time after a vertical blanking period T bl as shown in FIGS. 2A or 2B and consequently a color flicker appears in a reproduced picture to deteriorate the same. The error operation of the ACC circuit is caused by a transient noise which may be produced at the switching of the switching circuit 3. In general, the switching time of the switching circuit 3 is selected to occur at the beginning of the vertical blanking period T bl as shown in FIG. 2C. The burst signal b is arranged in this period T bl and jitters exist in the VTR, so that when the transient noise t produced at switching is positioned as shown in FIG. 2D, the transient noise t may coincide with or deviate from the burst signal b as to time or position. For example if the transient noise t is coincident with the burst signal b, the transient noise appears in the output signal from the burst gate circuit 18. In general, the transient noise has a higher level than the burst signal in level, so that the detected output signal from the burst detecting circuit 19 increases and the gain of the ACC circuit 16 decreases. Since the recovery time period of the ACC circuit 16 is selected to be more than a certain value, for example, several ten times a horizontal period, the chrominance signal S C for the respective field interval, which is the output of the ACC circuit 16, has its level decreased during its initial portion as compared with the remaining portion as shown in FIG. 2A.
On the other hand, when the transient noise does not coincide in time with the burst signal, the transient noise does not appear in the output of the burst gate circuit 18. Accordingly, the output of the ACC circuit 16 is not affected by the transient noise. However, if the transient noise deviates, in time, from the burst signal after having been coincident with the latter for a certain time interval, the gain of the ACC circuit 16 itself increases during the vertical blanking period T bl in accordance with the recovery time thereof. Accordingly, the output signal of the ACC circuit 16 is increased in level during the initial portion of the field interval as compared with the remaining portion thereof as shown in FIG. 2B. The transient noise and burst signal in the reproduced signal become coincident or not due to the jitter like relative variation of the rotary heads to the recording medium which is scanned by the rotary heads. As a result, the color flicker in response to the jitters appears clearly in the upper portion of the picture which appears on a television receiver or monitor receiving the reproduced color video signal.
The manner in which the invention can avoid the above described erroneous operation of the ACC circuit will now be described with reference to FIGS. 3A-3C.
If the flip-flop 4 produces the switching pulse which rises up or falls down at the period of each field interval T v as shown in FIG. 3A, the switching circuit 3 is switched at the rising up times and falling down times t 0 , t 1 , t 2 , . . . With the embodiment of this invention shown in FIG. 1, the switching pulse (FIG. 3A) from flip-flop 4 is differentiated by the differentiation circuit 22A, and the positive differentiated pulse therefrom is fed to the muting circuit 24. Further, the switching pulse shown in FIG. 3B, which is reversed in phase with respect to that shown in FIG. 3A, is differentiated by the differentiation circuit 22B and its positive going differentiated pulse is also fed to the muting circuit 24. As a result, the muting circuit 24 is supplied with the differentiated pulses produced at the times t 0 , t 1 , t 2 , . . . when the switching circuit 3 is switched, as shown in FIG. 3C, and the muting operation is carried out for the time interval within which each differentiated pulse exists, so that the chrominance signal S C is not fed to the ACC circuit 16 during this interval to avoid erroneous operation of the ACC circuit 16 by the transient noise. Further, since the differentiated pulses (FIG. 3C) for controlling the muting circuit 24 are formed in response to the switching pulse, the differentiated pulse and transient noise are coincident with each other in time to positively avoid any influence by the transient noise on the ACC circuit 16.
In the above embodiment of the invention described above, the muting circuit 24 is provided in connection with the transmission line of the chrominance signal S C . However, it is also possible to provide the muting circuit 24 in connection with the circuit which produces the control signal for the ACC circuit 16 and to thereby achieve the same effects, as shown in FIG. 4 by way of example. In FIG. 4, reference numerals that are the same as those used in FIG. 1 designate the same elements so that their description will be omitted for the sake of brevity.
Although the control signal for the ACC circuit 16 has been shown as being produced by detecting the burst signal, the present invention can also be applied to reproducing circuits in which the pilot signal and reference level signal in the video signal are used to produce the control signal for circuit 16.
Further, this invention can be adapted to a color VTR of the type having three, four or more rotary magnetic heads in addition to the type having two rotary magnetic heads.
The present invention can also be applied to apparatus in which signals recorded on a magnetic medium of sheet-like shape, rather than a magnetic tape, are reproduced.
Although illustrative embodiments of the invention have been described in detail herein, it will be apparent that many modifications and variations could be effected therein by one skilled in the art without departing from the spirit or scope of the present invention as defined in the appended claims. | Successive field intervals of a composite color television signal are respectively recorded on successive recording tracks which extend parallel to one another on a record medium such as a magnetic tape. During the reproduction of a color television signal in a conventional VTR (video tape recorder), successive field intervals of the color television signal are alternately reproduced from the successive record tracks by means of two signal reproducing heads which are switched alternately.
A color video signal reproducing circuit has an automatic gain control circuit for controlling the output level thereof and a muting circuit by which operation of the automatic gain control circuit is arrested for a predetermined period at the commencement of each interval of the reproduced color video signal so as to prevent color flicker from appearing on a television monitor regardless of timing axis variations caused by undesirable jitter components produced by the speed relation between the tape transport or drive and the head rotation in the VTR. | 7 |
PRIOR APPLICATIONS
[0001] This application claims priority to U.S. Provisional Application No. 61/596,187, filed Feb. 7, 2012, and U.S. Provisional Application No. 61/596,571, filed Feb. 8, 2012, and U.S. Provisional Application No. 61/597,749, filed Feb. 11, 2012, which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention is directed to compression latches of the type used to latch gasket-lined doors or gasket-lined door jambs. Compression latches have been designed to secure gasketed doors, trunk lids, panels, covers, and other structures. Such compression latches require a pawl and a clamp or other member to compress a generally elastomeric gasket or O-ring when securing the door, trunk lid, panel, cover or other structure.
[0003] The take-up, i.e., the compression distance moved by the pawl, clamp, or other member, to pull a door against a door jamb establishes the degree of compression of the gasket and the sealing force thereof. The linear travel of a pull member, once a door makes contact with a cabinet, establishes the sealing force of the gasket. Gasketed enclosures are often found in industry. These can include computer and communications cabinets, electrical transformer enclosures, sterilizing and autoclave enclosures, incubation and artificial environment enclosures, cooling chambers and freezers, humidity and controlled environment chambers, and various types of ovens, among others.
[0004] Compression latches are generally manually operated. As such, they can be operated by a handle or a lever. Levers are found on latches where the compression forces required against a gasket are greater, or the length of travel of the pull is longer. However, compression latches are specifically adjusted or specifically designed or selected for the particular application and the particular environment in which they are used. Such particular application and particular environment can also dictate other operating features for a latch, such as the requirements for handle and door locking and position holding, as well as the proximity distance of the lock on a door to a door jamb when the pull of the latch begins to operate.
SUMMARY OF THE INVENTION
[0005] The present invention is designed to latch the door to an oven. Such an oven may be designed for many different purposes, such as a climate chamber, a drying oven, an annealing or tempering oven, or a food processing oven, among others. Each of these ovens has a gasket or seal which is compressed when the oven door is fully closed. Thus a compression latch operation is well suited for these structures.
[0006] The compression latch of the present invention is lever operated. This enables that a first latch unit can be mounted near the top of the oven door and a second latch unit can be mounted near the bottom of the door. A bar-type handle is attached to and vertically extends between the two latch levers. The vertical bar handle operates both levers and therefore both latches in unison. The latches engage respective striker-keepers mounted on the body of the oven.
[0007] It is important that the vertical bar have a specific fully closed position, a specific fully open position, and a discernable intermediate position where a technician knows the latch is still fully closed but about to start to open. This would assist in minimizing accidental openings allowing the escape of hot air and gases towards the technician.
[0008] When closing the door it is desirable that the latch pawl comes into contact with its striker/keeper at a specific distance before the door is fully closed. In this way, the further movement of the vertical bar and thereby the further movement of the respectively connected latch levers, contributes to the compressing forces each latch exerts on the door gasket. For example, the latch pawl can engage the striker/keeper when the door is 10-20 mm from being fully seated against the gasket. This would require a linear movement of a pawl/pull member slightly more than that distance in order to compress the gasket.
[0009] It is also desirable that the latch housing size be minimized so that the latch can be used with small ovens and/or relatively thin oven doors. An envelope size for the latch housing can be in the range of 40-70 cubic centimeters. An example might be about 33 millimeters long by about 85 millimeters wide by about 20 millimeters high.
[0010] It is further desirable that the handle lever of each latch, itself, has a stable locked state when the latch is in the fully open position, and that this locked state be released only when the door is pushed to the closed position with a manual force by a technician, wherein the locked state of the latch is released for the latch to move into a closing mode to engage the keeper/striker to lock and seal the door.
[0011] These are objectives that are realized in the latch design of the present invention that provides a compression operation from a small package which promotes user friendly smooth operation. The latch housing has a snap-in feature which minimizes the tooling and components needed for installation. The operation of the latch is effected by the movement of a lever handle from left to right and vice versa with an over center position indicator providing an indication when the latch is locked. A blocking feature inhibits the latch from being locked when the door is open. The design is such that a positive movement by a technician is needed to close the latch and to open it.
[0012] The latch includes a series of links which fold into one another resulting in a very small package when the latch is closed. In a closed position the footprint of the latch is essentially rectangular except for a housing mounting leg at one side and a snap-in clamp at the other side.
[0013] When manually operated, the handle lever rotates in a semi-circle, from a closed secure position, to a closed but about to engage to an open position (at the top of the arc), to beyond the top to an operational area of the semi-circle where the latch opens.
[0014] The latch utilizes a rectangular keeper/striker cup, mounted to the door jamb, having a pull engaging lip and a striker plate. An elongate lever, operated by the vertical handle, is mounted to a first pivot point for rotation. That pivot point holds a torsion spring which biases the lever to a closed position.
[0015] The lever is pinned to an elongate first link at one end of the link. The first link has a pivot point at about its mid-length for its rotation thereon. The other end of the link is pinned to a second link and pinned to a first end of an elongate pawl
[0016] The lever operated compression latch has an elongate, hook-ended pawl with a pawl body having a longitudinal slot. The pawl is cam guided, and pin rotated and translated, to engage with and withdraw from a keeper cup. A fixed position cam post rides within the pawl slot and controls the pawl lateral translation. This cam also defines a pivot point about which the pawl rotates. The compound movement of the pawl includes a lateral translation towards the keeper cup while rotating there into, followed by a lateral withdrawal to exert a compression force between the latch body which is attached to a door and the keeper cup which is attached to a door frame thereby compressing the gasket.
[0017] A series of interconnected links is operated by the lever handle to fold into one another to provide a compact envelope when the latch is closed. These links expand outwardly to open the latch and disengage the pawl from the keeper when operated by the lever movement to the open state. Of this series of links, a pair of release links operates in contact with one another, and rotates on respective individual pivot points to extend outwardly from the latch envelope to engage a striker plate portion of the keeper cup. This striker engagement causes the release links to push the latch and the door from a sealing engagement of the keeper and door jamb for a short distance, prior to the latch and the door thereafter being separated and fully opened. This short distance of movement prior to the open state is a safety measure.
[0018] The striker engagement of the release links also causes the latch links to fold inwardly, which rotates and translates the pawl into keeper engagement and compression. This operation is facilitated with a floating spring having one end operating as a pivot member. A detent engages one of the links to provide a physical indication to the handle lever between the hard closed position and the closed about to open position.
[0019] From the fully closed position, when the handle, i.e., lever rotates, the pawl becomes free to translate out of the latch towards the keeper cup and the release links push the latch away from the keeper cup. This releases the compression state. Then after a slight lag and a further rotation of the lever, the pawl rotates. The pawl rotation is about 75 degrees from the keeper engagement position to a position fully rotated from the keeper and into the latch housing. When the latch is fully open, the handle lever is positively held in the open position. When the latch is fully open, the release levers are in the fully outwardly extending position. The handle lever, itself, is only released from the fully open position when the release levers strike the striker plate of the keeper cup. This causes the first and second links to rotate which releases the handle for movement.
[0020] The first link has a finger on its handle lever engaging end which engages an indentation in the handle lever to hold it fixed in the open position. The release linkage rotation causes the first link to rotate out of the fixed holding engagement with the handle lever.
[0021] The operation of the latch pawl is such that when the pawl force is released from exerting force against a gasket, the pawl finger hook continues to overlap the pull engaging lip of the striker cup. The handle when the pawl is in this position is held in a detent movement inhibited position which must be overcome by an additional force. This additional force overcomes the detent and moves the drive links, i.e., the first and second links connected to the pawl. The further movement of these drive links rotates the pawl to clear the finger hook from the striker cup and then rotates the pawl to withdraw it into the latch body. When the pawl is in the fully retracted position the release links are in their fully extended position. With the release links in the fully extended position the drive links cannot move the pawl.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The features, advantages and operation of the present invention will become readily apparent and further understood from a reading of the following detailed description with the accompanying drawings, in which like numerals refer to like elements, and in which:
[0023] FIG. 1 is a perspective view of the latch on an oven;
[0024] FIG. 2 is a perspective view of the door of the oven slightly open with the latch in an intermediate position;
[0025] FIG. 3 is a perspective view of the oven door fully open, and there being the use of two latches, i.e., an upper and lower one, with the lower latch in dashed lines and a handle bar connecting the upper and lower latches also shown in dashed lines;
[0026] FIG. 4 is a top view of the oven of FIG. 1 with the latch fully opened and the door freely opened;
[0027] FIG. 5 is a right-hand operation latch top view with the keeper/striker in dashed lines and the latch in the fully open position;
[0028] FIG. 6 is a top view of the latch of FIG. 5 in the intermediate or partial release position;
[0029] FIG. 7 is a top view of the latch of FIG. 5 in the fully open position with the release linkage extended and the hook-ended pawl rotated into the latch housing, and showing a top view of the keeper/striker;
[0030] FIG. 7 a is a perspective view of the latch;
[0031] FIG. 8 is a perspective view of a keeper/striker cup used with the latch with the back of the cup exploded away;
[0032] FIG. 9 is a plan/top view of the latch in the extreme closed position, the top housing member being removed;
[0033] FIG. 10 is a plan/top view of the latch in the engaged position, the top housing member being removed;
[0034] FIG. 11 is a plan/top view of the latch in the detent position, the top housing member being removed;
[0035] FIG. 12 is a plan/top view of the latch in the extreme open position, the top housing member 119 being removed;
[0036] FIG. 13 is a perspective exposed view of the latch components;
[0037] FIG. 14 is a plan/top view of the latch with the top of the housing removed and the latch in the closed position engaging the keeper/striker;
[0038] FIG. 15 is a front view of the latch of FIG. 14 in the closed position showing sectional cuts A, B, and C;
[0039] FIG. 16 is a plan/top view of the closed latch of FIG. 15 at section A-A;
[0040] FIG. 17 is a plan/top view of the closed latch FIG. 15 at section B-B;
[0041] FIG. 18 is a plan/top view of the closed latch FIG. 15 at section C-C;
[0042] FIG. 19 is a plan/top view of the latch with the top of the housing removed and the latch in the engaged position with the hooked finger of the pawl within the cup portion of the keeper/striker;
[0043] FIG. 20 is a front view of the latch of FIG. 19 in the engaged position showing sectional cuts D, E and F;
[0044] FIG. 21 is a plan/top view of the engaged latch of FIG. 20 at section D-D;
[0045] FIG. 22 is a plan/top view of the engaged latch of FIG. 20 at section E-E;
[0046] FIG. 23 is a plan/top view of the engaged latch of FIG. 20 at section F-F;
[0047] FIG. 24 is a plan/top view of the latch with the top of the housing removed and the latch in the detent position;
[0048] FIG. 25 is a front view of the latch of FIG. 24 in the detent position showing sectional cuts G, H and J;
[0049] FIG. 26 is a plan/top view of the detented latch of FIG. 25 at section G-G;
[0050] FIG. 27 is a plan/top view of the detented latch of FIG. 25 at section H-H;
[0051] FIG. 28 is a plan/top view of the detented latch of FIG. 25 at section J-J;
[0052] FIG. 29 is a plan/top view of the latch in the extreme open position;
[0053] FIG. 30 is a front view of the latch of FIG. 29 in the open position showing section cuts K, L and M;
[0054] FIG. 31 is a plan/top view of the open latch of FIG. 30 at section K-K;
[0055] FIG. 32 is a plan/top view of the open latch of FIG. 30 at section L-L;
[0056] FIG. 33 is a plan/top view of the open latch of FIG. 30 at section M-M;
[0057] FIG. 34 is a plan view of the latch with the tip of the housing removed and where the detent ball is in the depressed position where the pawl continues to be extended into the keeper and the release links are beginning to extend;
[0058] FIG. 35 is a front view of the latch of FIG. 34 in the detent ball depressed position showing section cuts N, P and R;
[0059] FIG. 36 is a plan/top view of the latch of FIG. 34 at section N-N;
[0060] FIG. 37 is a plan/top view of the latch of FIG. 34 at section P-P;
[0061] FIG. 38 is a plan/top view of the latch of FIG. 34 at section R-R;
[0062] FIG. 39 is a plan/top view of the closed latch of FIG. 14 in the sectional view B-B of FIG. 17 , but with the keeper/striker and its back plate mounted to a door jamb with mounting screws and nuts, and the gasket compressed, where the latch is positioned within the door; and
[0063] FIG. 40 is a plan/top view of the latch in the engaged detent position of FIG. 27 showing section H-H.
DETAILED DESCRIPTION OF THE INVENTION
[0064] The present invention is a latch 100 mounted on a door structure 501 of an enclosure such as an oven 500 , FIGS. 1-4 , which latch 100 has an extreme fully closed position, a detent position indicating a closed latch about to be opened, a further detent position indicating a partially opened latch, and an extreme fully open position. The latch is operated by a lever/handle. When in the extreme open position the lever/handle is held in a fixed abutment position so that it cannot be rotated towards the closed position. A release structure frees the handle when it moves against a striker plate mounted on a door jamb structure.
[0065] FIGS. 1 , 2 , 3 , and 4 show the latch 100 mounted on an oven door 501 and the latch and door in the closed, partially released opened, opened with two latches and opened with a single latch, respectively.
[0066] FIGS. 5 , 6 and 7 show the closed, engaged, and open positions of the latch 100 , respectively. The latch 100 is designed such that the operator will not cause it to strike against the door jamb mounted keeper/striker 201 while in the closed position, FIG. 5 , nor will the operator cause the latch to strike against the door jamb mounted striker 201 while in the in the engaged position, FIG. 6 .
[0067] FIG. 7 a shows a perspective view of the latch, while FIG. 8 shows an exploded perspective view of the keeper/striker 201 , 202 for the latch 100 . The latch housing 101 , 119 is a relatively quick installation. On one side there is an ear 401 with a vertical opening or channel 403 for a pin or screw 404 . On the other side there is a spring clamp 402
[0068] With the top housing member 119 removed, the latch is shown in detail in plan top views in FIGS. 9 , 10 , 11 , and 12 . In FIG. 9 , the latch 100 is in the closed position. In FIG. 10 , it is in the engaged position where the pawl 111 has traveled into the keeper/striker 201 cup so that the door is somewhat opened as shown in FIG. 2 , but the pawl still engages the keeper to prohibit the complete opening of the door. In FIG. 11 , the latch is in the detent position where the lever/handle 112 will not move freely indicating the door should not be closed in the latch in that position. In FIG. 12 the latch is in the open position where the release links can engage the keeper striker plate 201 to close the latch.
[0069] FIG. 13 is a perspective exploded view of the latch showing its components. Shown is a top housing member 119 and a bottom housing member 101 and two interacting linkages, which for the purposes of describing the function of the latch 100 will be known as the main (drive) linkage, and the release linkage.
[0070] The main/drive linkage has a pawl operation housing pivot pin 105 a , a lever handle operation housing pivot pin 105 b , an upper main/drive link 108 , a pawl pivot pin 109 , a handle pivot pin 110 , a pawl 111 with a hooked end 230 , a lever handle 112 , a lower main/drive link 114 , a main/drive linkage biasing spring 117 , and a lever handle biasing spring 118 . The housing pawl operation pivot pin 105 a and housing lever/handle operation pivot pin 105 b are rotational fits in the bottom housing member 101 and the top housing member 119 , and provide motion constraints for the pawl 111 and lever/handle 112 . Link 108 and link 114 pivot about their mid-points each being rotationally constrained between the bottom housing member 101 and top housing member 119 . The pawl pivot pin 109 and lever/handle pivot pin 110 are rotationally constrained at opposite ends between the link 108 and the link 114 . The pawl 111 is rotationally constrained to the pawl pivot pin 109 and has a sliding/rotational fit to the pawl operation housing pivot pin 105 a . The lever/handle 112 is rotationally constrained to the lever/handle housing pivot pin 105 b and has a sliding/rotational fit to the handle pivot pin 110 .
[0071] This arrangement enables a controlled linear and rotational transformation of the pawl 111 in relation to bottom housing member 101 , through an angular movement of the lever/handle 112 about the lever/handle operation housing pivot pin 105 b . The main/drive linkage spring 117 provides a bias to the main linkage 108 , 112 , driving it to either extreme of its available motion, while the lever/handle biasing spring 118 provides a bias to the lever/handle 112 , driving a rotation about lever/handle housing pivot pin 105 b.
[0072] The arrangement of the linkage and geometry of the components ensures that at one extreme the main/drive linkage can only be driven via the lever/handle 112 , henceforth known as being in the locked position, while at the other extreme, the main linkage cannot be driven by lever/handle 112 , henceforth known as being in the open position.
[0073] The release linkage consists of lower fixed pivot link 106 , a lower floating pivot link 107 , a bearing 113 , an upper floating pivot link 115 and a upper fixed pivot link 116 . The link 106 and the link 107 are rotationally constrained at one end between bottom housing member 101 and top housing member 119 , while their other ends are rotationally constrained to link 107 and link 115 the pin position of which is movable. The other ends of link 107 and the link 115 are rotationally constrained to the pawl pivot pin 109 in the main/drive linkage.
[0074] The bearing 113 is a rotational fit to link 106 and acts as a roller to reduce friction between any surfaces it comes into contact with. This release linkage provides a means of moving the main/drive linkage from its extreme open position.
[0075] Both linkages are constrained between the bottom housing member 101 and top housing member 119 , which provide the only mechanical fixings for the whole latch assembly 100 . Each of the upper main/drive link 108 and the lower main/drive link 114 have a stub shaft 120 which extends through a stub shaft journal hole 120 in the respective adjacent outer face of the upper and lower housing members. This provides the central pivot point for these two links
[0076] Further, an arrangement consisting of a detent spring 102 , a steel ball 103 and detent retainer 104 provide an intermediate stop/detent position between the locked and open positions of the main linkage. This structure provides a physical indication that the lever has moved from the full closed/locked position to an intermediate position where opening is about to begin. The detent retainer 104 is pressed into the bottom housing member 101 , as an interference fit, forming a retaining feature for a steel ball 103 , which is biased in place by the detent spring 102 .
[0077] The main drive link spring 117 is a torsion spring with two arms each with a downward pointed end (foot). One end of the spring 117 is pinned to the bottom housing member 101 at a fixed point 220 and the other end of the spring 117 is pinned to the pivot point pin 109 between the main/drive links 114 and 108 . This permits the spring 117 to float between different positions.
[0078] The lever/handle biasing spring 118 is a torsion spring with one short straight arm and a longer arm with a downward extending pointed end (foot). This spring 118 sits in a torroid-shaped cavity 221 in the top face of the lever/handle 112 , a short radial extending slot 222 extend from the torroid cavity 221 . The short leg of the spring 118 sits in the slot 222 while the coil of the spring 118 sits in the torroid-shaped cavity 221 . The longer arm of the spring 118 has its downward end secured to a receiving hole 223 in the adjacent sidewall casting of the bottom housing member 101 .
[0079] The latch 100 essentially has three, two-piece links. The links are structured with top and bottom members being a “pair” so that they may be separated to install, i.e., receive the respective pivot pins. One paired release link 106 , 116 has a fixed housing pin 105 b and a floating pin 224 tying it to the second paired release link 107 , 115 .
[0080] The other end of the second link 107 , 115 is pinned 225 to the end of the pawl and the main/drive link 108 , 114 with the pawl pivot pin 109 into which one end of the main/drive linkage spring 117 fits its upper arm downward leg. The opposite end of the main/drive links 108 , 114 is each tied to the lever/handle 112 having the elongate cavity 226 with the side recess 227 . The lever/handle 112 rotates counter clockwise to open the latch and clockwise when the latch is being closed.
[0081] FIG. 14 shows a plan/top view of the latch 100 in the closed position with the pawl 111 engaging the keeper/striker 201 . The spring 117 has its downward leg engaging a point 220 on the bottom housing. The handle spring 118 has one leg engaging a bottom housing receiving hole 223 and the other leg positioned within a slot 222 in the lever handle 112 . FIG. 15 shows a front view of the latch handle 112 extending outwardly (from a door) when the latch 100 is in the closed position showing sectional cuts A, B, and C through the latch 100 . FIG. 16 shows the closed latch 100 engaging the keeper striker 201 with it pawl 111 hooked finger portion 230 .
[0082] FIG. 17 illustrates the hold closed position where the drive link pin 110 is held in the side recess 302 of the three lobed guide slot 301 . This slot 301 has a main slightly curved portion which is formed by a left lobe area 231 and a right lobe area 232 , which actually operates as a cam guideway for the pin 110 which operates as a cam follower. The side recess 302 , in the middle, holds the pin 110 , FIG. 17 , when the latch is in the extreme closed position. This is really a stop or detent-hold position, establishing a final clockwise rotation position for the lever/handle 112 . It also prevents link 108 and link 114 from rotating in a clockwise rotation. This in turn prevents the pawl 111 from moving, thus holding any compressive load generated between the latch and the keeper.
[0083] FIGS. 19 , 20 , 21 , 22 , and 23 show different sectional cut views of the latch 100 in the engaged position. The engage position is where the hooked finger 230 still engages the cup of the keeper/striker 201 to hold the door 501 closed and the gasket 323 still compressed, but the latch 100 is about to open.
[0084] In the engaged position, as shown in FIG. 22 , the lever/handle 112 has been freely rotated counterclockwise about 10 degrees, at which point it provides a resistance indication, indicating that the latch while still closed is about to open. This resistance indication arises because the cam follower, i.e., pin 110 , is moved out of the side recess 302 to come into contact with the far side of the guide slot 301 , FIG. 22 . But as the pin 110 moves out of the side recess 302 , the links 108 , 114 and the pawl 111 will be free to move, releasing any compression generated between the latch and the keeper 201 .
[0085] In normal use, rotating the handle though the initial 10 degrees releases the compression, which moves the main linkage 108 , 114 , the pawl pivot pin 109 , the handle pivot pin 110 and the pawl 111 to an indeterminate position where the pin 110 will move someway into the right hand lobe of the guide slot 301 in the handle 112 , coming to rest when the compression force is reduced to zero.
[0086] As the lever/handle continues to rotate counterclockwise, the pin 110 is caused to move by the slot towards the right lobe. This action will start to rotate the link 108 clockwise which in turn will push the pawl 111 outwardly, being guided by its pawl slot 210 operation with the pawl operation housing pin 105 a . The secondary linkage 106 , 107 , 115 and 116 is also moving during this time and can assist the operator in overcoming any resistance or restriction caused by the gasket 323 taking a set and preventing the door form opening.
[0087] FIGS. 24 , 25 , 26 , 27 and 28 show different sectional cut views of the latch 100 in the detent position.
[0088] When cam follower, pin 110 , is fully in the right lobe, because the lever/handle 112 has been rotated counterclockwise about another 15 degrees, the detent position is attained, FIG. 27 . At this point there is sufficient resistance/friction in the mechanism to overcome the forces from the springs 117 and 118 . So in normal use, the user can move the lever/handle 112 counterclockwise to the stop caused by the detent feature. If the lever/handle 112 is released by the user at this point, it should remain in this position. This is to enable the door to be left ajar to release any pressure, steam or other gas from the inside of the enclosure while the pawl 111 remains engaged with the keeper 201 .
[0089] In the full detent position, the detent ball 103 is driven by the detent spring 102 and guided by the detent retainer 104 to contact the detent feature (dimple) 303 in the end of the main drive link 108 , FIG. 28 . This establishes the full lateral (straight outwardly transition) movement of the pawl, FIG. 27 where the latch and the door is held in the “cracked-open” position shown in FIG. 2 . In FIG. 27 the pawl 111 is shown in its fully outwardly extending position. The further movement of the pawl will be a counterclockwise rotation about its housing pin 105 a . This is only a transitional position. It is not intended that the latch can be left in this position as the “vent” position is the one recited above.
[0090] The further counter clockwise rotation of the lever/handle 112 brings the latch to the open position, FIG. 29 , where the pawl 111 is fully counterclockwise rotated into the housing (about 75 degrees). In this position the lever/handle 112 cannot rotate counterclockwise further because its right edge abuts the bottom housing member 101 wall, FIGS. 29 and 31 . FIGS. 29 , 30 , 31 , 32 and 33 show the latch 100 in different sectional cut views in the extreme open position with the lever handle 118 held fixed from movement by the detent operation of the ball 103 against the detent indentation of the lower main drive link 114 , shown in FIG. 28 . FIG. 24 shows a plan view of the latch 100 where the detent ball 103 (shown in FIG. 28 ) engages the detent indentation 233 , and holds the lever handle 112 positively in the fully open position.
[0091] As shown in FIG. 28 , the detent spring 102 exerts a force against the detent retainer 104 which holds the detent ball 103 to engage the detent indentation (depression) 233 .
[0092] The lever/handle 112 and thereby the latch 100 is held in the open position with the cam pin 110 fully in the left lobe of the guide slot 301 , FIG. 32 . In this position, the end of the main/drive link 114 abuts the abutment shoulder 305 on the handle, FIG. 33 . It is the pin 110 located within the left hand lobe of the guide slot 301 which prevents the lever/handle 112 from rotating. The abutment shoulder(s) 305 on the lever/handle 112 are only required during the latch closing movement, interacting with the end of the main/drive links 108 , 114 to prevent the pin 110 from entering the side recess 302 of the guide slot 301 in the lever/handle 112 which would cause the mechanism to lock up.
[0093] However, FIG. 33 does not show the lever/handle 112 as it is the lower link 114 which abuts the shoulder 305 . The upper main/drive link 108 is shown in FIG. 31 and the lower link 114 is shown in FIGS. 32 and 33 .
[0094] The benefit of the fixed pivot points is that they constrain a component's motion to one degree of freedom, thus enabling precise control of their movement. Controlled linear and angular displacement can only be achieved through either floating pivots, and/or sliding joints, although using a round pin within a slot enables a joint to slide and pivot within the same feature.
[0095] The floating main spring 117 ensures that the pawl 111 completes its full travel during either opening or closing, wherein the latch needs to change from one state to another without relying upon the operator. Thus, during opening, once the handle is rotated passed the detent position, the main spring 117 will drive the mechanism form the detent state to the fully open state without further movement of the handle.
[0096] During closing, the release linkage will push the main/drive linkage from the fully open state, through the detent state, where the main spring 117 will drive the main/drive linkage to ensure the pawl 111 is fully engaged with the keeper 201 . This ensures that the pawl does not unintentionally clash with the keeper. The detent state has been set to coincide with the “flip point” of the main mechanism so that the force required to hold the mechanism in that position is at it lowest despite the force being generated by the floating main spring 117 being at its greatest.
[0097] This is because the fixed end of the floating spring, the pivot point at the center of the pawl pin 109 and the center of ration of the main/drive links 108 , 114 are collinear at this point. Rotation of the main/drive links 108 , 114 in either direction will move the pawl pin 109 out of line with the fixed end of the floating spring and the center of rotation of the drive links 108 , 114 . The force of the floating main spring 117 will drive the rotation of the main/drive links 108 , 114 further in that direction. This effect can be achieved by another mechanism, but that would require springs to be located on or within one of the moving components, thereby requiring them to be larger, more expensive to produce and more complicated to assemble.
[0098] FIGS. 35 , 36 , 37 , and 38 show different sectional cut views of the latch 100 held in the detent state.
[0099] The keeper/striker 201 and its back plate 202 are held to the door jamb 320 with mounting screws 322 and nuts 321 , FIGS. 39 and 40 . In the fully engaged (locked) position, FIG. 39 , the pawl 111 hooked end 230 is fully exerted against the cup lip 234 to compress the gasket 323 . The travel of the pawl 111 is controlled by the operation of the cam pin 105 a which operates within the pawl slot 210 . In the fully engaged and gasket depressed state, the link 114 has pulled the pawl 111 fully into the housing so that the pin 105 a abuts the keeper/striker 201 end of the pawl 111 , FIG. 39 , and the gasket 323 is fully depressed to the sealing state.
[0100] In the release state, the link 114 has rotated so that the pawl 111 has moved outwardly from the housing so provide a space 235 between the main body of the oven and the oven door. FIG. 40 . In this state, the pin 109 has been moved along the pawl slot 210 and the push-out link 115 has started to rotate outwardly.
[0101] The latch is held in the door 501 by the spring clamp 402 , on one side, and by the ear 401 having the channel 403 for receiving a mounting screw 404 which seats against the inside face of the door 501 , on the other side.
[0102] Many changes can be made in the above-described invention without departing from the intent and scope thereof. It is therefore intended that the above description be read in the illustrative sense and not in the limiting sense. Substitutions and changes can be made while still being within the scope and intent of the invention. | A lever operated compression latch has an elongated, hook-ended pawl carrying a longitudinal slot, and is cam guided and pin rotated while translated to engage and withdraw from a keeper cup. The compound movement of the pawl includes a lateral translation towards the keeper cup while rotating there into, followed by a lateral withdrawal to exert a compression force between the latch body which is attached to a door and the keeper cup which is attached to a door frame. A series of interconnected links is operated by a lever handle to fold into one another to provide a compact envelope when the latch is closed and to expand outwardly to open the latch and disengage the pawl from the keeper when operated by the lever. Of this series of links, a pair of release links operates in contact with one another, and rotates on respective individual pivot points to extend outwardly from the latch envelope to engage a striker plate portion of the keeper cup. This striker engagement causes the release links to push the latch and the door from a sealing engagement with the keeper and door jamb for a short distance, prior to the latch and the door thereafter being fully opened. This striker engagement of the release links also causes the latch links to fold inwardly which rotates and translates the pawl into keeper engagement and compression. This operation is facilitated with a floating spring having one end operating as a pivot member. A detent engages one of the links to provide a physical indication to the handle lever between the hard closed position and the closed about to open position. | 8 |
BACKGROUND OF THE INVENTION
In the iron- and steel-making industry the blast furnace work has recently come to face serious difficulties as the result of the exhaustion of coal resources which, in turn, has caused deterioration of coal quality, a great rise in the price of high quality coals and difficulties in obtaining such coals. Thus, the production of coke by means of compounding coals has been adopted as a supplementary measure for improving the quality of coals used in the production of blast furnace cokes in order to overcome the insufficiency in strongly caking coal. In this case, however, it is necessary to improve the apparatus for the production of coal briquettes, namely, to improve the performances of the briquetting machine.
In a briquetting machine, a weakly caking coal or a noncaking coal is used either in place of or together with the aforesaid strongly caking coal or caking coal. A weakly caking or noncaking coal is finely pulverized with or without strongly caking or caking coal to such degree that at least 90% thereof is of a particle size of 3 mm of finer, the pulverized coal is kneaded together with a caking agent and cooled, and then the kneading mixture is briquetted into an ellipsoidal shape having a longer diameter of about 30 - 100 mm and a shorter diameter of about 20 - 30 mm or other shape in accordance with the purpose of use, to obtain a coke having high quality and high strength from a weakly caking or noncaking coal. Ordinarily, good results can be obtained by blending 3 to 4 kinds or at most 7 to 8 kinds of starting coals, in the same manner as in the usual caking processes of caking or strongly caking coals. The coal briquette thus obtained is used for the production of cokes, either alone or after having incorporated therein one third, based on the total weight, of a caking or strongly caking coal. Accordingly, the composition ratio of the starting coal mixture is so selected, according to the empirical rule and the results of preliminary experiments, that the volatile matter content, dilatation degree, and the fluidity, etc. fall into the desirable ranges. The balance between various properties such as ash content, sulfur content and the like, should also be taken into consideration.
Said caking agent is employed for the purpose of giving the weakly caking coal not only an adhesive character but also the caking power necessary for forming a coal briquette. There have hitherto been disclosed many types of caking agents, most of which have been obtained through a treatment of tars or pitches. They are roughly classified into petroleum type and coal type. A few examples of caking agents commercially available are shown below:
Petroleum type: P. D. A. (propane-deasphalted asphalt), S. D. A. (solvent-deasphalted asphalt), S.A. (straight asphalt), K. R. P. (Kreba Reginus pitch), A. S. P. (asphalt pitch) and natural asphalt;
Coal type: pitch (high, medium, low), tar, creosote oil, anthracene oil.
In addition to the above, it is also effective to use a petroleum type binder in combination with a coal type one in a certain definite proportion.
A variety of caking agents are used depending on the nature and combination of the starting coals used. The quantity of caking agent is usually in the range of 6 to 10% by weight based on the total coal.
Some of the caking agents are liquids, but the others are solids which melt at the kneading temperature. A caking agent is added to a finely pulverized compounded coal and kneaded with them so that the caking agent spreads over the pulverized coal well, coats the surface of said coal and adheres to the coal. This can be realized only in the presence of a certain quantity of water in the kneaded mixture. In other words, a petroleum type or coal type of caking agent can spread satisfactorily on the surface of finely devided coal only in the presence of water. A satisfactory results can be obtained by effecting the kneading in the presence of about 8 to 14% by weight of water, including the water originally contained in the starting coal. An excessive quantity of water is undesirable because it condenses and remains in the coal briquette. In the conventional processes, the water is fed by direct blowing of steam into the kneader which steam heats the kneader at the same time. The kneader rotates as low as 17 to 20 r.p.m. and this means the use of an excessive steam.
In general, starting coals contain about 8 to 14% water, because they have been stored outdoors. However, the product, raw coal for coal briquette preferably contains about 5 to 8% of water. Therefore, it is necessary to release the excessive water in the course of kneading and leave a desirable water content behind in the coal. Nevertheless, the excessive water tends to form condensed water in the conventional processes, particularly in the wet processes. Thus, the aforesaid desirable water content is difficult to realize so far as the conventional processes are concerned.
DESCRIPTION OF THE PRIOR ART
The process for preparing coal briquette presently adopted comprises the steps of weighing and mixing the starting coals, throwing the mixed coal into a tank, pulverizing the mixed coal by means of a pulverizing device, incorporating a caking agent into the mixed coal, kneading the resulting mixture, and charging it into a briquetting machine and briquetting it.
According to the conventional method, however, each of the above-mentioned steps is carried out separately from other steps in an independent apparatus, so that each apparatus requires auxiliary devices (for example, a transportation unit such as conveyor) and the process is complicated and requires much labor. In addition, it is difficult to obtain products having consistent quality.
The proper water content of a raw coal for briquetting is in the range of about 5 to about 8% by weight as mentioned above. The most appropriate water content is determined to match to the respective conditions such as the kind and size distribution of the starting coal, and the kind, characteristics and amount used of caking agent, etc. However, because in the conventional method, heating of the kneader is conducted by direct blowing of steam, the excess water in the coal cannot be fully released, and thus the proper water content cannot be attained.
If the water content of the raw coal for briquetting is below about 5%, there is obtained a coal having inferior or bad briquette moldability which, if briquettes moldable at all, results in a coal briquette having very low crushing resistance. If the water content of the raw coal for briquetting is over about 8%, the said coal has good briquette-moldability, but the coal briquette obtained has bad crushing resistance and light specific gravity and is not good for coking.
Regarding prior art, a further explanation will be given in the following paragraphs.
According to the prior art, starting coal is pulverized with a pulverizer such as a disintegrator, ball mill, hammer mill, impeller breaker, etc. Since coals are stored in the outside yards and exposed to rain and sunshine and thus contains various quantities of water, there can occur a number of troubles such as fluctuation in size distribution, variation in the quantity of contained water, variation in the quantity of coal treated, and thus there arise difficulties in mechanical operation (e.g., clogging, adhesion of coal particles to various parts of the machine, etc.). Among these troubles, the fluctuation in water content can be covered to some extent by the release of water in the course of the operation, but this will cause fluctuation in quality. Moreover, the variation in size distribution affects the properties of the coal briquette thus obtained. In some types of machines, a huge "dust and mist collector" must be provided in order to cope with dust. If one wishes to avoid this trouble, a special drying device such as rotary kiln must be provided in order to normalize the water content of the coal to be charged into the machine and improve the adhesive effect of the caking agent. These are both undesirable in view of environmental pollution and energy economy.
Thus the pulverized coal so obtained is then sent to the mixing step where it is mixed with caking agent. A variety of mixing devices can be utilized in this step. In case the added caking agent is a solid powder at ambient temperature, it can merely mechanically be mixed with the starting coal, because the temperature of the starting coal is also at around ambient temperature. In case the caking agent is supplied in the form of a liquid at elevated temperature, it can only adhere to and solidify on the surface of coal and cannot spread over the whole surface of the coal particles. At any rate, the caking agent cannot be uniformly spread and is merely mixed with the coal as a bulk.
In the next step, the resulting mixture is charged into a kneader. In this apparatus, steam is directly introduced into the mixture with stirring and kneading by which the mixture is heated and the caking agent is spread over the surface of the coal particles in the presence of water.
There are three types in the kneading: the vertical type, horizontal type and inclined type. Steam is directly blown into any of these types. Since the kneader has an shaft equipped with many agitating blades to knead the coal therein, it encounters increasing mechanical resistance as the caking agent dissolves, and the rotating speed of the shaft is usually about 20 r.p.m. and at most 40 to 50 r.p.m. With such rotating speed, it is impossible to spread the caking agent into the form of a thin film uniformly covering the coal surface. In other words, it is impossible at the present stage to obtain a sufficiently kneaded mixture satisfactorily usable in the production of coal briquette. In briquetting the starting coal, the caking agent should be mixed with, melted and spread onto the starting coal as sufficiently as possible. If the caking agent has a melting point of 100° C or higher, however, it cannot be melted by the prior art method, because the temperature of the starting coal cannot exceed 100° C because of the existence of water in the coal, unless its water content is reduced to zero which cannot be achieved by the introduction of steam. This is a fatal disadvantage of the prior art method.
In this type of kneader, steam is partially discharged from the top of the apparatus. This is for the reason that if the total heat of the steam is utilized, there occurs a partial condensation of steam to yield liquid water which constitutes excess water undesirable in the briquetting process. As a result, the heat efficiency of the kneader is so low as 30 to 40% which is undesirable from the viewpoint of energy economy. In addition, at the time of discharging steam from the kneader, the kneader blows out fine particles of coal together with the steam and thus a huge "dust and mist collector" is required for recovery of discharged coal. This constitutes another disadvantage of the prior art method.
The kneaded coal thus obtained is then sent to a series of independent apparatuses including a cooling apparatus, a heating apparatus, an apparatus for adding water and so on, in which the water content and temperature of the coal is regulated to the values suitable for the briquetting process. Conditions other than water content and temperature cannot be controlled so far as the prior art technique is adopted.
The description presented above is concerned with the general process according to the prior art. In the manufacture of coal briquettes of conventional type, there has been adopted the wet process and the dry process. However, they are no more than a slight modification of the above-mentioned general process. The wet process herein referred to is a process in which a starting coal is molded with a briquetting machine without removing the attached or included water in the state as it is (containing 8 - 14% water). The dry process referred to herein is a process in which the water content of the starting coal is reduced to 5 - 6% by means of, for example, a dryer and water addition to the coal is prevented as much as possible in the course of kneading by adopting an indirect heating method.
SUMMARY OF THE INVENTION
Accordingly, an object of the present invention is to provide a process for obtaining a strong coal briquette with ease from various kinds of coals and thereby overcoming the difficulties in the above mentioned prior art method and to provide an apparatus therefor.
Further object of the present invention is to provide a process for obtaining a raw coal for coal briquette which comprises pulverizing a starting coal, incorporating therein a caking agent and kneading the mixture at appropriately adjusted granular size, water content and temperature, and to provide an apparatus therefor.
Another object of the present invention is to provide a process in which a small quantity of caking agent can be spread uniformly on the surface of coal particles so as to form a uniform thin film thereon, and to provide an apparatus therefor.
Still another object of the present invention is to provide a process for obtaining a raw coal for coal briquette by which an excellent caking effect can be given to coal by the use of various caking agents, and to provide an apparatus therefor.
Still another object of the present invention is to provide an apparatus for obtaining a raw coal for coal briquette in which the pulverization of mixed coal, addition of caking agent to the pulverized coal and kneading of the resulting mixture can be carried out by means of a single machine and thereby the above-mentioned object of the invention can fully be achieved.
A still further object of the present invention is to provide an apparatus according to the preceding paragraph wherein the friction heat occurring in the course of pulverization and kneading of the starting coal can effectively be utilized for the operation of the apparatus.
Another still further object of the present invention is to provide an apparatus which is free from environmental pollution such as occurrence of dust and mist and can be operated by a continuous process with a high degree of automation.
Other objects of the invention of this application will become apparent from the following descriptions, accompanying drawings and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flow diagram of the apparatus of the present invention in which the steps for transporting a coal from the outdoor yard and fabricating it into a coal briquette are illustrated;
FIG. 2 shows a longitudinal cross sectional view of the pulverization-kneading apparatus used in the present invention shown in FIG. 1; and
FIG. 3 shows a cross sectional view taken along line A--A in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The important conditions necessary for briquetting include the followings: that the granular size should be controlled in accordance with the characteristics of the kneaded coal, that the mixture of a coal and a caking agent should be sufficiently kneaded at an appropriate temperature selected in accordance with the characteristics of the caking agent to spread the caking agent onto the whole surface of coal particles, and that the water content of the mixture should be adjusted to an appropriate value in order to obtain good spreading of the caking agent onto the coal particles.
The present invention has been accomplished as a result of extensively cnducted studies to over-come the disadvantages of the prior arts mentioned above. Thus, the present invention provides a process, and an apparatus for said process, by which can be produced raw coal for a coal briquette for use in the manufacture of cokes by the use of a caking agent which comprises pulverizing a starting coal while the water contained in the latter is left as it is, adjusting the granular size to an appropriate value suitable for the briquetting process, effectively utilizing the friction heat occurring at the time of pulverization for maintaining the system temperature at the softening temperature (fluid point) of the caking agent which constitutes one of the characteristic properties of the present invention, if necessary, supplying external heat to regulate the system temperature, thereby facilitating the contact between the particles of starting coal and the caking agent, and regulating the system water content to an appropriate value for briquetting by controlling the internal pressure of the vapor occurring in the process so as to increase or decrease the water content of the starting mixture, all the above-mentioned steps being carried out in a single apparatus. The caking agents usable in the invention include petroleum type caking agents, coal type caking agents, and many other types of caking agents.
According to the present invention, the pulverization of starting coal, the addition of caking agent and the kneading can be carried out in a single apparatus. The operation can be completed in a short period of time, for example in 3 to 10 minutes, preferably in 4 to 6 minutes so that the obtained raw coal for briquetting can be charged into the briquetting machine under the best conditions.
The characteristic features of the present invention are as follows: charging a starting coal into a treating tank equipped with two types of stirring devices, one being a conventional type and the other being a rotating blade which is provided at the bottom of the tank, and can be driven independently of the said conventional stirring device and pulverizing the charged coal therein under a high speed rotation of 500 - 1000 r.p.m., maintaining both the inlet and the outlet closed at this time so that the temperature of the starting material itself rises due to friction as its pulverization progresses. There occurs in general a temperature rise of about 30° to 100° C depending on the characteristics of the charged starting coal, its size and its water content. However the temperature rise is determined by taking into consideration of the melting point of the caking agent used, and if necessary, heat is added to the system indirectly from the outside by means of steam, heat transfer medium oil or electrical heating until the temperature of the starting coal reaches the necessary value, and transforming the water present in the coal into vapor to increase the inner pressure of the closed vessel, and if the temperature of starting coal exceed 100° C as the result, the temperature of the coal itself also rises beyond 100° C.
Since the treating tank is closed, all the dust and mist stays in the tank. When the size of the coal particles reaches the intended value and the temperature reaches the predetermined value, a caking agent is supplied from the top of the tank in the form of a liquid jet when it is a liquid or in the form of fine particles when it is a solid. At this time, the speed of the stirrer is decreased in accordance with the characteristics of the caking agent (400 - 800 r.p.m.). Excess water and generated gases are discharged through a control valve provided at the top of the apparatus into te exterior atmosphere. If the water content of the starting coal is insufficient as is often the case in summer, a supplementary quantity of water conducted fed through another inlet provided at the top of the apparatus. Maintenance of pressure is closely related to the water content of the starting coal and the characteristic melting point of the caking agent. If the pressure is insufficient, external steam is fed so as to maintain the necessary pressure and appropriate water content. During the above-mentioned operation, the speed of rotation is maintained at a given value. After a predetermined period of time (3 to 10 minutes) has elasped, the treated material is discharged through an outlet provided at the bottom of the apparatus and sent to a molding machine.
In the above-mentioned operation, the stirrer rotates at a high speed during the step of pulverization, but at a lower speed during the step of kneading, so as to accomplish the intended object of the invention. Because the kneading is carried out at a high temperature with strong stirring, and because it is carried out in the presence of an appropriate quantity of water, it is extremely effective.
In the process of the present invention, the granular size is adjusted to the optimum value by controlling the speed of the stirrer and the operation period in conformity with the nature of the mixed coal used. On the other hand, the kneading is carried out under optimum conditions, namely the pulverized coal is kneaded with caking agent under optimum temperature with addition or removal of water to maintain the best condition, in consideration of the size of the starting coal, its water content, the nature of the caking agent, etc. It is preferable, therefore, to determine the optimum conditions through a preliminary experiment with the same mixed coal and caking agent.
According to the invention, the starting coal is pulverized and the temperature thereof is kept at a desirable value and therefore, the added caking agent can be blended thoroughly with the coal particles, melted sufficiently over spread ver the particles and, at the same time, the water content of the system can be controlled more precisely than in any of the conventional processes. Water content of the coal briquette is preferably in the range of about 5 to about 8% as mentioned above, although it depends somewhat on the nature of the starting coal, the nature of the caking agent, the granular size of the coal, etc. In general, however, starting coal contains as much as 8 to 14% of water. Therefore, water is partially removed in the kneader at an elevated temperature so that the water content reaches a reasonable value. Since the process and apparatus of the present invention make it possible to regulate the water content precisely as mentioned above, it is always possible to obtain a starting coal of desirable water content. In the summer when the water content of coal is apt to be insufficient, it is possible to add water to the coal so as to keep the molded coal to a reasonable water content.
As has been mentioned above, the process of the invention is also advantageous in respect of energy economy in that it consumes only one half as much motive power (5 to 6 KWH per ton of molded coal) and one third as much heat energy (20,000 - 25,000 Kcal per ton of molded coal) as the conventional processes. It is also advantageous in view of the prevention of environmental pollution in that all conveyance of all materials is by gas stream so that no occurrence of dust and mist is observed in any of the operation units. This makes it possible to prevent environmental pollution without using any special expensive devices. Moreover, the apparatus of the invention occupies as little as one half the ground area of the conventional apparatuses, because its operation units do not necessitate many independent units.
The present invention will be further illustrated below with reference to the accompanying drawings. Starting coal 1 stored outdoors is sent into hopper 3 of pneumatic carrier placed indoors by means of belt conveyer 2. The starting coal is automatically and intermittently sent through pneumatic carrier 4 into treating tank 5. The end of the pneumatic carrier is so designed that it is tightly closed after the coal has been delivered. The treating tank 5 is equipped with thermometer 6 which measures the inner temperature. U type rotating blade 8 and rotating blade 22, fixed co-axially or to the same shaft, are rotated at a high speed by motive power source 16 through speed controller 17.
The starting coal in the tank is pulverized by the blade rotating at a high speed and a rise in temperature is caused by frictional heat. When the temperature indicated by the thermometer 6 does not reach the intended value, the starting coal is heated by the aid of a heat source placed in the external heating cabinet 9. The heat source may be of electrical heating type, superheated steam type, or the like. Upon external heating, the inner pressure rises. If the water content of the system is lower than the value expected from the system temperature, water is forced into the tank through water charge tube 28. When the inner temperature and the water content have just reached the intended value by the aid of external heating, a signal is produced to slow the speed of the regulator. At the same time, a caking agent stored in tank 12 is sent and ejected into tank 5 through pump 11 and pipe 10. The caking agent is mixed with starting coal by stirring and melts and spreads on the coal particles at a high temperature. Concurrently, the water contained in the starting coal vaporizes so that the inner pressure of the closed tank ascends. The pressure is measured with a pressure guage. When the pressure exceeds the intended value, steam is discharged through duct 13 and pressure control valve 14 into the external atmosphere.
After these steps have been completed, outlet 18 is opened and the material is sent into hopper 19 placed on the briquetting machine 20 and then into the briquetting machine 20 itself. The briquetted product is transported outside of the apparatus by conveyer 21. The step mentioned above take only 3 to 6 minutes, preferably 4 to 6 minutes in total.
Although the mixing of coal and caking agent are performed in batch operation, it can also be carried out continuously by using two tanks alternately. It is also possible to place two or three treating tanks 5 in parallel from which the treated material is discharged alternately into hopper 19 and briquetted continuously if the capacity of the briquetting machine so permits.
When the treated material thus obtained according to the process of the present invention is used, the coal briquette obtained has a higher density, a higher true specific gravity and a much lower water content than coals briquetted according to the conventional processes. Thus, an excellent starting material for the manufacture of cokes is obtained.
The treating tank of the invention which constitutes the characteristic feature of the invention will be illustrated below in further detail.
The U type rotating blade 8 keeps an angle of 5° to 30° with respect to the direction of rotation, and its cutting part has a taper for the convenience of the cutting work. The upper part of the rotating blade 8 is equipped with a protecting blade 26 which protects the upper wall of the tank against the adhesion of material. The lower rotating blade 22 is in the shape of a propeller and resides at the bottom of the tank 5.
Pressure-reserving device 23 is resistant to high speed rotation and is closely contacted with the shaft so as to maintain the inner pressure. Another pressure-reserving device 24 is provided for the purpose of maintaining the inner pressure of the tank throughout the operation and is so designed that it can be opened when the tank requires repair or the blade is changed.
In treating tank 5 coal collection blade 25 is provided on a shaft and has a sectoral cross section facing the direction of rotation of coal. The angle of the blade is changeable from outside. Adhesion-preventing blade 26 prevents the apparatus wall from the adhesion of coal dust. Double door 27 provided at the inlet for starting coal is a two-step, alternate-opening type of tight door which is used for the prevention of dust and mist as well as for the preservation of inner pressure.
When starting coal is sent through pneumatic carrier 4 into treating tank 5 as has been mentioned above, the upper and lower doors of the door 27 are opened and closed alternately to allow a necessary quantity of coal to be rapidly supplied to the tank. After the coal has been supplied, the door is kept closed in order to prevent the scattering of dust, the leakage of steam and the loss of heat.
Rotating blade 8 and 22 are fixed coaxially or fixed on the same shaft and can rotate with high speed. Having the shape of a propeller, the lower rotating blade makes the starting coal rise to the upper part of the tank. The floating coal is pulverized by the upper rotating blade 8. The latter has an angle of 5° to 30° to the direction of rotation so that it has a great contact area with the starting coal, which enhances the effect of pulverization and elevates the temperature of the coal itself owing to the friction. The shaft rotates at so high a speed as to expel the coal toward the wall of the tank due to centrifugal force. The collecting blade 25 is for the purpose of changing the fluid current and driving the coal toward the central position. The angle of the collecting blade can be altered from outside.
The adhesion of coal to the upper circumference of the tank is promoted by the presence of excessive water in the starting coal particularly at the beginning stage of the treatment (in the first one or two minutes). The adhesion-preventing blade 26 provided for the purpose of scraping off adhering coal is placed over the blade 8 and makes a scraping angle of 10°-30°.
The angles of collecting blade 25 and preventing blade 26 constitutes a particularly important factor. In the apparatus of the invention which is operated at high speed, the blade exert good effects upon pulverization and elevation of temperature. The subsequent operations and functions have already been mentioned above.
The following examples will further illustrate the invention of this application, where the examples are limited to those cases where a starting material for coal briquette is prepared without adding any external water. Addition of external water belongs to a special modification adopted during summer. One skilled in the art will easily understand the operations and the results in the case of adding water with reference to the description given below.
EXAMPLE 1
In this example, the dependencies of granular size, temperature elevation and water content upon the mode of pulverization were examined. A mixed coal composed of 70% Taiheiyo coal and 30% BK coal (hereinafter referred to as Coal A) was pulverized either with the conventional disintegrator or by the process of the present invention. The results obtained were as shown in Table 1. The apparatus of the present invention used for the pulverization has the following dimensions:
Lower stirring blade: 1000 mm in length, 50 mm in width and 5 mm in thickness;
Upper stirring blade: 250 mm in height of U shape, 130 mm in horizontal length of U shape, 5 mm in thickness, 50 mm in width;
Quantity of coal treated per run per tank; 10 liter coal/one run;
Duration of treatment: 4 minutes;
Mode of heating; indirect heating.
Table 1__________________________________________________________________________Pulverization of Coal A (Japanese coal)Granular Starting Disinte- The process of the inventionsize coal grator 400 r.p.m. 600 r.p.m. 1000 r.p.m.__________________________________________________________________________3 mm above 50.4% 24.5% 14.6% 8.1% 0 %3 - 2 mm 13.3% 16.1% 10.5% 5.9% 7.1 %2 - 1 mm 12.1% 14.5% 12.4% 11.8% 9.8 %1 mm under 24.2% 44.9% 62.5% 74.2% 83.1 %Water contentbefore 9.8% 9.8% 9.8% 9.8% 9.8%pulverizationWater contentafter -- 9.2% 8.0% 7.3% 6.8%pulverizationRise of tempe-rature -- +2° C +51° C +72° C +85° C__________________________________________________________________________
In another experiment, a mixed coal for manufacture of metallurgical cokes which has comprised of British, Australian, Russian and Japanese coals (hereinafter referred to as Coal B) was pulverized with the same apparatus under the same conditions as the above. The results obtained were as shown in Table 2.
Table 2__________________________________________________________________________Pulverization of Coal B(mixed coal of foreign coals and Japanese coal)Granular Starting Disinte- The process of the inventionsize coal grator 400 r.p.m. 600 r.p.m. 1000 r.p.m.__________________________________________________________________________3 mm above 19.0% 12.5% 6.9% 3.0% 0 %3 - 2 mm 11.9% 11.4% 8.8% 7.0% 2.4%2 - 1 mm 17.8% 17.9% 12.4% 12.7% 8.7%1 mm under 51.3% 58.2% 71.9% 76.6% 88.6%Water contentbefore 7.8% 7.8% 7.8% 7.8% 7.8%pulverizationWater contentafter -- 7.5 6.0% 5.5% 5.9%pulverizationRise of tempe-rature -- +1.5° C +55° C +79° C +95° C__________________________________________________________________________
According to the process of the present invention, as seen in Tables 1 and 2, the granular size decreases with the rise in rotating speed, the water content decreases after the pulverization, and the temperature rises owing to frictional heat. Since the rotating speed of the rotating blade can be controlled smoothly in the range of 0 to 1500 r.p.m., the granular size can be adjusted to an arbitrarily chosen value.
EXAMPLE 2
Coal B was pulverized with the same apparatus as used in Example 1 at a rotating speed of 800 r.p.m. Immediately after completion of the pulverization, a petroleum type caking agent (propane-deasphalted asphalt, mp. 50°- 75° C) was added and the resulting mixture was indirectly heatd with external steam of 2 kg/cm 2 . The rotating speed was elevated to 700 r.p.m. and the excessive water was discharged in the form of steam. After operation for 3 minutes, the starting coal was discharged and briquetted with a briquetting machine.
The products thus obtained were compared with those obtained by the conventional process.
Into the starting coal (Coal B) was incorporated a petroleum type caking agent in a proportion of 6.5%, 7.0% or 7.5%. The results obtained were as summarized in Table 3.
The conditions of the conventional process employed in this example were as follows: 70% strong caking coal; 30% caking coal (containing 15% Japanese coal); Coking Index of the mixed coal 88% or higher; after mixing, the mixture was pulverized to a size of 3 mm under 88%; the mixed coal was further mixed by means of a double screw type mixer (manufactured by Keihan Co., Japan), during which the same quantity of the same caking agent as mentioned above was added.
Table 3__________________________________________________________________________ Conventional process Process of the inventionProportion of caking agent* 6.5% 7.0% 7.5% 6.5% 7.0% 7.5%__________________________________________________________________________Briquetting temperature (° C) 73 73 74 98 103 111Water content of briquet-ting process (%) 9.8 9.7 9.8 5.0 5.0 4.9Water content in briquet-ting coal (%) 9.3 9.0 9.0 4.9 4.9 4.8Crushing hardness (kg/P)** 43 54 63 78 83 91Sp.gr. of product 1.112 1.118 1.120 1.221 1.231 1.241__________________________________________________________________________ (Note) *Caking agent P.D.A. **Crushing hardness (kg/P) was obtained in accordance with the Testing Standard of Japanese National Railroads, and is represented in terms of pressure resistance per piece of molded coal.
According to the conventional process, as seen in Table 3, the change in the quantity of caking agent causes no great changes in the temperature and water content at the time of briquetting nor in specific gravity of product and only a slight change in crushing hardness (from 43 kg/P at 6.5% addition to 63 kg/P at 7.5% addition).
Therefore by the conventional process granular size seems to be unchanged by the briquetting conditions, and only the increase in the absoluble amount of caking agent affects the crushing behavior. The result obtained by the invention are in great contrast to those of the conventional method in that the crushing strength is higher than in the conventional process by about 30 - 35 kg/P for all percentage of addition (6.5%, 7.01% and 7.5%).
A crushing strength of 55 or more is satisfactory to resist handling. The high crushing strength obtained according to the invention is attributable to the afore-mentioned precisely controlled granular size of the coal as well as to the higher temperature of the kneading system which permits the caking agent to be sufficiently dissolved, mixed and spread onto the surface of the coal granules. This results in the high specific gravity and high crushing strength of the product.
EXAMPLE 3
A number of experiments were carried out in the same apparatus as in Example 1, using a mixed coal obtained by mixing Taiheiyo coal and KIB coal in various ratios and using as a caking agent, P.D.A. and soft pitch. The results were as shown in Table 4.
Table 4__________________________________________________________________________Run No. 1 2 3 4Item__________________________________________________________________________Test conditions:1. Rotation number 400 500 600 450of mixer (rpm)2. Amount of 500 480 450 550charged material(kg)3. Time period of 4 4.5 4 3.5treatment (min)4. Name of used Taiheiyo ibid Taiheiyo Taiheiyocoal 70 50 20 KIB 30 KIB 50 KIB 805. Kind of caking PDA PDA PDA Softagent pitch6. Amount of the same(% by weight) 6.0 6.5 7.0 7.5Measured items:1. Granular size ofcharged coal 80 80 83 85(% under 3 mm)2. Granular size oftreated coal 85 88 91 89(% under 3 mm)3. Water content of 9.7 11.0 9.0 12.0charged coal (%)4. Water content of 5.1 5.0 4.7 5.3Briquetted coal(%)5. Temperature of 34° C 33° C 32° C 34° Cbriquetting6. Water releasing Observed Observed Observed Observedupon treatmentPhysical properties of product7. Crushing strength 75 83 94 97(kg/P)8. Trommel strength(%) 88 91 93 949. Specific gravity 1,198 1,210 1,220 1,213__________________________________________________________________________
EXAMPLE 4
The procedure of Example 2 was repeated except that the caking agent was used in an amount of 7.5% and coal B was used as the starting coal. The coal briquette was coked under the same coking conditions using the coal kneaded either according to the process of the present invention or according to the conventional process. Strengths (drum indices) of the resulting cokes were compared as shown in Table 5.
Table 5______________________________________(Starting Coal B, caking agent 7.5%)Process Conventional Process ofDrum index process the invention______________________________________D.sub.15.sup.30 92.0 93.8D.sub.15.sup.150 78.8 82.3______________________________________
The method and conditions used in coking were as follows:
The cokes were prepared by dry distillation with a chamber type coking furnace. Strengths of the resulting cokes were measured according to the procedure of JIS (Japanese Industrial Standard).
The drum indices shown in Table 5 were those of the cokes prepared from starting coal B and 7.5% petroleum type caking agent. The process of the invention is superior to the conventional process in drum index by +1.3% with regard to 30/15 and by +3.5% with regard to 150/15. The differences in drum indices between the two processes are due to the differences in granular size of coal, melting behavior and spreading behavior of caking agent and water content under molding condition. Thus, it is understandable that the process of the invention gives not only better physical properties but also a better coking property to the molded coal.
As is obvious from the description presented above, the process according to the present invention is superior to the conventional processes in view of the characteristic properties and coking property of the coal briquette obtained and in view of energy economy. Moreover, it causes less environmental pollution and requires less installment area in the construction of the factory. Thus, the process of the invention doubtlessly provides an excellent method capable of said application in the molded coal industry hereafter. | The present invention relates to a process for preparing coal briquettes which comprises pulverizing a starting coal mixture, incorporating therein a caking agent, kneading the resulting mixture and molding it and more particularly to a process for preparing coal briquettes which comprises pulverizing said starting coal to the desired degree, incorporating said caking agent in the starting coal mixture at an appropriate temperature in the presence of an appropriate water content, thereby uniformly coating the surface of the starting coal mixture with the caking agent under precise control to obtain an excellent molding material, and then briquetting the latter, as well as to an apparatus for carrying out the process. | 2 |
RELATED APPLICATIONS
[0001] This application claims benefit of U.S. Ser. No. 62/159,884 filed May 11, 2015; U.S. Ser. No. 62/159,885, filed May 11, 2015; U.S. Ser. No. 62/244,901, filed Oct. 22, 2015; U.S. Ser. No. 62/244,902, filed Oct. 22, 2015; and U.S. Ser. No. 62/244,903, filed Oct. 22, 2015, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to relatively non-corrosive, high load nitrapyrin liquid formulations, comprising polar solvents and novel metal corrosion inhibitors and method of preparing and using the same.
BACKGROUND AND SUMMARY
[0003] (Trichloromethyl)pyridine compounds, such as nitrapyrin (2-chloro-6-(trichloromethyl)pyridine), inhibit the process of nitrification and have been or are currently used in combination with nitrogen based fertilizers as described in U.S. Pat. No. 3,135,594, which is herein incorporated by reference. The application of these compounds helps to maintain levels of ammonium nitrogen applied to the soil in the ammonium form (plant accessible stabilized nitrogen); higher levels of plant accessible nitrogen in the soil enhances crop performance and can increase crop yields.
[0004] Due to their volatile nature some formulations of nitrapyrin, also referred to herein as liquid inhibitior compositions, are best applied by incorporating them mechanically into the soil, or by watering them into the soil within about 8 hours after applying them to the surface of the soil. Some encapsulated formulations of nitrapyrin are suitable for rapid or dump release of nitrapyrin into the soil. Some formulations of nitrapyrin encapsulated with lignin sulfonates, especially useful for quick release applications, are disclosed in U.S. Pat. No. 4,746,513, which is incorporated herein by reference. Polycondensation encapsulation, as disclosed in U.S. Pat. No. 5,925,464, has also been used to encapsulate agriculturally active ingredients such as nitrapyrin, particularly to enhance handling safety and storage stability of the active ingredient by using polyurethane rather than polyurea encapsulants.
[0005] Encapsulated nitrapyrin formulations exhibit certain advantages over liquid non-encapsulated formulations of nitrapyrin, such as improved stability. Despite the advantages of encapsulated nitrapyrin formulations, liquid non-encapsulated formulations of nitrapyrin are still used, at least in part, because they tend to be easier to formulate and may cost less than encapsulated nitrapyrin formulations. As with most any soil amendment there is an advantage to using formulations that include a high level of the agriculturally active component of the formulation. Formulations that have higher levels of an active ingredient generally mean that less material must be moved, stored, and applied to the field; the net result is that these formulations may exhibit lower material handling costs.
[0006] In most commercially available liquid formulations the level of nitrapyrin has been limited by the need to pair nitrapyrin with relatively non-corrosive solvents. Some aspects of the present invention provide a liquid formulation of nitrapyrin (i.e., a liquid inhibitor composition) that includes a relatively high level of nitrapyrin. In these inventive formulations nitrapyrin is present in polar solvents and is especially formulated to be non-corrosive or at least less corrosive than previous formulations of nitrapyrin that included significant levels of polar solvents. Dibasic ester, as used herein, refers to a compound containing two ester groups. Examples of dibasic esters include, but are not limited to, dimethyl glutarate, dimethyl succinate, dimethyl adipate, dimethyl 2-methylglutarate, and mixtures thereof.
[0007] Some embodiments include a liquid formulation of nitrapyrin comprising of: nitrapyrin, at least one polar solvent selected from the group consisting of: (1) N,N-dialkyl fatty acid amides such as those found in products such as, but not limited to, di-substituted amides including for example N,N-di-methyloctanamide (N,N-dimethylcarprylamide) and N,N-dimethyldecanamide (N,N-dimethylcapramide), compounds sold under the trade names, Hallcomid M810, Hallcomid M10, still other compounds that can be used in capacity include, for example, Rhodiasolv® ADMA 810, Rhodiasolv® ADMA 10, Genagen 4166 and Genagen 4296; (2) cyclohexanone; (3) dibasic esters such as, but not limited to, dimethyl 2-methylglutarate, which is available as Rhodiasolv® IRIS, and a dibasic ester mixture composed of dimethyl glutarate, dimethyl succinate, and dimethyl adipate which is available as Rhodiasolv® RPDE; (4) glycol ethers and polyalkylene diglycol ethers such as, but not limited to, dipropylene glycol methyl ether which is available as Dowanol™ DPM; (5) alkylene carbonates such as, but not limited to, propylene carbonate which is available as Jeffsol AG 1555; (6) methyl-5-(dimethylamino)-2-methyl-5-oxopentanoate which is available as Rhodiasolv® Polarclean; (7) organophosphate compounds such as, but not limited to, trialkyl phosphates, (8) alkoxybenzene compounds such as, but not limited to, methoxybenzene (anisole) and ethoxybenzene, (9) ketones such as, but not limited to, cyclopentanone and cyclohexanone, and at least one inhibitor of metal corrosion. The liquid formulations of the present invention may include high levels of nitrapyrin and exhibit relatively non-corrosive properties, making them suitable for use with metal objects such as metal storage tanks and metal application equipment.
[0008] In one embodiment, the corrosion inhibitor is selected from the group consisting of: nicotinamide, a picoline, 2,6 lutidine, expoxidized linseed oil (ELO) and DER 331 liquid epoxy resin.
[0009] In one embodiment, the corrosion inhibitor is niacin, also known as nicotinic acid. In another embodiment, the corrosion inhibitor is a niacin-derivative. In yet another embodiment, the corrosion inhibitor is niacinamide (it is understood that the terms “niacinamide” and “nicotinamide” are synonymous), methyl isonicotinate, niacin esters, acipimox, aluminum nicotinate, niceritrol, nicoclonate, nicomol, inositol hexaniacinate, oxiniacic acid or combinations thereof.
[0010] Non-limiting examples of niacin derivatives include methyl isonicotinate, niacin esters, niacinamide salicylate, niacinamide ascorbate, niacinamide folate, niacinamide lipoate, niacinamide lactate, niacinamide glycolate, niacinamide mandalate, niacinamide malate, niacinamide hydroxycitrate, niacinamide hydroxytetronate, niacinamide aleurate, niacinamide petroselinate, niacinamide pantothenate, niacinamide adenosine monophosphate (AMP), niacinamide diphosphate (ADP), niacinamide adenosine triphosphate (ATP), niacinamide hydroquinone carboxylate, nicotinic acid, niacinamide, Acipimox (5-methylpyrazinecarboxylic acid, 4-oxide), aluminum nicotinate, Niceritrol (3-pyridinecarboxylic acid 2,2-bis [[3-pyridinylcarbonyl]oxy]methyl)-1,3-propanediyl ester, Nicoclonate, Nicomol (2,2,6,6-(1-hydroxycyclohexyl) tetramethyltetrakis (3-pyridinecarboxylate), inositol hexaniacinate, and Oxiniacic Acid (3-pyridinecarboxylic acid, 1-oxide.
[0011] In another embodiment, the corrosion inhibitor is derivatized linseed oil, including, but not limited to, epoxidized linseed oil. In another embodiment, the corrosion inhibitor is 1,2-epoxydecane. In another embodiment, the corrosion is an amino alcohol, for example, 2-amino-2-methyl-1-propanol (i.e., AMP-95 or AMP-99). In another embodiment, the corrosion inhibitor is an imidazole compound, for example, 1-methyl imidazole. In another embodiment, the polar solvent is diethylene glycol butyl ether (DGBE). In another embodiment, the corrosion inhibitor and/or co-solvent is an esteramide compound.
[0012] In yet another embodiment, the corrosion inhibitor is selected from niacinamide, methyl isonicotinate, niacin esters, acipimox, aluminum nicotinate, niceritrol, nicoclonate, nicomol, inositol hexaniacinate, oxiniacic acid, linseed oil or derivatized linseed oil, including but not limited to epoxidized linseed oil, 1,2-epoxydecane, an amino alcohol, for example, 2-amino-2-methyl-1-propanol, 1-methyl imidazole, a quinolone compound such as quinaldine, or any combination thereof.
[0013] In another aspect, described herein are liquid fertilizer compositions for use in agricultural applications comprising: one more nitrogenous fertilizer compounds; at least one nitrification inhibitor comprising a (trichloromethyl)pyridine compound; a polar solvent; and, optionally, a corrosion inhibitor.
[0014] In one embodiment, the liquid inhibitor composition or liquid fertilizer composition further comprises at least one additional component including, but not limited to, a co-solvent, a pH adjustor, flow agents, preservatives, buffering agents, antifoam agents, compatibility agents, deposition agents, dispersants, drift control agents, penetrants, surfactants, spreaders, and wetting agents, and the like. In one embodiment, the nitrogenous fertilizer compound is anhydrous ammonia.
[0015] Polar solvents that can be used to practice some embodiment of the invention include, but are not limited to, cyclohexanone, propylene carbonate, N,N-dialkyl fatty acid amides: specifically the mixture of C8/C10 fatty acid N,N-dimethylamides (Hallcomid M810), other fatty acid amides also C8 & C10 N,N-dimethylamides individually, the dibasic ester mixture composed of dimethyl glutarate, dimethyl succinate, and dimethyl adipate, which is available as Rhodiasolv® RPDE, organophosphate compounds which are trialkyl phosphates, and alkoxybenzene compounds such as methoxybenzene (anisole) and ethoxybenzene. In one embodiment, the organophosphate compound may be selected from the group including triethyl phosphate, tri(isobutyl)phosphate, tributoxyethyl phosphate (TBEP) and tris(2-ethylhexyl) phosphate. In one embodiment, the polar solvent is comprised of the dibasic ester mixture composed of dimethyl glutarate, dimethyl succinate, and dimethyl adipate (Rhodiasolv® RPDE) and cyclohexanone. In one embodiment, the alkoxybenzene compound is methoxybenzene (anisole). In one embodiment, the organophosphate compound is triethyl phosphate.
[0016] Polar solvents that have not worked in some of the exemplary formulation disclosed herein include; (1) dipropylene glycol monomethyl ether (Dowanol DPM), (2) methyl-5-(dimethylamino)-2-methyl-5-oxopentanoate (Polarclean), solvent mixture composed of reaction mass of dimethyl glutarate, dimethyl succinate, and dimethyl adipate (Rhodiasolv® RPDE), and N-butylpyrrolidone (TamiSolve NxG).
[0017] Corrosion inhibitors that may not be well suited, or even efficacious, for the practice of the instant invention include, methyltrioctyl ammonium chloride, poly(12-hydroxyoctadecanoic acid-co-ethylenimine) (e.g., Atlox LP6).
[0018] Corrosion inhibitors that may be used to practice some embodiments of the invention include, for example, pyridinecarboxamides (i.e., nicotinamide or niacinamide), methylpyridines (i.e., α-picoline, 2,6 lutidine), epoxidized seed or vegetable oils (i.e., epoxidized linseed oil (ELO), epoxidized soybean oil, etc.) and epoxy resin (liquid reaction product of epichlorohydrin and bisphenol, such as, D.E.R.™ 331™ liquid epoxy resin (DER 331)).
[0019] Molecules of the following formulas reduce and/or protect against metal corrosion caused by certain nitrification inhibitors including those disclosed herein, these molecules include:
[0020] (1) methylpyridines:
[0000]
[0021] (2) pyridine carboxamides:
[0000]
[0022] (3) pyridine carboxylic acid and esters:
[0000]
[0023] (4) epoxidized seed or vegetable oils:
[0000]
[0024] wherein R 1 , R 2 , and R 3 independently represent C 14 -C 20 alkyl groups substituted with from zero to four epoxide groups;
[0025] (5) an epoxy resin based on bisphenol-type chemistry:
[0000]
[0026] wherein R 1 and R 2 independently represent H, C 1 -C 4 alkyl, or phenyl, and R 3 and R 4 independently represent H, C 1 -C 4 alkyl, C 1 -C 4 haloalkyl, or phenyl;
[0027] (6) 1,2-epoxyalkanes:
[0000]
[0028] (7) 1-alkylimidazoles:
[0000]
[0029] (8) amine salts of nicotinic acid:
[0000]
[0030] wherein R 1 , R 2 and R 3 independently represent H, (C 1 -C 18 ) alkyl or (C 1 -C 18 ) alkyl substituted with one or more substituents selected from, but not limited to, halogen, hydroxy, alkoxy or alkylthio, provided that the substituents are sterically compatible and the rules of chemical bonding and strain energy are satisfied, or any two of R 1 , R 2 and R 3 represent —(CH 2 ) n — where n is an integer from 3-5.
[0031] (9) primary, secondary & tertiary amines:
[0000]
[0032] wherein R 1 , R 2 and R 3 independently represent H, (C 1 -C 18 ) alkyl or (C 1 -C 18 ) alkyl substituted with one or more substituents selected from, but not limited to, halogen, hydroxy, alkoxy or alkylthio, provided that the substituents are sterically compatible and the rules of chemical bonding and strain energy are satisfied, or any two of R 1 , R 2 and R 3 represent —(CH 2 ) n — where n is an integer from 3-5;
[0033] (10) tertiary amine oxides:
[0000]
[0034] wherein R 4 , R 5 and R 6 independently represent (C 1 -C 18 ) alkyl or (C 1 -C 18 ) alkyl substituted with one or more substituents selected from, but not limited to, halogen, hydroxy, alkoxy or alkylthio, provided that the substituents are sterically compatible and the rules of chemical bonding and strain energy are satisfied, or any two of R 1 , R 2 and R 3 represent —(CH 2 ) n — where n is an integer from 3-5, or wherein R 4 is a straight or branched chain (C 1 -C 18 ) alkyl or an alkyletherpropyl or alkylamidopropyl of the formula:
[0000]
wherein R 7 is a straight or branched chain (C 10 -C 18 ) alkyl, and
[0036] R 5 and R 6 independently are straight or branched chain (C 1 -C 18 ) alkyl or ethoxylates or propoxylates of the formula:
[0000]
[0037] wherein n is an integer from 1 to 20;
[0038] (11) tetra-substituted ammonium salts:
[0000]
[0039] wherein R 1 , R 2 and R 3 independently represents (C 1 -C 16 ) alkyl or (C 1 -C 18 ) alkyl substituted with one or more substituents selected from, but not limited to, halogen, hydroxy, alkoxy or alkylthio, provided that the substituents are sterically compatible and the rules of chemical bonding and strain energy are satisfied, or any two of R 1 , R 2 and R 3 represent —(CH 2 ) n — where n is an integer from 3-5, R 4 represents ((C 1 -C 16 ) alkyl or arylalkyl), and X − is selected from, but not limited to, chloride, bromide, or iodide;
[0040] and mixtures thereof.
[0041] A first set of embodiments includes a composition comprising an inhibitor of nitrification; at least one polar solvent miscible corrosion inhibitor; a first solvent, wherein said first solvent is a polar solvent which readily dissolves the nitrification inhibitor; and an optional second solvent, the optional second solvent is miscible in the first solvent and wherein the second solvent is no more polar than the first solvent, in some of these embodiments the inhibitor of nitrification is a (trichloromethyl) pyridine compound such as nitrapyrin (2-chloro-6-(trichloromethyl)pyridine.
[0042] A second set of embodiments is provided according to the first set of embodiments wherein the at least one polar solvent miscible corrosion inhibitor is selected from the group consisting of:
[0043] (1) methylpyridines:
[0000]
[0044] (2) pyridine carboxamides:
[0000]
[0045] (e.g., nicotinamide and isomers thereof)
[0046] (3) pyridine carboxylic acid and esters:
[0000]
[0047] (e.g., nicotinic acid, nicotinate esters, and isomers thereof)
[0048] (4) epoxidized seed or vegetable oils:
[0000]
[0049] wherein R 1 , R 2 , and R 3 independently represent C 14 -C 20 alkyl groups substituted with from zero to four epoxide groups.
[0050] (5) epoxy resin (based on bisphenol-type chemistry)
[0000]
[0051] wherein R 1 and R 2 independently represent H, C 1 -C 4 alkyl, or phenyl, and R 3 and R 4 independently represent H, C1-C4 alkyl, C1-C4 haloalkyl, or phenyl.
[0052] (6) 1,2-epoxyalkanes:
[0053] (e.g., 1,2-epoxydecane)
[0000]
[0054] (7) 1-alkylimidazoles:
[0000]
[0055] (8) amine salts of nicotinic acid:
[0000]
[0056] wherein R 1 , R 2 and R 3 independently represent H, (C 1 -C 18 ) alkyl or (C 1 -C 18 ) alkyl substituted with one or more substituents selected from, but not limited to, halogen, hydroxy, alkoxy or alkylthio, provided that the substituents are sterically compatible and the rules of chemical bonding and strain energy are satisfied, or any two of R1, R2 and R3 represent —(CH2)n- where n is an integer from 3-5.
[0057] (9) primary, secondary & tertiary amines:
[0000]
[0058] wherein R 1 , R 2 and R 3 independently represent H, (C 1 -C 18 ) alkyl or (C 1 -C 18 ) alkyl substituted with one or more substituents selected from, but not limited to, halogen, hydroxy, alkoxy or alkylthio, provided that the substituents are sterically compatible and the rules of chemical bonding and strain energy are satisfied, or any two of R 1 , R 2 and R 3 represent —(CH 2 ) n — where n is an integer from 3-5.
[0059] (10) tertiary amine oxides:
[0000]
[0060] wherein R 4 , R 5 and R 6 independently represent (C 1 -C 18 ) alkyl or (C 1 -C 18 ) alkyl substituted with one or more substituents selected from, but not limited to, halogen, hydroxy, alkoxy or alkylthio, provided that the substituents are sterically compatible and the rules of chemical bonding and strain energy are satisfied, or any two of R 1 , R 2 and R 3 represent —(CH 2 ) n — where n is an integer from 3-5, or
[0061] wherein R 4 is a straight or branched chain (C 1 -C 18 ) alkyl or an alkyletherpropyl or alkylamidopropyl of the formula:
[0000]
[0062] wherein R 7 is a straight or branched chain (C 10 -C 18 ) alkyl, and
[0000] R 5 and R 6 independently are straight or branched chain (C 1 -C 18 ) alkyl or ethoxylates or propoxylates of the formula:
[0000]
[0063] wherein n is an integer from 1 to 20, or mixtures thereof.
[0064] (11) tetra-substituted ammonium salts:
[0000]
[0065] wherein R 1 , R 2 and R 3 independently represents (C 1 -C 16 ) alkyl or (C 1 -C 18 ) alkyl substituted with one or more substituents selected from, but not limited to, halogen, hydroxy, alkoxy or alkylthio, provided that the substituents are sterically compatible and the rules of chemical bonding and strain energy are satisfied, or any two of R 1 , R 2 and R 3 represent —(CH 2 ) n — where n is an integer from 3-5, R 4 represents ((C 1 -C 16 ) alkyl or arylalkyl), and X − is selected from, but not limited to, chloride, bromide, or iodide. In some embodiments, N—((C 1- C 16 ) alkyl or arylalkyl) tri((C 1 -C 16 ) alkyl)ammonium salts are those in which R 1 , R 2 , R 3 and R 4 are the same or where R 1 , R 2 and R 3 are CH 3 and R 4 is (C 2 -C 16 ) alkyl or arylalkyl.
[0066] A third set of embodiments includes a formulation, comprising: 2-chloro-6-(trichloromethyl)pyridine, wherein the 2-chloro-6 (trichloromethyl)pyridine is present in the formulation in the range of about 200 to about 400 g/L; at least one polar solvent, selected from the group consisting of: a mixture of N, N-dimethyloctanamide (N,N-dimethylcaprylamide) and N, N-dimethyldecanamide (N, N-dimethylcapramide); and a dibasic ester, wherein the first solvent comprises between about 40 to about 70 weight percent of the formulation; at least one polar solvent miscible corrosion inhibitor, selected from the group consisting of: a liquid epoxy resin; 2, 6-dimethylpyridine; epoxidized linseed oil; and nicotinamide; wherein each said polar solvent miscible corrosion inhibitor, comprises about 0.5 to about 2.5 weight percent; and at least one optional solvent selected from the group consisting of: a solvent naphtha, wherein the second solvent comprises about 5.0 to about 20.0 weight percent of the formulation.
[0067] A fourth set of embodiments includes a formulation comprising: about 240 to about 350 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 40 to about 60 weight percent of a mixture of N, N-dimethyloctanamide (N, N-dimethylcaprylamide) and N, N-dimethyldecanamide (N, N-dimethylcapramide); about 0.5 to about 1.5 weight percent of liquid epoxy resin and about 0.5 to about 1.5 weight percent 2, 6-dimethylpyridine; and about 5 to about 20 weight percent solvent naphtha.
[0068] A fifth set of embodiments includes a formulation comprising: about 230 to about 300 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 45 to about 55 weight percent of a mixture of N, N-dimethyloctanamide (N, N-dimethylcaprylamide) and N,N-dimethyldecanamide (N,N-dimethylcapramide); about 0.75 to about 1.4 weight percent of liquid epoxy resin; about 0.5 to about 1.5 weight percent 2, 6-dimethylpyridine; and about 10 to about 15 weight percent solvent naphtha.
[0069] A sixth set of embodiments includes a formulation comprising: about 240 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 50.0 to about 55 weight percent of a mixture of N,N-dimethyloctanamide (N,N-dimethylcaprylamide) and N,N-dimethyldecanamide (N,N-dimethylcapramide); about 1.0 to about 1.1 weight percent of liquid epoxy resin oil; about 0.5 to about 1.5 weight percent 2, 6-dimethylpyridine; and about 11.0 to about 14.0 weight percent solvent naphtha.
[0070] A seventh set of embodiments includes a formulation comprising: about 240 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 50.55 weight percent of a mixture of N, N-dimethyloctanamide (N, N-dimethylcaprylamide) and N, N-dimethyldecanamide (N,N-dimethylcapramide); about 1.2 weight percent of liquid epoxy resin oil; about 0.5 to about 1.5 weight percent 2, 6-dimethylpyridine; and about 12.64 weight percent solvent naphtha.
[0071] An eighth set of embodiments includes a formulation comprising: about 200 to about 400 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 20 to about 50 weight percent of a dibasic ester; about 0.5 to about 2.5 weight percent of epoxidized linseed oil; about 0.5 to about 2.5 weight percent nicotinamide; and about 20.0 to about 50.0 weight percent cyclohexanone.
[0072] A ninth set of embodiments includes a formulation comprising: about 240 g/L to about 350 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 45 to about 55 weight percent of a dibasic ester; about 1.0 to about 2.0 weight percent of epoxidized linseed oil; and about 0.8 weight percent nicotinamide; and about 11.0 to about 14.0 weight percent cyclohexanone.
[0073] A tenth set of embodiments includes a formulation comprising: about 240 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 50.47 weight percent of a dibasic ester; about 1.5 weight percent of epoxidized linseed oil; about 0.8 weight percent nicotinamide; and about 12.62 weight percent cyclohexanone.
[0074] A twelfth set of embodiments includes a formulation, comprising: about 200 to about 400 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 40 to about 60 weight percent of a dibasic ester; about 0.5 to about 2.5 weight percent of epoxidized linseed oil; and about 0.4 to about 1.5 weight percent nicotinamide.
[0075] A thirteenth set of embodiments include the twelfth embodiment: about 240 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 63.08 weight percent of a dibasic ester; about 1.5 weight percent of epoxidized linseed oil; and about 0.6 to about 1.0 weight percent nicotinamide.
[0076] A fourteenth set of embodiments include a formulation, comprising: about 240 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 63.08 weight percent of a dibasic ester; about 1.5 weight percent of epoxidized linseed oil; and about 0.8 weight percent nicotinamide.
[0077] A fifteenth set of embodiments includes a formulation, comprising: about 200 to about 400 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 40 to about 70 weight percent of triethyl phosphate; about 0.5 to about 2.5 weight percent of epoxidized linseed oil; and about 0.5 to about 2.5 weight percent of methyl nicotinate.
[0078] A sixteenth set of embodiments includes a formulation, comprising: about 200 to about 400 g/L of 2-chloro-6-(trichloromethyl)pyridine; about 40 to about 70 weight percent of methoxybenzene; about 0.5 to about 2.5 weight percent of nicotinamide; and about 0.5 to about 2.5 weight percent of 2-amino-2-methyl-1-propanol.
[0079] A seventeenth set of embodiments including at least one of the formulations according to any of the first through the sixteenth set of embodiments and at least additional agricultural ingredient selected from the group consisting of: herbicides, insecticides, mitocides, fungicides, and fertilizers.
[0080] An eighteenth set of embodiments including any of the formulations according to the seventeenth set of embodiments, wherein the agricultural ingredient is a fertilizer.
[0081] A nineteenth set of embodiments including any of the formulation according to the eighteenth set of embodiments, wherein the fertilizer includes nitrogen.
[0082] A twentieth set of embodiments including methods for treating soil, comprising the steps of: applying at least one of the formulations according to the first through the nineteenth set embodiments to at least one area selected from the area consisting of: the surface of a portion of soil, beneath the surface of a portion of soil, a portion of a plant, and a portion of a surface adjacent to a plant.
[0083] A twenty-first set of embodiments including any of the methods according to the twentieth set of embodiments, wherein the applying step includes injecting at least one of the formulations into a portion of soil.
DETAILED DESCRIPTION
[0084] 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 are within the scope of this disclosure and the claims.
[0085] Unless noted otherwise as used herein the term ‘about’ refers to a range of values from less than 10 percent to greater than 10 percent of the stated value, for example about 1.0 encompasses values from 0.9 to 1.1.
[0086] (Trichloromethyl)pyridine compounds useful in the composition of the present invention include compounds having a pyridine ring which is substituted with at least one trichloromethyl group and mineral acid salts thereof. The presence of a (trichloromethyl)pyridine compound suppresses the nitrification of ammonium nitrogen in the soil or growth medium, thereby preventing the rapid loss of ammonium nitrogen originating from nitrogen fertilizers, organic nitrogen constituents, or organic fertilizers and the like. Suitable compounds include those containing chlorine or methyl substituents on the pyridine ring in addition to a trichloromethyl group, and are inclusive of chlorination products of methyl pyridines such as the lutidines, the collidines and the picolines. Suitable mineral acid salts of the (trichloromethyl)pyridine compounds include hydrochlorides, nitrates, sulfates and phosphates.
[0087] The (trichloromethyl)pyridine compounds useful in the practice of the present invention are typically oily liquids or crystalline solids dissolved in a solvent. Other suitable compounds are described in U.S. Pat. No. 3,135,594. A preferred (trichloromethyl)pyridine is 2-chloro-6-(trichloromethyl)pyridine, also known as nitrapyrin, and the active ingredient of the product N-SERVE™ (Trademark of Dow AgroSciences LLC).
[0088] N-SERVE™ has an active nitrapyrin loading level of about 240 g/L. The nitrapyrin loading level of N-SERVE™ is set in part by the solubility of nitrapyrin in the solvents used in the formulation (e.g., Aromatic 100) and its corrosiveness at elevated temperature (i.e., 50° C.). Still other non-polar hydrophobic solvents which can be used in relatively non-corrosive formulations of nitrapyrin include, but are not limited to, other naphthalene depleted solvents, i.e., aromatic solvent that includes less than about 1% naphthalene. Some non-ionic, hydrophobic post-added solvents that can be used to prepare liquid formulations of nitrapyrin include, but are not limited to: cyclohexanone; Aromatic 100 Fluid, also known as solvent naphtha or light aromatic; Aromatic 150 Fluid, also known as solvent naphtha, heavy aromatic, high flash aromatic naphtha type II, heavy aromatic solvent naphtha, hydrocarbons, C10 aromatics, >1% naphthalene, A150, S150; and Aromatic 200 Fluid, also known as solvent naphtha, heavy aromatic, high flash aromatic naphtha type II, heavy aromatic solvent naphtha, hydrocarbons, C10-13 aromatics, >1% naphthalene, A200, and S200.
[0089] Nitrapyrin tends to be more soluble in polar solvents than in non-polar solvents. Unfortunately, formulations of nitrapyrin in polar solvents tend to be corrosive, especially towards carbon steel storage containers. Due at least in part to their corrosive properties, formulations of nitrapyrin in polar solvents have proved to be difficult to commercialize. Some aspects of the present invention include identifying and using especially useful corrosion inhibition additives which make practical liquid formulations of nitrapyrin in polar solvent that include on the order of ˜360 g/L of nitrapyrin. These inventive formulations are markedly less corrosive than are currently available nitrapyrin polar solvent formulations.
[0090] In one embodiment, the (trichloromethyl)pyridine compound is nitrapyrin. The (trichloromethyl)pyridine compound is present in the liquid inhibitor composition at a lower range of 2% by weight of the composition, or in other embodiments, at a lower range of 3% by weight of the composition, or in other embodiments, at a lower range of 5% by weight of the composition.
[0091] In another embodiment, the (trichloromethyl)pyridine compound is present in the liquid inhibitor composition at a lower range 0.5%, or 1%, or 2%, or 3%, or 4%, or 5%, 6%, or 8%, or 10% or 12% or 14%, by weight of the composition. In another embodiment, the (trichloromethyl)pyridine compound is present in the liquid inhibitor composition at an upper range of 75%, or 65%, or 60% by weight of the composition. In another embodiment, the (trichloromethyl)pyridine compound is present in the liquid inhibitor composition at an upper range of 60% by weight of the composition. In another embodiment, the (trichloromethyl)pyridine compound is present in the liquid inhibitor composition at an upper range of 55% by weight of the composition. In another embodiment, the (trichloromethyl)pyridine compound is present in the liquid inhibitor composition at an upper range of 59%, or 57%, or 55% or 53% or 50%, by weight of the composition. In another embodiment, the (trichloromethyl)pyridine compound is present in the liquid inhibitor composition at an upper range of 48%, or 46%, or 45% or 42% or 40%, by weight of the composition.
[0092] Described herein are high load compositions (in one embodiment, a loading level of 360 g/L) of nitrapyrin, which demonstrate stability in various extreme conditions, such as cold conditions. The compositions as described herein are also capable of provide corrosion resistance to carbon steel tanks.
[0093] In one embodiment, the (trichloromethyl)pyridine compound is dispersed in the liquid inhibitor composition at loading level of at least 200 g/L, or in another embodiment, at least 250 g/L, or in another embodiment, at least 300 g/L, or in another embodiment, at least 320 g/L, or in a further embodiment, at least 340 g/L, or in another embodiment, at least 360 g/L, or in yet another embodiment, at least 380 g/L, or in another embodiment, at least 400 g/L.
[0094] In one embodiment, the (trichloromethyl)pyridine compound, typically 2-chloro-6-(trichloromethyl)pyridine, has a solubility at 25° C. of at least 300 grams per liter (g/L), or in another embodiment, at least 320 g/L, or in a further embodiment, at least 340 g/L, or in another embodiment, at least 360 g/L, or in yet another embodiment, at least 380 g/L, or in another embodiment, at least 400 g/L.
[0095] In one embodiment, the liquid inhibitor composition are made by contacting one or more nitrification inhibitors with a solvent comprising at least one organophosphate compound, whereby the nitrification inhibitor is dissolved or dispersed in the solvent. The liquid inhibitor composition can further comprises at least one additional component, typically a corrosion inhibitor.
[0096] The liquid fertilizer compositions, as described herein, comprise: one more nitrogenous fertilizer compounds; at least one nitrification inhibitor comprising a (trichloromethyl)pyridine compound; a solvent comprising an organophosphate compound; and, optionally, a corrosion inhibitor. In one embodiment, the liquid inhibitor composition further comprises at least one additional component including, but not limited to, a co-solvent, a pH adjustor, flow agents, preservatives, buffering agents, antifoam agents, compatibility agents, deposition agents, dispersants, drift control agents, penetrants, surfactants, spreaders, and wetting agents, and the like.
[0097] In one embodiment, the nitrogenous fertilizer compound is anhydrous ammonia.
[0098] In yet another aspect, described herein are liquid fertilizer compositions comprising, based on weight of the composition: (a) up to about 99 wt %, by weight of composition, of one or more nitrogenous fertilizer compounds, which in one embodiment is anhydrous ammonia (b) a (trichloromethyl)pyridine compound, which in one embodiment is 2-chloro-6-(trichloromethyl)pyridine, (c) a solvent comprising an organophosphate compound, and (d) a corrosion inhibitor. In one embodiment, the organophosphate compound is an alkyl phosphate. In one embodiment, the organophosphate compound is triethyl phosphate. In one embodiment, the organophosphate compound is triethyl phosphate, tri(isobutyl)phosphate, tributoxyethyl phosphate (TBEP) or tris(2-ethylhexyl) phosphate.
[0099] Methods of making a liquid fertilizer composition comprising contacting one or more nitrogenous fertilizer compounds with a liquid inhibitor composition, as described herein. In one embodiment, the nitrogenous fertilizer compound is anhydrous ammonia. The liquid inhibitor composition comprises, in one embodiment, at least one of a nitrification inhibitor, which is dissolved or dispersed in a solvent comprising at least one organophosphate compound. In one embodiment, the nitrification inhibitor comprises a (trichloromethyl)pyridine compound. The liquid inhibitor composition, in one embodiment, further comprises at least one additional component, typically a corrosion inhibitor.
[0100] In one embodiment, the liquid fertilizer compositions as described herein are utilized for treating soil. The term “treating” in one embodiment means contacting the compositions as described herein with soil. The term “treating”, in yet another embodiment, means concurrent mechanical mixing of the described compositions with soil. In another embodiment, the term “treating” means applying the described compositions to the surface of the soil and thereafter mechanically incorporating the compositions into soil (for example, at a certain depth). In yet another embodiment, the term “treating” means incorporating the described compositions into the soil at a certain depth, such as by injection and irrigation.
[0101] In one embodiment, the term “treating” means injecting the liquid fertilizer composition as described herein into soil at a depth of less than or equal to 10 inches. In another embodiment, the term “treating” means injecting the liquid fertilizer composition as described herein into soil at a depth of less than or equal to 9 inches, or in some embodiments, less than or equal to 8 inches, or in some embodiments, less than or equal to 7 inches, or in some embodiments, less than or equal to 6 inches, or in some embodiments, less than or equal to 5 inches, or in some embodiments, less than or equal to 4 inches, or in some embodiments, less than or equal to 3 inches.
[0102] In another aspect, described herein are methods for fertilizing target plants, comprising applying a liquid fertilizer composition to soil or environment of a target plant, the liquid fertilizer composition comprising: one more nitrogenous fertilizer compounds; at least one nitrification inhibitor comprising a (trichloromethyl)pyridine compound; a solvent comprising an organophosphate compound, and, optionally, a corrosion inhibitor. In one embodiment, the liquid inhibitor composition further comprises at least one additional component including, but not limited to, a co-solvent, a pH adjustor, flow agents, preservatives, buffering agents, antifoam agents, compatibility agents, deposition agents, dispersants, drift control agents, penetrants, surfactants, spreaders, and wetting agents, and the like. In one embodiment, the nitrogenous fertilizer compound is anhydrous ammonia.
[0103] In one embodiment, the liquid inhibitor composition or liquid fertilizer composition, as described herein, forms a stable composition at temperatures less than or equal to 15° C., or 10° C., or 7° C., or 5° C., or 3° C. In another embodiment, the liquid inhibitor composition or liquid fertilizer composition, as described herein, forms a stable composition at temperatures less than or equal to 0° C. In another embodiment, the liquid inhibitor composition or liquid fertilizer composition, as described herein, forms a stable composition at temperatures less than or equal to −1° C., or −2° C., or −3° C., or −4° C., or −5° C., or −6° C., or −7° C., or −8° C., or −9° C., or −10° C. In one embodiment, a stable composition means that no flocculation or crystallization is observed over a period of time.
[0104] In one embodiment, the liquid inhibitor composition or liquid fertilizer composition, as described herein, forms a stable composition for a period of at least 24 hours. In one embodiment, the liquid inhibitor composition or liquid fertilizer composition, as described herein, forms a stable composition for a period of at least 48 hours. In one embodiment, the liquid inhibitor composition or liquid fertilizer composition, as described herein, forms a stable composition for a period of at least 1 week. In one embodiment, the liquid inhibitor composition or liquid fertilizer composition, as described herein, forms a stable composition for a period of at least 2 weeks.
[0105] In one embodiment, the compositions as described herein are stable for at least 3 months in metal containers. In one embodiment, the compositions as described herein are stable for at least 2 months in metal containers at 25° C. (or in some embodiments, 50° C.). In one embodiment, the compositions as described herein are stable for at least 1 month in metal containers at 25° C. (or in some embodiments, 50° C.). The metal containers can be, in one embodiment, carbon steel containers.
[0106] In another embodiment, compounds suitable as the organic solvent component of the composition and methods of the present invention form liquid, or otherwise stable, compositions with the nitrification inhibitor at temperatures at or greater than −16° C., in alternative embodiments, greater than −14° C., in other embodiments, greater than −12° C., in other embodiments, greater than −10° C., in further embodiments, greater than −8° C., in other embodiments, greater than −5° C., in other embodiments, greater than −3° C., in other embodiments, greater than −2° C., in other embodiments, greater than 0° C., in other embodiments, greater than 2° C., in other embodiments, greater than 4° C., in other embodiments, greater than 5° C.
[0107] In some embodiments, at the specified temperature ranges or at greater than a specified temperature (as described herein), the liquid fertilizer composition is stable, meaning the nitrification inhibitor(s) do not react with the solvent or solvent component under anticipated manufacturing, storage, and use conditions. In another embodiment, at the specified temperature ranges or at greater than a specified temperature (as described herein), the liquid fertilizer composition is stable, meaning the liquid fertilizer composition or liquid inhibitor composition is or substantially is in one phase, i.e., no visible crystals, no visible precipitation, and/or no visible multiple liquid phases.
[0108] In one embodiment, the organophosphate compound is according to formula (I)
[0000]
[0109] wherein R1, R2 and R3, are each independently chosen from H, a C1-C16 alkyl group, a C1-C16 alkenyl, group, a C1-C16 alkoxyalkyl group, a C7-C30 alkylarylalkyl group, a C7-C30 arylalkyl group, or an aryl group; provided that at least one of R1, R2 or R3 is not H. In another embodiment, R1, R2 and R3, are each independently chosen from H, a C1-C12 alkyl group, a C1-C12 alkenyl, group, a C1-C12 alkoxyalkyl group, a C7-C30 alkylarylalkyl group, a C7-C30 arylalkyl group, or an aryl group; provided that at least one of R1, R2 or R3 is not H. In one embodiment, R1, R2 and R3, are each independently chosen from H, a C1-C4 alkyl group, a C4-C8 alkyl group, a C1-C12 alkenyl, group, a C1-C4 alkoxyalkyl group, a C7-C30 alkylarylalkyl group, a C7-C30 arylalkyl group, or an aryl group; provided that at least one of R1, R2 or R3 is not H.
[0110] In yet another embodiment, R1, R2 and R3, are each independently chosen from a linear or branched C1-C12 alkyl group, a linear or branched C1-C12 alkenyl, group, a linear or branched C1-C12 alkoxyalkyl group, a linear or branched C7-C30 alkylarylalkyl group, a linear or branched C7-C30 arylalkyl group, or an aryl group. In one embodiment, R1, R2 and R3, are each independently chosen from a C1-C12 alkyl group, more typically, a C2-C8 alkyl group.
[0111] In one embodiment, R1, R2 and R3, are each independently a C1-C3 alkyl group, typically an ethyl group. In another embodiment, R1, R2 and R3, are each independently a branched C1-C12 alkyl group, typically, a 2-ethylhexyl group. In one embodiment, R1, R2 and R3, are each independently a C1-C12 alkoxyalkyl group, typically a butoxyethyl group.
[0112] The present invention described herein will become apparent from the following detailed description and examples, which comprises in one aspect, a liquid inhibitor composition for use in agricultural applications and/or liquid fertilizer compositions comprising: at least one nitrification inhibitor comprising a (trichloromethyl)pyridine compound; a polar solvent blend comprising at least two polar solvents: (i) a dibasic ester blend and (ii) a ketone such as cyclohexanone; and, optionally, a corrosion inhibitor.
[0113] In another aspect, described herein are methods of making liquid inhibitor compositions comprising contacting one or more nitrification inhibitors with a polar solvent blend comprising at least two polar solvents: (i) a dibasic ester blend and (ii) a ketone such as cyclohexanone, whereby the nitrification inhibitor is dissolved or dispersed in the polar solvent blend. In one embodiment, the nitrification inhibitor comprises a (trichloromethyl)pyridine compound. The liquid inhibitor composition, in one embodiment, further comprises at least one additional component, typically a corrosion inhibitor.
[0114] In another aspect, described herein are liquid fertilizer compositions for use in agricultural applications comprising: one or more nitrogenous fertilizer compounds; at least one nitrification inhibitor comprising a (trichloromethyl)pyridine compound; a polar solvent blend comprising at least two polar solvents: (i) a dibasic ester blend and (ii) a ketone such as cyclohexanone; and, optionally, a corrosion inhibitor.
[0115] In certain embodiments, the dibasic ester blend comprises:
[0116] a diester of formula (IIa):
[0000]
[0117] a diester of formula (IIb):
[0000]
[0000] and
[0118] a diester of formula (IIc):
[0000]
[0119] R 1 and/or R 2 can individually comprise a hydrocarbon having from about 1 to about 8 carbon atoms, typically, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, n-butyl, isoamyl, hexyl, heptyl or octyl.
[0120] In certain other embodiments, the dibasic ester blend comprises:
[0121] a diester of the formula (IIIa):
[0000]
[0122] a diester of the formula (IIIb):
[0000]
[0000] and, optionally,
[0123] a diester of the formula (IIIc):
[0000]
[0124] R 1 and/or R 2 can individually comprise a hydrocarbon having from about 1 to about 8 carbon atoms, typically, methyl, ethyl, propyl, isopropyl, butyl, isobutyl, n-butyl, isoamyl, hexyl, heptyl, or octyl. In such embodiments, the blend typically comprises (by weight of the blend) (i) from about 5% to about 30% of the diester of formula (IIIc), (ii) from about 70% to about 95% of the diester of formula (IIIb), and (iii) from about 0% to about 10% of the diester of formula (IIIc). More typically, the blend typically comprises (by weight of the blend): (i) from about 6% to about 12% of the diester of formula (IIIa), (ii) from about 86% to about 92% of the diester of formula (IIIb), and (iii) from about 0.5% to about 4% of the diester of formula (IIIc).
[0125] Most typically, the blend comprises (by weight of the blend): (i) about 9% of the diester of formula (IIIa), (ii) about 89% of the diester of formula (IIIb), and (iii) about 1% of the diester of formula (Inc). The blend is generally characterized by a flash point of 98° C., a vapor pressure at 20° C. of less than about 10 Pa, and a distillation temperature range of about 200-275° C.
[0126] In some embodiments, the polar solvent blend comprises (by weight of the solvent blend) up to 100 wt % or 99.9 wt % of the ketone. In one embodiment, the polar solvent blend comprises (by total weight of the polar solvent blend) up to 80 wt % of the ketone. In one embodiment, the polar solvent blend comprises (by total weight of the polar solvent blend) up to 90 wt % of the ketone. In one embodiment, the polar solvent blend comprises (by total weight of the polar solvent blend) up to 70 wt % of the ketone. In one embodiment, the polar solvent blend comprises (by total weight of the polar solvent blend) up to 65 wt % of the ketone. In one embodiment, the polar solvent blend comprises (by total weight of the polar solvent blend) up to 60 wt % of the ketone. In one embodiment, the polar solvent blend comprises (by total weight of the polar solvent blend) up to 55 wt % of the ketone. In one embodiment, the polar solvent blend comprises (by total weight of the polar solvent blend) up to 50 wt % of the ketone. In one embodiment, the polar solvent blend comprises (by total weight of the polar solvent blend) up to 45 wt % of the ketone. In one embodiment, the polar solvent blend comprises (by total weight of the polar solvent blend) up to 40 wt % of the ketone. It is believe that the composition of the polar solvent blend allows for the loading levels as described herein.
[0127] Suitable example of ketones include but are not limited to any one or more of acetone, methyl ethyl ketone, methyl propyl ketone, cyanoacetone, ethoxy: acetone, acetonylacetone, diacetone alcohol, methyl isobutyl ketone, diethyl ketone, diisopropyl ketone, diisobutyl ketone, methyl-n-amyl ketone, methyl-n-hexyl ketone, cyclopentanone, methylcyclohexanone, methyl-cyclopentanone, cyclohexanone, methylallylcyclohexanone, phenylcyclohexanone, cyclohexylcyclohexanone, benzylcyclohexanone, phorone, isophorone, and, B-ionone, methyl vinyl ketone, methyl isopropenyl ketone, methyl propenyl ketone, mesityl oxide, chloroacetone, acetophenone, benzophenone, methyl 2-naphthyl ketone, propiophenone, butyrophenone, p-acetyl biphenyl, p-methylacetophenone, p-methoxyacetophenone, p-chloroacetophenone, p-bromoacetophenone, acetoa'cetic ester, acetoacetic nitrile, acetoacetic amide, acetyl-p cymene, dibenzyl ketone, and the like. In one embodiment, the ketone is cyclohexanone.
[0128] In some embodiments, the dibasic ester blend comprises adducts of alcohol and linear diacids, each adduct having the formula (IV):
[0000] R—OOC-A-COO—R (IV)
[0129] wherein R is an alkyl group (e.g., methyl, ethyl, etc.) and A is a mixture of —(CH2)4-, —(CH2)3, and —(CH2)2-. In other embodiments, the blend comprises adducts of alcohol, typically ethanol, and linear diacids, the adducts having the formula R1-OOC-A-COO—R2, wherein at least part of R1 and/or R2 are residues of at least one linear alcohol having 4 carbon atoms, and/or at least one linear or branched alcohol having at least 5 carbon atoms, and wherein A is a divalent linear hydrocarbon. In some embodiments A is one or a mixture of —(CH2)4-, —(CH2)3, and —(CH2)2-. In other embodiments, the dibasic ester comprises adducts of an alcohol and linear or branched diacids, the adducts having the formula (IV): R—OOC-A-COO—R, wherein R is an alkyl group (e.g., methyl, ethyl, etc.) and A one of the following: —(CH2)4-, —(CH2)3, —(CH2)2-, —CH2-, or any mixture thereof.
[0130] The dibasic ester blend may be derived from one or more by-products in the production of polyamide, for example, polyamide 6,6. In one embodiment, at least one dibasic ester comprises a blend of linear or branched, cyclic or noncyclic, C1-C20 alkyl, aryl, alkylaryl or arylalkyl esters of adipic diacids, glutaric diacids, and succinic diacids. In another embodiment, the composition comprises a blend of linear or branched, cyclic or noncyclic, C1-C20 alkyl, aryl, alkylaryl or arylalkyl esters of adipic diacids, methylglutaric diacids, and ethylsuccinic diacids
[0131] Generally, polyamide is a copolymer prepared by a condensation reaction formed by reacting a diamine and a dicarboxylic acid. Specifically, polyamide 6,6 is a copolymer prepared by a condensation reaction formed by reacting a diamine, typically hexamethylenediamine, with a dicarboxylic acid, typically adipic acid.
[0132] In one embodiment, the blend of dibasic esters can be derived from one or more by-products in the reaction, synthesis and/or production of adipic acid utilized in the production of polyamide, the composition comprising a blend of dialkyl esters of adipic diacids, glutaric diacids, and succinic diacids (herein referred to sometimes as “AGS” or the “AGS blend”), In one embodiment the dibasic ester blend comprises dimethyl adipate, dimethyl glutarate and dimethyl succinate.
[0133] In one embodiment, the blend of esters is derived from by-products in the reaction, synthesis and/or production of hexamethylenediamine utilized in the production of polyamide, typically polyamide 6,6. The composition comprises a blend of dialkyl esters of methylglutaric diacids, ethylsuccinic diacids, and optionally adipic diacids (herein referred to sometimes as “MGA”, “MGN”, “MGN blend” or “MGA blend”). In one embodiment the dibasic ester blend comprises dimethyl adipate, dimethyl methylglutarate and dimethyl ethylsuccinate.
[0134] In one embodiment, the liquid inhibitor composition or liquid fertilizer composition further comprises at least one additional component including, but not limited to, a co-solvent, a pH adjustor, flow agents, preservatives, buffering agents, antifoam agents, compatibility agents, deposition agents, dispersants, drift control agents, penetrants, surfactants, spreaders, and wetting agents, and the like. In one embodiment, the nitrogenous fertilizer compound is anhydrous ammonia.
[0135] In another aspect, described herein are methods of making a liquid fertilizer compositions comprising contacting one or more nitrogenous fertilizer compounds with liquid inhibitor composition. In one embodiment, the nitrogenous fertilizer compound is anhydrous ammonia. The liquid inhibitor composition comprises, in one embodiment, at least one of a nitrification inhibitor, which is dissolved or dispersed in a solvent blend comprising at least two polar solvents: (i) a dibasic ester blend and (ii) a ketone such as cyclohexanone. In one embodiment, the nitrification inhibitor comprises a (trichloromethyl)pyridine compound. The liquid inhibitor composition, in one embodiment, further comprises at least one additional component, typically a corrosion inhibitor.
[0136] In another embodiment, one or more second solvents can be used to dissolve or disperse (trichloromethyl)pyridine compounds at high loading levels and include, but are not limited to, solvent naphtha, aromatic solvents, mineral oils, kerosene, and chlorinated aliphatic and aromatic hydrocarbons. In one particular embodiment, the one or more second solvents used to dissolve or disperse (trichloromethyl)pyridine compounds at high loading levels include but are not limited to xylene and solvent naphtha.
[0137] In one particular embodiment, the co-solvent is an esteramide compound according to formula (II):
[0000] R1OOC-A-CONR2R3 (II)
[0138] wherein:
A is a divalent linear or branched (C2-C8)aliphatic group, and R1, R2, and R3 are each independently (C1-C12)alkyl, (C1-C12)aryl, (C1-C12)alkaryl or (C1-C12)arylalkyl, and R2 and R3 may each optionally be substituted with one or more hydroxyl groups.
[0140] The inventive formulations of (trichloromethyl)pyridine compound may be applied to the soil or a growth medium at a rate in the range of at least one lower limit selected from the group of lower limits consisting of about 0.1, about 0.25, about 0.5 and about 0.58 kg/hectare to at least one upper limit selected from the group consisting of about 1.0, about 1.2 and about 1.5 kg/hectare. The preferred amount can be easily ascertained by the application preference, considering factors such as soil pH, temperature, soil type and mode of application.
[0141] The formulations of the present invention can be applied in any manner which will benefit the crop of interest. In one embodiment the inventive formulation is applied to growth medium in a band or row application. In another embodiment, the formulation is applied to or throughout the growth medium prior to seeding or transplanting the desired crop plant. In yet another embodiment, the formulation can be applied to the root zone of growing plants.
[0142] The soil may be prepared in any convenient manner compatible with the use of the present invention, including mechanically mixing the formulation with the soil. Still other application may include applying the formulation to the surface of the soil and thereafter dragging, dicing or cutting the formulation into the soil to a desired depth. Still other methods of delivering the nitrification inhibitor into the soil, include methods such as injection, and spraying, or irrigation. In many applications the (trichloromethyl)pyridine compound is delivered into the soil to the desired depth of up to 6 inches (15.24 cm.).
[0143] In some embodiments the inventive nitrapyrin formulation may be used along with other agriculturally active ingredients such as insecticides, fungicides, mitocides, herbicides, and the like.
[0144] Some exemplary herbicides which can be used along with the inventive nitrapyrin formulations include, but are not limited to acetochlor, alachlor, aminopyralid, atrazine, benoxacor, bromoxynil, carfentrazone, chlorsulfuron, clodinafop, clopyralid, dicamba, diclofop-methyl, dimethenamid, fenoxaprop, flucarbazone, flufenacet, flumetsulam, flumiclorac, fluroxypyr, glufosinate-ammonium, glyphosate, halosulfuron-methyl, imazamethabenz, imazamox, imazapyr, imazaquin, imazethapyr, isoxaflutole, quinclorac, MCPA, MCP amine, MCP ester, mefenoxam, mesotrione, metolachlor, s-metolachlor, metribuzin, metsulfuron methyl, nicosulfuron, paraquat, pendimethalin, picloram, primisulfuron, propoxycarbazone, prosulfuron, pyraflufen ethyl, rimsulfuron, simazine, sulfosulfuron, thifensulfuron, topramezone, tralkoxydim, triallate, triasulfuron, tribenuron, triclopyr, trifluralin, 2,4-D, 2,4-D amine, 2,4-D ester and the like, 4-CPA, 4-CPB, 4-CPP, 2,4-D, 3,4-DA, 2,4-DB, 3,4-DB, 2,4-DEB, 2,4-DEP, 3,4-DP, 2,4,5-TB, 2,3,6-TBA, allidochlor, acetochlor, acifluorfen, aclonifen, alachlor, alloxydim, alorac, ametridione, ametryn, amibuzin, amicarbazone, amidosulfuron, aminocyclopyrachlor, aminopyralid, aminopyralid, amiprofos-methyl, amitrole, anilofos, anisuron, asulam, asulam, atraton, atrazine, azafenidin, azimsulfuron, aziprotryne, barban, BCPC, beflubutamid, benazolin, bencarbazone, benfluralin, benfuresate, bensulfuron, bensulide, bentazone, benzadox, benzfendizone, benzipram, benzobicyclon, benzofenap, benzofluor, benzoylprop, benzthiazuron, bicylopyrone, bifenox, bilanafos, bilanafos, bispyribac, bromacil, bromobonil, bromobutide, bromofenoxim, bromoxynil, brompyrazon, butachlor, butafenacil, butamifos, butenachlor, buthidazole, buthiuron, butralin, butroxydim, buturon, butylate, cafenstrole, cafenstrole, cambendichlor, carbasulam, carbasulam, carbetamide, carboxazole chlorprocarb, carfentrazone, CDEA, CEPC, chlomethoxyfen, chloramben, chloranocryl, chlorazifop, chlorazine, chlorbromuron, chlorbufam, chloreturon, chlorfenac, chlorfenprop, chlorflurazole, chlorflurenol, chloridazon, chlorimuron, chlornitrofen, chloropon, chlorotoluron, chloroxuron, chloroxynil, chlorpropham, chlorsulfuron, chlorthal, chlorthiamid, cinidon-ethyl, cinmethylin, cinosulfuron, cisanilide, clethodim, cliodinate, clodinafop, clofop, clomazone, clomeprop, clomeprop, cloprop, cloproxydim, clopyralid, clopyralid, cloransulam, CPMF, CPPC, credazine, cumyluron, cyanatryn, cyanazine, cycloate, cyclosulfamuron, cycloxydim, cycluron, cyhalofop, cyperquat, cyprazine, cyprazole, cypromid, daimuron, dalapon, dazomet, delachlor, desmedipham, desmetryn, diallate, dicamba, dichlobenil, dichloralurea, dichlormate, dichlorprop, dichlorprop-P, diclofop, diclosulam, diethamquat, diethatyl, difenopenten, difenoxuron, difenzoquat, diflufenican, diflufenzopyr, dimefuron, dimepiperate, dimethachlor, dimethametryn, dimethenamid, dimethenamid-P, dimexano, dimidazon, dinitramine, dinitramine, dinofenate, dinoprop, dinosam, dinoseb, dinoterb, diphenamid, dipropetryn, diquat, disul, dithiopyr, diuron, DMPA, DNOC, EBEP, eglinazine, endothal, epronaz, epronaz, EPTC, erbon, esprocarb, ethalfluralin, ethametsulfuron, ethidimuron, ethiolate, ethofumesate, ethoxyfen, ethoxysulfuron, etinofen, etnipromid, etnipromid, etnipromid, etobenzanid, EXD, fenasulam, fenasulam, fenasulam, fenoprop, fenoxaprop, fenoxaprop-P, fenoxasulfone, fenteracol, fenthiaprop, fentrazamide, fenuron, flamprop, flamprop-M, flazasulfuron, florasulam, fluazifop, fluazifop-P, fluazolate, flucarbazone, flucetosulfuron, fluchloralin, flufenacet, flufenican, flufenpyr, flumetsulam, flumezin, flumiclorac, flumioxazin, flumipropyn, fluometuron, fluorodifen, fluoroglycofen, fluoromidine, fluoronitrofen, fluothiuron, flupoxam, flupoxam, flupropacil, flupropanate, flupyrsulfuron, fluridone, flurochloridone, fluroxypyr, flurtamone, fluthiacet, fomesafen, fomesafen, foramsulfuron, fosamine, furyloxyfen, glufosinate, glyphosate, halauxifen, halosafen, halosafen, halosulfuron, haloxydine, haloxyfop, haloxyfop-P, hexazinone, imazamethabenz, imazamox, imazapic, imazapyr, imazaquin, imazethapyr, imazosulfuron, indanofan, indaziflam, iodobonil, iodosulfuron, ioxynil, ipazine, ipfencarbazone, iprymidam, isocarbamid, isocil, isomethiozin, isonoruron, isopolinate, isopropalin, isoproturon, isouron, isoxaben, isoxachlortole, isoxaflutole, isoxapyrifop, karbutilate, ketospiradox, lactofen, lenacil, linuron, MCPA, MCPA-thioethyl, MCPB, mecoprop, mecoprop-P, medinoterb, mefenacet, mefluidide, mesoprazine, mesosulfuron, mesotrione, metam, metamifop, metamifop, metamitron, metazachlor, metazosulfuron, metflurazon, methabenzthiazuron, methalpropalin, methazole, methiobencarb, methiozolin, methiuron, methiuron, methometon, methoprotryne, methyldymron, metobenzuron, metobromuron, metolachlor, S-metolachlor, metosulam, metoxuron, metribuzin, metsulfuron, molinate, monalide, monisouron, monochloroacetic acid, monolinuron, monuron, morfamquat, naproanilide, napropamide, naptalam, neburon, nicosulfuron, nipyraclofen, nitralin, nitrofen, nitrofluorfen, norflurazon, noruron, OCH, orbencarb, orthosulfamuron, oryzalin, oryzalin, oxadiargyl, oxadiazon, oxapyrazon, oxasulfuron, oxaziclomefone, oxyfluorfen, parafluron, paraquat, pebulate, pelargonic acid, pendimethalin, penoxsulam, pentanochlor, pentoxazone, perfluidone, pethoxamid, phenisopham, phenmedipham, phenmedipham-ethyl, phenobenzuron, picloram, picloram, picolinafen, picolinafen, pinoxaden, piperophos, pretilachlor, primisulfuron, procyazine, prodiamine, prodiamine, profluazol, profluralin, profoxydim, proglinazine, prometon, prometryn, propachlor, propanil, propaquizafop, propazine, propham, propisochlor, propoxycarbazone, propyrisulfuron, propyzamide, prosulfalin, prosulfocarb, prosulfuron, proxan, prynachlor, pydanon, pyraclonil, pyraflufen, pyrasulfotole, pyrazolynate, pyrazosulfuron, pyrazoxyfen, pyribenzoxim, pyributicarb, pyriclor, pyridafol, pyridate, pyriftalid, pyriminobac, pyrimisulfan, pyrithiobac, pyroxasulfone, pyroxsulam, quinclorac, quinmerac, quinoclamine, quinonamid, quizalofop, quizalofop-P, rhodethanil, rimsulfuron, sebuthylazine, secbumeton, sethoxydim, siduron, simazine, simeton, simetryn, sulcotrione, sulfallate, sulfentrazone, sulfometuron, sulfosulfuron, sulglycapin, swep, tebutam, tebuthiuron, tefuryltrione, tembotrione, tepraloxydim, terbacil, terbucarb, terbuchlor, terbumeton, terbuthylazine, terbutryn, tetrafluron, thenylchlor, thiazafluron, thiazopyr and triclopyr, thidiazimin, thidiazuron, thidiazuron, thiencarbazone-methyl, thifensulfuron, thiobencarb, tiocarbazil, tioclorim, topramezone, tralkoxydim, tri-allate, triasulfuron, triaziflam, tribenuron, tricamba, tridiphane, trietazine, trifloxysulfuron, trifluralin, triflusulfuron, trifop, trifopsime, trihydroxytriazine, trimeturon, tripropindan, tritac, tritosulfuron, vernolate, xylachlor, and compounds of the following Formula
[0000]
[0000] wherein Ar represents a phenyl group substituted with one to four substituents independently selected from halogen, C1-C6 alkyl, C1-C6 alkoxy, C2-C4 alkoxyalkyl, C2-C6 alkylcarbonyl, C1-C6 alkylthio, C1-C6 haloalkyl, C1-C6 haloalkoxy, C2-C4 haloalkoxyalkyl, C2-C6 haloalkylcarbonyl, C1-C6 haloalkylthio, —OCH2CH2-, —OCH2CH2CH2-, —OCH2O— or —OCH2CH2O—; R represents H or F; X represents C1 or vinyl; and Y represents C1, vinyl or methoxy; and their salts and esters as disclosed, for example, in U.S. Pat. No. 7,314,849 B2, U.S. Pat. No. 7,300,907 B2, U.S. Pat. No. 7,786,044 B2 and U.S. Pat. No. 7,642,220 B2. Depending upon the stability of the herbicide compounds used in the presence of the component of the inventive formulation and the preferred mode of applying the compounds these compounds may be applied along with the inventive nitrapyrin formulation. In many instances the compound may be applied by any suitable means either before or after the inventive formulation is applied to the soil.
[0145] Especially suitable herbicides useful with the compositions and methods described herein include 2,4-D, 2,4-DB, aminocyclopyrachlor, aminopyralid, clopyralid, dicamba, fluroxypyr, halauxifen, MCPA, MCPB, picloram, triclopyr, acetochlor, atrazine, benfluralin, cloransulam, cyhalofop, diclosulam, dithiopyr, ethalfluralin, florasulam, flumetsulam, glufosinate, glyphosate, haloxyfop, isoxaben, MSMA, oryzalin, oxyfluorfen, pendimethalin, penoxsulam, propanil, pyroxsulam, quizalofop, tebuthiuron, trifluralin, and the compound of the Formula.
[0000]
[0000] and its C1-C12 alkyl or C7-C12 arylalkyl ester or salt derivatives such as, for example, the benzyl ester.
[0146] Some exemplary insecticides which can be used along with the inventive nitrapyrin formulations include, but are not limited to abamectin, acephate, acetamiprid, acrinathrin, alpha-cypermethrin, alpha-endosulfan, azadirachtin, azinphos-ethyl, azinphos-methyl, bendiocarb, benfuracarb, bensultap, beta-cyfluthrin, beta-cypermethrin, bifenthrin, bufencarb, buprofezin, butacarb, cadusafos, carbaryl, carbofuran, carbosulfan, cartap, cartap hydrochloride, chlorantraniliprole, chlorfenapyr, chlorfenvinphos, chlorfluazuron, chlormephos, chlorpyrifos, chlorpyrifos-methyl, chromafenozide, clothianidin, cyantraniliprole, cyfluthrin, cyhalothrin, cypermethrin, deltamethrin, diazinon, dicrotophos, diflubenzuron, dimethoate dinotefuran, disulfoton, emamectin, emamectin benzoate, endosulfan, endothion, endrin, EPN, esfenvalerate, etaphos, ethiofencarb, ethion, ethiprole, ethoate-methyl, etofenprox, fenamiphos, fenazaflor, fenethacarb, fenitrothion, fenobucarb, fenpropathrin, fensulfothion, fenthion, fenthion-ethyl, fenvalerate, fipronil, flonicamid, flubendiamide, flucythrinate, fonofos, fufenozide, furathiocarb, gamma-cyhalothrin, gamma-HCH, halfenprox, halofenozide, heptenophos, hyquincarb, imidacloprid, indoxacarb, isazofos, isobenzan, isocarbophos, isofenphos, isofenphos-methyl, isoprocarb, isothioate, isoxathion, kinoprene, lambda-cyhalothrin, lepimectin, lufenuron, malathion, methamidophos, methomyl, methoxyfenozide, mevinphos, mexacarbate, milbemectin, monocrotophos, nitenpyram, novaluron, omethoate, oxamyl, oxydemeton-methyl, oxydeprofos, oxydisulfoton, parathion, parathion-methyl, penfluron, permethrin, phenthoate, phorate, phosalone, phosfolan, phosmet, phosphamidon, pirimetaphos, pirimicarb, pirimiphos-ethyl, pirimiphos-methyl, primidophos, profenofos, profluthrin, promecarb, propaphos, propoxur, prothiofos, pymetrozine, pyrafluprole, pyridalyl, pyrifluquinazon, pyriprole, pyriproxyfen, spinetoram, spinosad, spirotetramat, sulfoxaflor, sulprofos, tau-fluvalinate, tebufenozide, tebufenpyrad, teflubenzuron, tefluthrin, tetramethylfluthrin, theta-cypermethrin, thiacloprid, thiamethoxam, thicrofos, thiocyclam, thiocyclam oxalate, thiodicarb, thiometon, thiosultap, thiosultap-disodium, thiosultap-monosodium, thuringiensin, tolfenpyrad, triazophos, triflumuron and zeta-cypermethrin. Depending upon the stability of the insecticide compounds used in the presence of the component of the inventive formulation and the preferred mode of applying the compounds these compounds may be applied along with the inventive nitrapyrin formulation. In many instances the compound may be applied by any suitable means either before or after the inventive formulation is applied to the soil.
[0147] Some exemplary fungicides which can be used along with the inventive nitrapyrin formulations include, but are not limited to tricyclazole, phthalide, carpropamide, pyroquilon, diclocymet, fenoxanil, probenazole, isoprothiolane, iprobenfos, isotianil, tiadinil, kasugamycin, flutolanil, mepronil, pencycuron, polyoxins, validamycin, toclophos-methyl, boscalid, penthiopyrad, thifluzamide, bixafen, fluopyram, isopyrazam, propiconazole, difenoconazole, fenbuconazole, ipconazole, triadimefon, hexaconazole, azoxystrobin, metaminostrobin, orysastrobin and acibenzolar-S-methyl. Some of these fungicides may not be effective for disease control when applied at the timing of application of the inventive formulation because fungal disease propagation and growth cycles may not be optimal. The effective use and application timing of these fungicides can be easily determined by one of normal skill in the art. Depending upon the stability of the fungicide compounds used in the presence of the component of the inventive formulation and the preferred mode of applying the compounds these compounds may be applied along with the inventive nitrapyrin formulation. In many instances the compound may be applied by any suitable means either before or after the inventive formulation is applied to the soil.
[0148] Some exemplary herbicide safeners which can be used along with the inventive nitrapyrin formulations include, but are not limited to benoxacor, benthiocarb, cloquintocet-mexyl, daimuron, dichlormid, dicyclonon, dimepiperate, fenchlorazole-ethyl, fenclorim, flurazole, fluxofenim, furilazole, Harpin proteins, isoxadifen-ethyl, mefenpyr-diethyl, mephenate, MG 191, MON 4660, naphthalic anhydride (NA), oxabetrinil, 829148 and N-phenyl-sulfonylbenzoic acid amides. Depending upon the stability of the herbicide safener compounds used in the presence of the component of the inventive formulation and the preferred mode of applying the compounds these compounds may be applied along with the inventive nitrapyrin formulation. In many instances the compound may be applied by any suitable means either before or after the inventive formulation is applied to the soil.
[0149] Some exemplary plant growth regulators which can be used along with the inventive nitrapyrin formulations include, but are not limited to 2,4-D, 2,4-DB, IAA, IBA, naphthaleneacetamide, α-naphthaleneacetic acid, kinetin, zeatin, ethephon, aviglycine, 1-methylcyclopropene (1-MCP), ethephon, gibberellins, gibberellic acid, abscisic acid, ancymidol, flurprimidol, mefluidide, paclobutrazol, tetcyclacis, uniconazole, brassinolide, brassinolide-ethyl and ethylene. Depending upon the stability of the plant growth regulator compounds used in the presence of the component of the inventive formulation and the preferred mode of applying the compounds these compounds may be applied along with the inventive nitrapyrin formulation. In many instances the compound may be applied by any suitable means either before or after the inventive formulation is applied to the soil.
Exemplary Formulations
[0150] The high load nitrapyrin SL formulations (360 g/L) comprising polar solvents were prepared by dissolving nitrapyrin technical in the solvent systems, which included polar solvent miscible corrosion inhibitors. The solutions were mixed under IKA mixing until they were essentially homogeneous.
[0151] Referring now to Table 1. All samples were tested for metal corrosion stability at different time intervals at 50° C. temperature and compared against N-Serve commercial control formulation. Results are shown in the Table 1. Metal coupons (Carbon steel; AISI 1018) were tested for corrosion stability in 40 ml prepared nitrapyrin formulations. Coupons were ˜45% submerged in the solution for the corrosion testing. Metal coupons were approximately one half inch in width and three inches in length with a thickness of 1/16th to ⅛th of an inch. During the testing, coupons were visually inspected for corrosion by checking any color changes or residue deposits on the coupon surface. The results of these experiments are summarized in Table 1.
[0000] TABLE 1 Example composition of stable high load nitrapyrin SL formulations (360 g/L nitrapyrin technical) comprising polar solvents after corrosion testing with carbon steel coupons at 50° C. Control (N-Serve) sample has a nitrapyrin loading of 240 g/L. Nitrapyrin # of days technical Corrosion without Sample Loading Inhibitor visible # (Wt %) Solvents Additives corrosion 1 24.74 Aromatic 100 ELO 53 (Control) (66.53 wt (0.75 wt %) %)Xylene (7.398 wt %) 2 34.6 Hallcomid ELO 67 M-8-10 (1 wt %)2,6 (63.4 wt %) Lutidine (1 wt %) 3 34.6 Hallcomid ELO (1 7 M-8-10 wt %)Nicotin- (63.4 wt %) amide (1 wt %) 4 32.9 Cyclohexanone DER331 53 (6439 wt %) (1.2 wt %)2,6 Lutidine (1 wt %) 5 34.6 Hallcomid DER331 43 M-8-10 (1.2 wt %)2,6 (63.2 wt %) Lutidine (1 wt %) 6 32.94 Cyclohexanone DER331 46 (51.89 wt %)Aro- (1.2 wt %)2,6 matic 100 Lutidine (12.97 wt %) (1 wt %) 7 34.62 Hallcomid ELO 67 M-8-10 (1 wt %)2,6 (50.71 wt %)Aro- Lutidine matic 100 (1 wt %) (12.68 wt %) 8 34.62 Hallcomid DER331 >120 M-8-10 (1.2 wt %)2,6 (50.55 wt %)Aro- Lutidine matic 100 (1 wt %) (12.64 wt %) 9 32.94 Cyclohexanone DER331 (1.8 32 (51.41 wt %)Aro- wt %)α- matic 100 picoline (12.85 wt %) (1 wt %) 10 34.62 Hallcomid ELO (1.5 22 M-8-10 wt %)Nicotin- (50.71 wt %)Aro- amide matic 100 (0.5 wt %) (12.68 wt %) 11 34.62 Hallcomid ELO (1.5 51 M-8-10 wt %)Nicotin- (50.71 wt %)Aro- amide matic 100 (2.5 wt %) (12.68 wt %) 12 34.62 Hallcomid DER331 (1.2 35 M-8-10 wt %)α- (50.55 wt %)Aro- picoline matic 100 (1 wt %) (12.64 wt %) 13 34.29 Hallcomid DER331 (1.8 18 M-8-10 wt %)Nicotin- (46.44 wt %)Aro- amide matic 100 (2 wt %) (15.48 wt %) 14 34.29 Hallcomid ELO (1.5 30 M-8-10 wt %)Nicotin- (61.89 wt %) amide (2 wt %) 15 34.62 RhodiaSolv ELO (1.5 >120 RPDE wt %)Nicotin- (50.47 wt %)Cyclo- amide hexanone (.8 wt %) (12.62 wt %) 16 34.62 RhodiaSolv ELO (1.5 105 RPDE wt %)Nicotin- (63.08 wt %) amide (0.8 wt %) 17 34.62 RhodiaSolv ELO 19 RPDE (1.5 wt %) (63.88 wt %) 18 30.90 RhodiaSolv ELO (1 4 PolarClean wt %)Nicotin- (67.10 wt %) amide (1 wt %) 19 30.90 RhodiaSolv ELO 4 PolarClean (1 wt %)2,6 (67.10 wt %) Lutidine (1 wt %) 20 30.90 RhodiaSolv DER331 4 RPDE (1.2 wt %) (66.90 wt %) 2,6 Lutidine (1 wt %) 21 30.90 RhodiaSolv DER331 4 RPDE (1.2 wt %) (66.90 wt %) Nicotinamide (1 wt %) 22 32.94 Dowanol DPM DER331 3 (62.76 wt %) (1.8 wt %) Nicotinamide (2.5 wt %) 23 33.65 Dowanol DPM ELO 3 (62.35 wt %) (1.5 wt %) Nicotinamide (2.5 wt %) 24 34.6 TamiSolve NxG ELO 4 (61.40 wt %) (1.5 wt %) Nicotinamide (2.5 wt %)
Common chemical names of commercially available solvents found in Table 1: Hallcomid M-8-10: Mixture of N,N-dimethyloctanamide (N,N-dimethylcaprylamide) and N,N-dimethyldecanamide (N,N-dimethylcapramide); RhodiaSolv RPDE: Solvent mixture composed of a reaction mass of dimethyl adipate, dimethyl glutarate and dimethyl succinate; and Aromatic 100: Solvent Naphtha (petroleum), light aromatic; TamiSolve NxG: N-butylpyrrolidone.
Example 2
[0152] A stock solution of 360 g/L nitrapyrin technical grade in triethyl phosphate was prepared and additives in specific amounts to limit corrosion to carbon steel were added to this solution. A small quantity (˜15 mL) of the solution in glass jars were left for storage stability at room temperature (˜20 C) and −12 C. The −12 C sample was seeded after it reached 24 hrs age by incorporating few small grains of nitrapyrin technical in the cold solution and was immediately stored back to the −12 C storage temperature. A carbon steel coupon was partially submerged into the solution stored at 54 C. The coupon was periodically observed for any sign of corrosion in liquid and vapor phases. The solutions at room temperature and −12 C were observed for any inhomogeneity, crystallization and flowability. Table 2 shows summary of the observations.
[0000]
TABLE 2
Coupon
Day
Corrosion
Composition
Tested
(54 C.)
−12 C. stability
Stock solution
28 days
Corroded
Small amount
(no additive)
overnight
of crystals
formed overnight
Stock (99%) +
28 days
No corrosion
Homogeneous
AMP-95 (1%)
solution
Stock (99%) + Quinaldine
28 days
No corrosion
Small amount
(1%)
of crystals
Stock (98.5%) +
18 days
No corrosion
Small amount
Epoxidized linseed
of crystals
oil (1%) +
AMP 95 (0.5%)*
Stock (98.5%) +
18 days
No corrosion
Small amount
Epoxydecane
of crystals
(1%) + AMP
99 (0.5%)
Stock (98.5%) +
18 days
No corrosion
Small amount
Epoxidized linseed
of crystals
oil (1%) +
Methyl Nicotinate (0.5%)
Stock (98.5%) +
18 days
No corrosion
Homogeneous
Epoxydecane
solution
(1%) + Methyl
Nicotinate (0.5%)
Example 3
[0153] Homogeneous compositions of nitrapyrin technical grade (90%, 360 g/L) were made in different ratios of mixture of cyclopentanone or cyclohexanone and Rhodiasolv RPDE (mixture of dimethyl glutarate, dimethyl adipate and dimethyl succinate). A small quantity (˜15 mL) of the solution in glass jars were left for storage stability evaluation at room temperature (˜20 C) and −10 C. The −10 C sample was seeded after it reached 24 hrs age by incorporating few small grains of nitrapyrin technical in the cold solution and was immediately stored back to the −10 C temperature. The solutions at different temperatures were observed for any inhomogeneity, crystallization and flowability. No crystals or any other inhomogeneities were observed in the solution at any temperatures within 2 weeks of storage. Table 3 shows a summary of the compositions and their stability.
[0000]
TABLE 3
Composition (360 g/L Nitrapyrin
Stability at room temperature
technical in solvent mixtures)
and −10 C.
Cylcopentanone/RPDE (60-40 wt %)
Homogeneous solution
Cylcohexanone/RPDE (60-40 wt %)
Homogeneous solution
Cyclopentanone
Homogeneous solution
Cyclohexanone
Homogeneous solution
[0154] Corrosion Tests:
[0155] A stock solution of 360 g/L nitrapyrin technical grade in cyclohexanone/RPDE (60:40 weight ratio) was prepared and corrosion inhibitors in specific amounts were added to this solution. The resultant solutions were tested for corrosion issues with carbon steel tanks using following protocol. A carbon steel coupon was partially submerged into the solution stored at 54 C. The coupon was periodically observed for any sign of corrosion in liquid and vapor phases. Table 4 shows a summary of the observations.
[0000]
TABLE 4
Composition
Coupon appearance
Stock (no corrosion inhibitor)
Corrosion in liquid and vapor
phase overnight
98.5 wt % Stock + 1.0 wt %
No sign of corrosion in liquid
Epoxydecane + 0.5% Nicotinamide
or vapor phase for duration of
observation (45 days)
98.5 wt % Stock + 1.0 wt %
No sign of corrosion in liquid
Epoxydecane + 0.5% 1-methyl
or vapor phase for duration of
Imidazole
observation (18 days)
97.0 wt % Stock + 1.0 wt %
No sign of corrosion in liquid phase
Nicotinamide + 2.0 wt %
and slight corrosion in vapor phase
epoxidized linseed oil
for duration of observation (90 days);
test conducted at 50 C.
Example 4
[0156] Storage stability tests: Homogeneous composition of nitrapyrin technical grade (360 g/L) was dispersed in methoxybenzene solvent, and a quantity of about 15 mL of the solution in glass jars were left for storage stability at room temperature (˜20° C.), 54° C. and −7° C. The −7° C. sample was seeded after it reached 24 hrs age by incorporating few small grains of nitrapyrin technical in the cold solution and was immediately stored back to the −7° C. temperature. The solutions at different temperatures were observed for any inhomogeneity, crystallization and flowability. No crystals or any other inhomogeneities were observed in the solution at any temperatures within 2 weeks of storage.
[0157] Corrosion tests: A stock solution of 360 g/L nitrapyrin technical grade in methoxybenzene was prepared and corrosion inhibitors in specific amount were added to this solution. The resultant solutions were tested for corrosion issues with carbon steel tanks using following protocol. A carbon steel coupon was partially submerged into the solution stored at 54° C. The coupon was periodically observed for any sign of corrosion in liquid and vapor phases. Table 5 shows summary of the observations.
[0000]
TABLE 5
Composition
Coupon appearance
Stock (no corrosion inhibitor)
No sign of corrosion in liquid
or vapor phase until 45 days;
later corrosion in vapor phase
98.5 wt % Stock + 1.0 wt % Methyl
No sign of corrosion in liquid
Isonicotinate + 0.5% AMP-95
or vapor phase for duration of
observation (70 days)
99.0 wt % Stock + 0.5 wt %
No sign of corrosion in liquid
Nictotinamide + 0.5% AMP-95
or vapor phase for duration of
observation (70 days)
99.0 wt % Stock + 0.5 wt %
No sign of corrosion in liquid
Nictotinamide + 1% Epoxydecane
or vapor phase for duration of
observation (24 days)
[0158] 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. | This invention relates to stable liquid formulations of the nitrification inhibitor nitrapyrin comprising polar solvents that are stabilized with small amounts of compounds which help to reduce the tendency of polar solutions of nitrapyrin to corrode metal surfaces. Many of the formulations disclosed herein exhibit useful physical, chemical, and bioactive properties including reduced levels of corrosion when in contact with ferrous metals. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
None, however, Applicant filed Disclosure Document Number 325,421 on Feb. 22, 1993, which document concerns this application; therefore, by separate paper it is respectfully requested that the document be retained and acknowledgment thereof made by the Examiner. (MoPEP 1706)
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention relates to the disposal of acid gas produced from hydrocarbon wells, such as oil wells. Oil field engineers have ordinary skill in this art.
(2) Description of the Related Art
A problem exists in the oil field when producing hydrocarbons from strata deep within the earth. These hydrocarbons(in gas and liquid form) often contain carbon dioxide and hydrogen sulfide. As used in this application, these gases are referred to as "acid gas". The acid gas is detrimental to the hydrocarbon usage, and therefore it is desired to remove it from the produced fluid. Processes for removing it are well known.
The hydrocarbon wells will often produce water as well. The produced water also is undesirable and is separated out. The water produced with the hydrocarbons from a strata deep below the surface of the earth is not pure water. The produced water is contaminated with different dissolved and suspended matter. In most cases, the produced water is also considered a pollutant and it is undesirable that it should be released on the surface of the earth where it would pollute surface streams or underground aquifers. One method of disposing of the produced water is to inject it into a productive or non-productive porous underground formation not containing potable water. Such an underground formation hereafter is called "disposal strata".
The separated acid gas often has insufficient value to justify further treatment or purification for any further usage. Treatment is often performed to reduce pollution. Acid gas is considered to be a pollutant and the discharge of acid gas into the atmosphere is undesirable, inasmuch as it results in "acid rain".
It is not an environmental pollution to inject the produced water with absorbed acid gases into disposal strata. In fact, the terminology of "productive or non-productive porous formation" is found in the government regulations concerning the disposal of produced water.
To inject fluids into a disposal strata, often takes high pressures. Although some injection wells extending into disposal strata might achieve satisfactory injection with no more than 400 psi, it is more common that injection pressures of 1500 psi-3000 psi are required.
Prior to this invention, at least two plants or installations which absorb acid gas into water for disposal previously exist. Both of these installations use fresh water at least partially. Each of these installations use an absorption tower. Absorption towers are basically bubble towers where the gas is bubbled through water in a series of trays. I.e., the tower would contain several trays, each tray having several bubble caps for the bubbling of the gas through the water.
Neither of these prior plants operated completely on produced water. Fresh water absorbs more acid gas than the produced water. The fresh water used by these installations is from aquifers and is potable and suitable for domestic and agricultural use such as irrigation of crops. Produced water is suitable for neither drinking nor agricultural irrigation.
Fresh water, in many oil fields, is a scarce commodity and in any event, there are more productive uses for fresh water such as agricultural irrigation.
SUMMARY OF THE INVENTION
(1) Progressive Contribution to the Art
According to this invention the acid gas is absorbed directly into produced water without substantial use of fresh water. It will be understood that the practice of this invention requires a certain quantity of produced water, which in most oil fields is available. However, if there is insufficient produced water, a supplement of fresh water would be necessary to practice the invention. The water used will be chiefly or primarily produced water.
Instead of absorbing the gas in the water by use of an absorption tower, the gas is thoroughly mixed with the water in a static mixer.
Static mixers are described by a manufacturer as an in-line mixer with no moving parts. It is a simple, cost-effective solution for mixing and contacting problems. It consists of a series of stationary, rigid elements placed lengthwise in a pipe. These elements form intersecting channels that split, rearrange, and recombine component streams into smaller and smaller layers until one homogeneous stream exists.
A Koch static mixer having 11 elements identified as 6" SMV-LY is satisfactory for a plant using approximately 10,000 Barrels (Bbl.) (42 gallons) of water a day.
After the gas is absorbed in the static mixer it is normally necessary to maintain the pressure upon the produced water with the absorbed acid gas therein to a pressure at least as great as the pressure within the static mixer. As a matter of design it is pressurized and maintained at least 10 psi higher than the static mixer pressure.
(2) Objects of this Invention
An object of this invention is to dispose of acid gas and produced water.
Another object of this invention is to avoid any atmospheric pollution and pollution of aquifers having potable water.
Yet another object is to conserve fresh water.
Further objects are to achieve the above with devices that are sturdy, compact, durable, lightweight, simple, safe, efficient, versatile, ecologically compatible, energy conserving, and reliable, yet inexpensive and easy to manufacture, install, operate, and maintain.
Other objects are to achieve the above with a method that is rapid, versatile, ecologically compatible, energy conserving, efficient, and inexpensive, and does not require highly skilled people to install, operate, and maintain.
The specific nature of the invention, as well as other objects, uses, and advantages thereof, will clearly appear from the following description and from the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 of the drawing is a schematic representation of an embodiment of this invention.
FIG. 2 is a schematic representation of an embodiment of the static mixing unit.
As an aid to correlating the terms of the claims to the exemplary drawing, the following catalog of elements and steps is provided:
10 acid gas source
11 compressor
12 water source
13 "Y"
14 static mixing unit
15 water pump
16 inlet
18 exit
20 booster pump
22 conduit
24 pipeline
26 injection pump
28 strata
30 injection well
32 surface of earth
34 pressure gauge
35 tank
36 regulator valve
38 make up pump
40 mixer
42 valve
44 branch
46 gas meter
48 water meter
50 micro-processor
52 variable speed motor
54 gas pressure regulator
56 water pressure regulator
74 header
76 branch
78 valve
80 mixer
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, there may be seen a schematic representation of the invention. An acid gas source 10 is available. Normally, the acid gas would be under pressure less than 20 pounds per square inch gauge(hereafter psig). Likewise, there is a produced water source 12 also under less than 20 psig.
Gas is compressed by compressor 11 and fed to one inlet leg of "Y" 13. The gas would be fed at a pressure of at least about 20 psig. Produced water from source 12 would be pumped by pump 15 into another inlet leg of "Y" 13. The water would be at the same pressure as the gas from the compressor.
These two fluids are fed through the "Y" 13 to static mixing unit 14 at its inlet 16. The flow through the mixing would be for a very short time. The dwell time in the mixing would be less than about 10 seconds. The acid gas will be absorbed in the produced gas between the time the produced water and gas enter the static mixer and the produced water with the acid gas absorbed therein leave by exit 18.
From the exit, the produced water with the acid gas absorbed therein is immediately fed through conduit 22 to booster pump 20. Although the pump 20 is schematically illustrated as a radial flow or centrifugal pump, it is preferred that a horizontal split case centrifugal pump (axial flow) be used. It is desired that effort be used to prevent the gas from breaking out of the liquid. Therefore 90° elbows and short turns at the pump are avoided after the gas is absorbed in the produced liquid.
The produced water with the gas absorbed therein flows through pipeline 24 to injection pump 26. From the injection pump the produced water with the acid gases absorbed therein is injected into one of disposal strata 28. All of the strata 28 will be far below the surface of the earth 32. As may be seen in the drawing, the pipeline 24 is shown broken, inasmuch as this may represent a considerable distance, perhaps well over 5,000 feet. Also injection well 30 is shown broken, inasmuch as the depth of the well might well be over 5,000 feet.
Inasmuch as the injection of fluid into disposal strata far below the surface of the earth is well known to those having ordinary skill in this art, it is not further described here except to note that the pressure at the outlet of injection pump will usually be over 1500 psi.
It is highly desirable, if not absolutely necessary, that the pressure of the produced water with the absorbed gas, never be reduced to less than the pressure wherein the gas separates or "breaks out" from the produced water. This break out pressure is called the "critical pressure." The pressure at the inlet of the booster pump 20 as determined by pressure gauge 34 will usually be considered the "critical pressure".
To prevent pressure from dropping below the critical pressure, there is provision for an additional flow of water into the pipeline at the inlet of the injection pump 26. Regulator valve 36 regulates the pressuwe at the inlet of the pump 26 by having a flow of additional water into the inlet of the injection pump 26 in the event the pressure falls below the critical pressure. In practice it is desirable that the pressure at the inlet of the pump 26 be 10 psi above the critical pressure.
Make up pump 38 has an inlet from some source of liquid. For simplicity in the drawing representing an embodiment, this is shown to be the source of produced water 12 temporarily stored in tank 35 near make up pump 38. In practice this source of liquid could be any source of liquid, preferably some type water.
Those with ordinary skill in the art will understand the pressure regulation devices necessary to accomplish the purpose to always maintain the inlet pressure of the injection pump greater than the inlet pressure of the booster pump 20.
It is desirable in static mixers used in static mixing unit 14 to have the fluids reside for about two to four seconds. Satisfactory elements for the static mixing unit are designated as SMV and SMVL elements as manufactured by KOCH Engineering Co., Inc., P.O. Box 8127, Wichita, Kans. 67208. In 6" to 12" pipe the use of 10-12 such elements works well. It has been found that when the flow of water through the static mixer is below a velocity wherein the residence time is over about 3.5 seconds, in such a mixer the gas is not as well absorbed into the water as at the optimum velocity when the water is retained about 2.6 seconds.
Also, it appears that if the velocity of the water through the static mixer is increased so that the residence time is less than about 2.2 seconds, problems of gas breaking out of the water are experienced.
It was found in the pilot plant described later, by doubling the number of elements in a mixer increases the operable range of the residence time in the mixers. In 3" pipe 22 elements per mixer is usual practice. I.e., with the twenty two 3" SMV-AY elements that the optimum flow rate was about from 1.7 feet per second to about 2.7 feet per second with a residence time close to 2.6 seconds. However, it appears that if forty four elements were used that the velocity range could be reduced to as low as about 1.2 feet per second with a residence time of about 10 seconds, or increased to about 3 feet per second with a residence time at about 4 seconds (2 seconds for each 22 elements).
An example of a design of a plant using 10,000 to 20,000 Bbl/day, more than one static mixer section of 10-12 elements are might be used in the static mixing unit. One embodiment of a design is shown in FIG. 2. There is seen two static mixers identified as mixer 40, and mixer 80. Each mixer 40 and 80 are constructed of 6" SMV-LY elements with 11 elements used. The flow to mixer 40 would be controlled by valve 42 which is connected between the mixer 40 and branch 44 leading from the "Y" 13 to the static mixing unit 14. The flow into the mixer 80 would be controlled by valve 78 in branch 76 leading from the "Y" 13. The branches 44 and 76 form header 74. Therefore if the flow of water was approximately 300 gallons per minute (the approximate equivalent of 10,000 Bbl/day), the valve 78 could be closed and the valve 42 opened so that the flow of water through mixer 40 would be in the desired range of about 2.6 seconds residence time.
If the flow of water was about 600 gallons per minute (about 20,000 Bbl/day), both the mixers 40 and 80 could be utilized by opening both valves 42 and 78.
Another way of controlling the flow would be to have storage facilities for the acid gas and water so that low water flows could always be avoided and the gas and water stored until the mixer could run for a limited period of time at an optimum flow rate.
The residence time of the water in the mixer is the critical concern of the flow through the static mixer. I.e., if there was plenty of water available but very little acid gas being produced at the time, any amount of gas less than the designed amounts could be used.
To provide the proper flow of water and acid gas to the static mixing unit 14, gas meter 46 is placed at the inlet of compressor 11 measuring the gas from acid gas source 10. Water meter 48 is placed at the inlet to water pump 15 measuring the water from produced water source 12. Microprocessor 50 receives its input from the meters 46, 48 and the pressure gauge 34. The booster pump 20 is driven by variable speed motor 52 thereby providing for a variable flow from the static mixing unit. I.e., to reduce the flow the booster motor speed could be decreased therefore producing more back pressure at the exit 18 of the static mixing unit. If a greater flow of water was desired the variable speed motor could be increased therefore reducing the back pressure at the exit 18 of the static mixing unit. By knowing the pressure of the gauge 34 and the temperature, the amount of water to absorb the gas is measured by meter 46 would be known and the flow adjusted until the meter 48 produced the desired flow. So it will be understood that if the flow of gas was greater, either the flow through the static mixing unit exceeded the stable conditions as described above, the flow could be decreased by that amount. Therefore it will be understood that pressure regulator valve 54 to regulate the outlet pressure from the compressor 11 and pressure regulator 56 to regulate the water pressure at the inlet of the "Y" 13 would be desirable controls. Those having ordinary skill in the art will understand the micro-processors necessary to achieve the controls within the parameters set out above.
Also, from a knowledge of the absorption characteristic of the produced water for acid gas, the microprocessor could calculate the "critical pressure". If the supply of produced water greatly exceeded the quantity required, the booster pump might be eliminated.
It is expected that the produced water from each oil field will have different acid gas absorption characteristics from the produced water from all other oil fields. Therefore the specific values and observations that follow are based upon a pilot plant which was operated at Yates Foster Ranch at the Dagger Draw Field located in Eddy County, N. Mex. This plant is located about 17 miles North-Northwest of Carlsbad, N. Mex.
The acid gas at the Pilot Plant normally was about 40% CO 2 , and 60% H 2 S, 1.5% hydrocarbons, and less than 0.2% N 2 on a mol basis.
According to this operation, a maximum of 1,000 standard cubic feet (hereinafter MSCF) of acid gas could be absorbed in 160 barrels of produced water (42 gallons per barrel) with the water at 84° F. and the static mixer at 20 psig.
However, if the pressure were increased to about 42 psig, 1 mscf of acid gas could be absorbed in 80 barrels of water at 84° F. On the other hand if the temperature of the water at 20 psig was reduced to 77° F., 1 mscf of acid gas could be absorbed in 150 barrels of water. On the other hand if the temperature was increased to about 91° F., 170 barrels of water would be required to absorb 1 mscf of acid gas. For good operation, normally there should be provisions to maintain at 5% to 10% excess water than the minimum required. Also as a safety factor the injection pump inlet pressure should be at least 10 psi above the critical pressure.
It will be understood that the specifications of this invention have been written for one having ordinary skill in the art. It will be understood that many devices have not been described in detail inasmuch as they would be well known to such a person and also many things have not been mentioned, such as emergency connections to a flare, or other emergency and safety devices that would normally be employed in the design of such equipment.
The embodiment shown and described above is only exemplary. I do not claim to have invented all the parts, elements or steps described. Various modifications can be made in the construction, material, arrangement, and operation, and still be within the scope of my invention.
The restrictive description and drawings of the specific examples above do not point out what an infringement of this patent would be, but are to enable one skilled in the art to make and use the invention. The limits of the invention and the bounds of the patent protection are measured by and defined in the following claims. | Acid gas (a mixture of carbon dioxide and hydrogen sulfide) is absorbed by produced water from hydrocarbon wells. The acid gas is absorbed in the produced water in a static mixer. The time from the entry of the produced water into the static mixer to its exit is less than ten seconds. The produced water with the absorbed acid gas is pressurized to flow through a pipeline to an injection pump. The injection pump injects the produced water with the absorbed acid gas into injection wells which return the produced water into disposal strata. The produced water with the acid gas is maintained at a pressure higher than the pressure at the exit of the static mixer. | 1 |
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to internal combustion engines and, and, more specifically, to pistons for such engines.
The configuration of pistons in internal combustion engine has been the subject of design and development for decades. Particularly in the field of compression ignition, or diesel engines, the configuration of the portion of the piston exposed to the combustion process has been highly developed. The reason for this is that the compression ignition engine relies on the heat of compression to ignite fuel that has been injected in measured and timed quantities to provide the appropriate combustion which results in maximum efficiency and power. With the advent of regulations placed on emissions from internal combustion engines by the EPA, the design of the combustion chamber has received increased attention.
It is common to provide a diesel engine combustion chamber within a cylinder having reciprocating pistons. The pistons are displaced from a maximum volume to a minimum volume during which the air that has entered the combustion chamber is compressed and its temperature increased. In the vicinity of the minimum volume or top dead center (TDC), fuel is injected into the compressed air and the resultant mixture ignited to provide the expansion stroke for the piston. There are two major systems for orienting the fuel injection relative to the piston. The first is a high swirl system in which the fuel is injected and the air flows in a circular motion around the crown of the piston. The other is a quiescent or zero swirl arrangement in which the fuel is injected from a central location in a uniform radial pattern and distribution. To enhance the mixture of the compressed air and fuel, a so called Mexican hat has been proposed for the piston crown. This involves a central peak with a curved annular outer section to promote mixture within the molecules of air and the fuel.
However, for ever decreasing emissions limitations, particularly in the area of soot formation, the traditional crown configurations impose a limit on the reduction of soot and oxidization.
What is needed in the art, therefore, is a piston having a configuration for minimizing soot and increasing combustion efficiency.
SUMMARY OF THE INVENTION
In one form, the invention is a piston for an internal combustion (IC) reciprocating engine. The piston includes a cylindrical form having a connection to provide reciprocating motion in response to a combustion event involving air and an injected fuel quantity from an injector providing fuel injection from a central location in a radiated, substantially non-swirl pattern. A crown is formed on the end of the cylindrical form, the crown having an annular recess with a center of rotation substantially coaxial with the central location for the injector. A central peak is in the recess and forms an angle with respect to the central axis that is approximately parallel with the injected fuel. A substantially curved outer section directs air compressed by the piston around the curve and toward the central axis to mix with and be directed along the peak by the injected fuel.
In another form, the invention is an internal combustion engine including a cylinder block having at least one cylinder for receiving a piston. A cylindrical piston is reciprocable within the cylinder in response to a combustion event involving air and an injected fuel quantity from an injector providing fuel injection from a central location in a radiated, substantially non-swirl pattern. A fuel injector injects fuel into the combustion chamber in a measured and timed quantity. The piston has a crown formed on the end thereof facing the combustion chamber, the crown having an annular recess with a central axis substantially coaxial with the central location for the injector and a internal central crown portion forming an angle with respect to the central axis that is approximately parallel with the injected fuel and a substantially curved outer portion directing air compressed by the piston around the curve and toward said central axis to mix with and be directed along the peak by the fuel.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a cross sectional view of an engine having a piston embodying the present invention; and,
FIG. 2 is an expanded detailed view of the piston incorporated in FIG. 1 .
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplifications set out herein illustrates one embodiment of the invention, in one form, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an engine 10 of the reciprocating internal combustion engine type. Engine 10 operates on the principal of reciprocating pistons moved in response to a combustion event in a combustion chamber. As illustrated herein, the reciprocating motion of the pistons is converted into rotary motion through the means of a crankshaft. However, it should be apparent to those skilled in the art that the reciprocating motion of the pistons may be utilized in the form of a linear electrical generator in which movement of pistons and ferromagnetic materials induces an electrical power output.
Engine 10 includes a block 12 having a plurality of bores 14 for receiving reciprocating pistons 16 , only one of which is shown. The cylinder bores 14 may be cast integral with the block 12 or, as illustrated herein, may be separate liners so as to enhance the rebuilding process.
The piston 16 includes a cylindrical form 18 having a pivotal connection 20 for receiving a wrist pin 22 connected to a connecting rod 24 . Connecting rod 24 is rotatably connected to a crank throw or crankpin 26 on a crankshaft 28 suitably journaled within block 12 to provide a rotary power output in response to reciprocation of piston 16 . It should be noted that a plurality of pistons may be provided depending upon the requirements and duty cycle of the engine 10 .
Piston 16 reciprocates within cylinder 14 to define a combustion chamber 30 bounded by the cylinder 14 , a crown 32 of piston 16 , and a head 34 . Head 34 has intake passages 36 and exhaust passages 38 . Combustion air passes through intake passage 36 past intake valve 40 for entry into combustion chamber 30 . Products of combustion exit combustion chamber 30 past exhaust valve 42 to exhaust port 38 .
The intake air, as is apparent to those skilled in the art, may be pressurized by a compressor of a turbocharger and cooled by means of an after cooler. The exhaust gasses passing from exhaust port 38 typically pass through a turbocharger turbine and then to exhaust after treatment devices. It is also common to provide exhaust gas recirculation which provides a portion of the exhaust gas to the intake port 36 , either cooled or uncooled, to reduce the combustion temperatures and reduce the oxides of nitrogen.
Engine 10 , as illustrated, operates on a compression ignition cycle in which air that has entered combustion chamber 30 past intake port 36 and valve 40 is pressurized to such an extent that fuel injected from an injector nozzle 44 via line 46 from fuel injection system 48 at the appropriate time and in the appropriate quantity is ignited by the heat of compression. Injection from nozzle 44 may be from a variety of systems including high pressure common rail, distributor pump, and direct injection in which pressure is generated at the nozzle. Control of fuel injection system 48 is from an ECM 52 via interconnection 50 .
In any of the systems, the fuel is injected from an axis A coaxial with the axis of the injector 44 in a radiated pattern so as to permeate the combustion chamber 30 . As is well known to those skilled in the art, the number of discrete holes provided in injector 40 , their cross sectional flow area and the angle they make with respect to the central axis A of injector 44 is selected according to the design requirements of engine 10 . Although the preferred location of injector 44 is coaxial with the axis of combustion chamber 30 , it should be apparent to those skilled in the art that the injector 44 may be offset from the central axis.
In accordance with the present invention, piston 16 has a crown 32 that improves the combustion process. The configuration of crown 32 is shown in expanded detail in FIG. 2 . Piston crown 32 has an upper surface 54 connecting with the piston body 18 . It should be noted that piston body 18 has circumferential grooves 56 , 58 , and 60 for appropriate compression and oil scraper rings (not shown).
Upper surface 54 has an annular recess 62 defined by an outer diameter 64 . The annular recess 62 is coaxial with the axis of injector 44 whether the injector 44 is on the center line of the combustion chamber 30 or elsewhere. The recess 62 has a central crown portion 66 with a peak 68 coaxial with axis A. The central crown portion 66 blends into an annular curved portion 70 having a substantial curve to outer diameter 64 such that air compressed within recess 62 curves around portion 70 and is directed towards central axis A.
The configuration of central crown portion 66 is such that it is approximately parallel to the angle of injection 72 from a point 74 on injector 44 . The range of angles .PHI.-.beta. as shown in FIG. 2 with respect to the axis A is between 0.degree. and 5.degree. The included angle the surface of the crown portion makes with the axis A is between approximately 50.degree. and 80.degree. The outer diameter 64 of the opening to recess 62 is no greater than 40% of the piston diameter thus giving an aggressive swish motion within recess 62 . The configuration of the outer curved portion 70 relative to the central crown portion is such that it turns the fluid through greater than 180.degree.
In operation, the piston 16 moves from bottom dead center towards the head 34 to decrease the volume of the combustion chamber 30 and thus pressurize and increase the temperature of the air within combustion chamber 30 . As the piston moves towards top dead center, the central crown portion 66 from the peak 66 causes the air to be moved down the peak and around the curved section 70 onto itself. When the injection event is initiated, the high pressure of injection adds to the motion of the air to enhance and increase the mixture. The net result of this is substantially lower soot formation. Furthermore, the increased turbulence of the fuel/air mixture leaving the relatively small bowl enhances the oxidization of soot to prevent a generation of particulates. It should be noted in FIG. 2 that the outer diameter 64 and peak 68 are curved so as to prevent the occurrence of sharp corners and, thus, localized hot spots and stress generators. It should be noted that the fuel injected from injector 44 cannot have swirl relative to the central axis A in order to promote the efficient entrainment of fuel particles within the air. It is also to be noted that the recess 62 may be offset from the central axis of piston 16 so long as the central axis of the recess 62 is coaxial with the axis of a fuel injector.
While this invention has been described with respect to at least one embodiment, the present invention can be further modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using its general principles. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. | A piston crown for a diesel engine in which the crown has an annular recess coaxial with an injector injecting fuel in a radiated, non-swirl pattern. The recess has an internal central crown portion approximately parallel to the angle of the fuel injected and a curved outer section to curve air compressed by the piston significantly enough that it is directed back toward the central axis and mixes with the fuel injected along the internal central crown portion to promote mixing and reduction in soot formation. | 8 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to apparatus and methods for energy storage and, more particularly, apparatus and methods for permitting in-situ determination and utilization of the state of charge and state of health of storage components in a microgrid.
[0002] Microgrids are rapidly expanding as part of the effort to reduce dependence on fossil fuels and to increase the efficiency of generating electric energy. The microgrids typically consist of power generators, renewable energy sources and energy storage components. For energy storage, components such as rechargeable batteries, super-capacitors, fuel-cells, and the like, are used. One of the main objectives of the microgrids is to effectively use the electric storage to maintain line voltage regulation which can mainly occur due to the unpredictable duty cycles of the renewables. In order to lower the mass, volume and cost of each energy storage components and for microgrid life cycle cost reduction, it is essential that the stored energy is expended and restored efficiently while maximizing energy storage component operational life.
[0003] Conventional energy storage component charge/discharge control is based upon terminal voltage monitoring and the labeled component capacity values. The terminal voltage, particularly in the dynamic charge/discharge environment of the electric grid, is not a true indicator of storage component state of charge and can result in overcharge or overdischarge of the device. Further, the component capacity fades with time and, if the component utilization is not based upon its current capacity, premature wear and system failure can result.
[0004] As can be seen, there is a need for methods and apparatus for effective utilization of diverse types of energy storage components with a microgrid based upon their state of charge and state of health.
SUMMARY OF THE INVENTION
[0005] In one aspect of the present invention, a method for effectively utilizing energy storage components within a microgrid comprises connecting one or more energy storage components to an electric bus; connecting a controller to the energy storage components, the controller having a state of charge and a state of health algorithm adapted to measure the state of charge and the state of health of the energy storage components under dynamic charge or discharge conditions; connecting one of a switch or power electronics to the controller to regulate bidirectional flow of energy between the electric bus and energy storage component; interconnecting the controllers with a local energy storage system bus; and controlling the controllers via a master microgrid controller connected to the local energy storage system bus.
[0006] In another aspect of the present invention, a method for controlling charge and discharge of energy storage components in a microgrid comprises managing a state of charge of the energy storage components to preserve a lifespan of the energy storage components; and performing trend analysis of a state of health of the energy storage components to predict advance maintenance actions.
[0007] In a further aspect of the present invention, a microgrid energy storage component system comprises one or more energy storage components connected to an electric bus; a controller connected to the energy storage components, the controller having a state of charge and a state of health algorithm adapted to measure the state of charge and the state of health of the energy storage components under dynamic charge or discharge conditions; one of a switch or power electronics connected to the controller to regulate bidirectional flow of energy between the electric bus and energy storage component; a local energy storage system bus interconnected with the controllers; and a master microgrid controller connected to the local energy storage system bus.
[0008] These and other features, aspects and advantages of the present invention will become better understood with reference to the following drawings, description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a block diagram of a microgrid energy storage component management topology according to an exemplary embodiment of the present invention;
[0010] FIG. 2 is a block diagram of a microgrid energy storage component management topology according to another exemplary embodiment of the present invention; and
[0011] FIG. 3 is a flow chart describing a method for the utilization of energy storage components within a microgrid, according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The following detailed description is of the best currently contemplated modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention is best defined by the appended claims.
[0013] Various inventive features are described below that can each be used independently of one another or in combination with other features.
[0014] Broadly, embodiments of the present invention provide an online method and apparatus for determining state of charge (SoC) and state of health (SoH) of energy storage components in a microgrid environment The SoC and SoH can be determined from the energy storage component's voltage, charge or discharge current and temperature.
[0015] Referring to FIGS. 1 and 2 , there are shown microgrid energy storage component management systems 100 , 200 according to an exemplary embodiment of the present invention. The systems 100 , 200 may provide for effective utilization of energy storage components within a microgrid.
[0016] FIG. 1 shows the energy storage component management system 100 where a local energy storage system controller 102 may manage charge/discharge operation for all energy storage components (as described in greater detail below) based upon parameters provided by a master microgrid controller 104 and the individual controllers 106 , 108 , 110 .
[0017] FIG. 2 shows the energy storage component management system 200 where each controller 206 , 208 , 210 directly interfaces with a master system controller 204 . The master system controller 204 may perform charge/discharge operation for the subordinate energy storage components based upon the microgrid power status and the state of charge and state of health status of the energy storage components.
[0018] Referring to both FIGS. 1 and 2 , for microgrid systems consisting of more than one cluster of energy systems, a hierarchal control scheme may be implemented. Each exemplary system may include an alternate current (AC) 112 , 212 and a direct current (DC) bus 114 , 214 and several energy storage components 116 , 118 , 120 and 216 , 218 , 220 .
[0019] The energy storage components can be of different types, such as primary or secondary batteries, supercapacitors, fuel cells, and the like. The energy storage component 116 , 216 may have a terminal voltage compatible with the DC bus 114 , 214 and may be connected to the DC bus 114 , 214 via a switch 126 , 226 . The energy storage component 118 , 218 may interface with the DC bus 114 , 214 via a bidirectional DC to DC converter 128 , 228 . The energy storage component 120 , 220 may interface with the AC bus 114 , 214 via a bidirectional inverter 130 , 230 . The controllers 106 , 108 , 120 , 206 , 208 , 220 may include state of health and state of charge algorithms for the corresponding energy storage components and may be capable of managing the power electronics (such as converters 128 , 228 or inverters 130 , 230 ) or switches (such as switch 126 , 226 ) that provide interface between the energy storage components and the power bus. In some embodiments of the present invention, the power electronics may be integrated into the controller. For example, the DC/DC converter 128 may be integrated into the controller 108 .
[0020] Exemplary parameters needed to derive the state of charge and state of health data are energy storage component real-time voltage, current and temperature. These parameters may be input to the appropriate state of charge and state of health algorithms for the energy storage components. Without being limited to any particular method, in an exemplary embodiment of the present invention, the state of charge and state of health may be determined by methods described in commonly owned U.S. Pat. No. 7,576,545, the contents of which are herein incorporated by reference.
[0021] Referring to FIG. 3 , there is described a method 300 for effectively utilizing energy storage components within a microgrid. The method may include a step 302 of connecting one or more energy storage components to an electric bus. The energy storage components may be a battery, supercapacitor, fuel cell, or the like. The electric bus may be an AC bus or a DC bus. A step 304 may include connecting a controller to the energy storage components. The controller may include algorithms for determining the state of charge and the state of health of the energy storage components. A step 306 may include connecting one of a switch or power electronics to the controller to regulate flow of energy from the electric bus to and from the energy storage components. A step 308 may include a step of interconnecting the controllers with a local energy storage system bus. A step 310 may include a step of controlling the controllers via a master microgrid controller connected to the local energy storage system bus.
[0022] Under the proposed methods, in deploying an energy storage system for charge and discharge operation, the following parameters may be taken into consideration: 1) Energy and power demand, 2) Energy storage component type, 3) Forecasted/estimated ON time, 4) State of charge/depth of discharge, and 5) Duty cycle balancing (if identical or similar energy storage components exist, their utilization may be managed to equalize usage).
[0023] The state of health of each energy storage component may be available and utilized in microgrid management. The state of health of each energy storage component may be expressed in terms of a number. When the component state of health depletes below an acceptable limit, maintenance action may be indicated. The state of health of each component may be monitored and recorded by the microgrid maintenance system. Energy storage component state of health trend analysis may be conducted and advance maintenance actions may be indicated.
[0024] The apparatus and methods of the present invention may provide 1) a single or multilevel hierarchal control of energy storage components that insure robust operation of the microgrid, 2) a robust control strategy based on the energy storage component state of charge and state of health, 3) energy storage component life preservation/extension through state of charge management and duty cycle balancing, and 4) state of health trend analysis and energy storage component prognostics.
[0025] It should be understood, of course, that the foregoing relates to exemplary embodiments of the invention and that modifications may be made without departing from the spirit and scope of the invention as set forth in the following claims. | An online method and apparatus for determining state of charge (SoC) and state of health (SoH) of energy storage components in a microgrid environment is disclosed. The apparatus and methods may estimate SoC and SoH of an energy storage device in a real-time fashion. The SoC may be used to preserve/extend the life of the energy storage components, while the SoH may be used for trend analysis and energy storage component prognostics. | 8 |
RELATED APPLICATIONS
This application is a Continuation of a copending application filed on the same day, Ser. No. 14/251,580. This application is also related to one other copending application filed on the same day, with the same inventors and assignee, and with the same teachings and spec. All the teachings of those 2 applications are also incorporated here by reference.
BACKGROUND OF THE INVENTION
Nowadays, the water supply (and separation of salt and other chemicals) is extremely important for human consumption (drinking or general use, e.g., bathing), animal consumption, industrial use, agriculture, washing purposes, plants, trees, vegetation, and food supplies.
The drinking water is in short supply, especially for countries in the warm climate or near desert, with no or small amount of rain and snow. In addition, getting pure and drinking water from ocean or sea is very expensive and requires a lot of energy. Furthermore, the pollution for such an energy requirement is a big concern for the environment. In addition, the energy is also in short supply and expensive, e.g., for oil or coal. Furthermore, the hungry nations or people may go to war or cause riots, with suffering and disastrous results, to go after scarce resources, such as food and water. In addition, the population of the world is increasing drastically and very fast. Furthermore, the vegetation and agriculture/trees/forests are hard to maintain without the proper supply of the water. In addition, the food or water is getting more expensive and scarce for most of the world. Furthermore, the weather patterns are getting more extreme and disastrous for most of the world.
So, one needs solutions for collecting water, in an efficient and less expensive way, with less pollutions and less energy, with use of green/renewable energy, if possible, to support the plants, animals, agriculture, and human consumptions, in various applications and usages.
SUMMARY OF THE INVENTION
This solution (our solutions) has to be reliable, flexible, low-maintenance, low-overhead, low-cost installation, practical, and easy-to-install. Since it is modularized, it is easier for transportation and maintenance, with less cost and down-time. It should be easy to manufacture, and tough against the natural elements, e.g., high humidity and corrosion by sea water, with lots of salts and acidity. Since there is no solution in the market now, our solution is the first of its kind. That is, the inventions and embodiments described here, below, have not been addressed or presented, in any prior art.
For example, in some regions in the Middle East, we have conditions of dry land with no or small amount of rain, with little vegetation, in need of water, but having a sea with high humidity nearby, at high temperatures, especially during Summer time, to tap to, for our inventions here, to collect water, is a big advantage. According to www.Britannica.com, Encyclopedia Britannica, Inc., the relative humidity is high for those areas, near or on sea or sea shore, e.g. for Red Sea, between Africa and Middle East/Asia. So, the location has all the basic ingredients. For example, high wind near the sea, for windmill power generators, and hot direct Sun with not much cloud for Solar panels green power generation, nearby, can be supplement or main power sources for motors and fans and pumps and others used in our water collector system or installation or assembly, to reduce gas emissions and pollutants, e.g. CO and CO2.
Since it is modularized, in one embodiment, it is cheaper to make or scale it for longer stretches of sea shores. One can copy the system for thousands of miles, with less cost per mile, due to economy of scale. If a portion is bad or defective or out-of-order, we can replace or repair, without stopping the operation of the other sectors or sections. The controls can be centralized or localized or semi-localized or distributed. The controller, through local sensors and weather forecast satellite and information from outside or remote locations, can optimize so that when the humidity is low or the conditions or efficiency for process is low/non-optimum, the process stops, e.g., the fans are stopped, so that it does not work inefficiently, wasting energy as a net result.
In one embodiment, we have a rules engine for the controller for this process, using a processor or more processors, to partially or fully close/turn off or turn-on sections of the seashore, according to the local condition for weather and pressure/temperature and humidity, and/or the differences between those parameters locally, based on those rules or history of the performances/results/efficiencies/rates/power generated/water/gallons collected, in the past, or patterns/corresponding outcomes, to optimize the results and efficiency of water generation/collection, with less energy, especially less of non-renewable energy forms/resources.
In one embodiment, we have various calculations and modules related to various tasks and goals for this project.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example/embodiment for the structure or facility for capturing the air with high humidity from surface of the sea or river.
FIG. 2 shows an example/embodiment for the structure or facility for capturing the air with high humidity from surface of the sea or river.
FIG. 3 shows an example/embodiment for the flexible pipes, e.g., plastic or elastic or accordion-shaped or variable-volume or extendable or compressible.
FIG. 4 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces.
FIG. 5 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces.
FIG. 6 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces.
FIG. 7 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces.
FIG. 8 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces.
FIG. 9 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces, e.g., with the pumps or fans or motors at multiple locations.
FIG. 10 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces, connected together in the middle or fanned out or distributed or T-shaped or aggregated for more throughput, as parallel inputs, accumulated, with one branch or line going to the tower or shore.
FIG. 11 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces, with multiple jackets inside each other.
FIG. 12 shows an example/embodiment for the system with water coming or collected from humidity from sea, and the motors or fans are energized or powered by the solar or wind or ocean wave energy generators.
FIG. 13 shows an example/embodiment for the system with water coming or collected from humidity from sea, with various distribution means, e.g., nozzles, or pipes to the green houses or closed enclosures, such as rectangular box housing.
FIG. 14 shows an example/embodiment for the system with e.g. the tube staying on sea surface, using a light weight floater, such as a tire tube with air in it, or wooden material, or hollow plastic floater.
FIG. 15 shows an example/embodiment for the system with wire mesh or net or chains or cables or fabrics, holding the assembly together.
FIG. 16 shows an example/embodiment for the system with funnel collector with wide entrance or opening, for wider reach on sea surface.
FIG. 17 shows an example/embodiment for the system with multiple or arrays of collectors on each floater, with multiple floaters (or hanging on the air, similar to FIG. 15 ).
FIG. 18 shows an example/embodiment for the system with metal bars for flexible pipes (or rigid pipes), to hold them intact.
FIG. 19 shows an example/embodiment for the system with multiple metal bar systems or assemblies, attached to multiple cranes or towers (two or more), for better control on length or position or rotation of the collector tip near the water.
FIG. 20 shows an example/embodiment for the system with disengaging rod or chain, to fold down the assembly or arm, and pull back the floater by an extra cable or crane toward the shore.
FIG. 21 shows an example/embodiment for the system with various sensors and their possible locations, so that we can get feedback to the controller and HQ or processor, so that it adjusts the cranes and collector tips.
FIG. 22 shows an example/embodiment for the system with various/multiple stages for refrigeration, along the pipes.
FIG. 23 shows an example/embodiment for the system with various/multiple stages for compressors, along the pipes, with an expansion chamber at the end.
FIG. 24 shows an example/embodiment for the system with pipes exchanging heat with sea, or land, during different seasons, and day/night, at different temperatures.
FIG. 25 shows an example/embodiment for the system with floating or structure near the surface of the sea near the shore, with dark absorbing top surface, with grains to absorb more Sun light and energy.
FIG. 26 shows an example/embodiment for the system with fan and radiator or heat exchanger.
FIG. 27 shows an example/embodiment for the system with a structure with roof covered with solar panels or light reflectors.
FIG. 28 shows an example/embodiment for the system with a horizontal fan or vertical fan axis, with collector tip opening located horizontally, parallel to the water or sea surface.
FIG. 29 shows an example/embodiment for the system with a vertical fan, connected to a motor for rotation of the fan, with cable for electricity from tower, or from solar panels on the floater or boat.
FIG. 30 shows an example/embodiment for the system with a angled fan, with plane between vertical and horizontal, 0 to 90 degrees, e.g. 45 or 60 degrees.
FIG. 31 shows an example/embodiment for the system with roof and heat exchanger with ground, plus insulation coverage, to cool down and extract water.
FIG. 32 shows an example/embodiment for the system with various extensions or arms for different configurations for collector section, to collect water on the sea.
FIG. 33 shows an example/embodiment for the system with pipes connected by hinges, which are bent, or can be adjusted manually or by motor/gears/gear box, with flexible or solid pipes.
FIG. 34 shows an example/embodiment for the system which controls the operation for water extraction with various devices and components.
FIG. 35 is an example/embodiment for the system to control the bars on arm from tower or crane or shore.
FIG. 36 is an example/embodiment for the system for the fan power and control wires and cables.
FIG. 37 depicts the equilibrium (saturated) water vapor partial pressure for a range of water vapor temperature. The dotted line depicts an exponential fit with the fit parameters.
FIG. 38 depicts the water dew point temperature associated with various water vapor temperatures and relative humidity.
FIG. 39 depicts the water content in saturated vapor-air mixture per mixture as well as dry content.
FIG. 40 depicts dew point temperature at various total mixture pressure with respect to the dew point temperature at a baseline total pressure (1 atm).
FIG. 41 depicts the percentage reduction in evaporation as the salinity of water increases.
FIG. 42 depicts an embodiment of invention with a platform immersed in water having a light (radiation) absorbing surface or coating with opening(s).
FIG. 43 depicts an embodiment of invention with a modularized platform immersed in water having a light (radiation) absorbing surface or coating with opening(s).
FIG. 44 depicts an embodiment of invention with a platform immersed in water having a light (radiation) absorbing surface or coating with opening(s) and a transparent cover containing the air flow.
FIG. 45 depicts an embodiment of invention with a platform with heat exchange to increase evaporation and a transparent cover containing the air flow.
FIG. 46 depicts an embodiment of invention with an automatically controllable/adjustable blower/fan enhancing or creating air flow over the water surface to increase the evaporation and a capture fan to collect the water vapor-air mixture for further processing.
FIG. 47 depicts an embodiment of invention with an automatically controllable/adjustable blower/fan supported on a floater or pier to enhance or create air flow over the water surface to increase the evaporation and a air-vapor capture mechanism.
FIG. 48 depicts an embodiment of invention with a platform over water (e.g., floating) having a transparent cover for passing radiation (heat) to water and air flow mechanism (e.g., fan/blower moving air-vapor mixture below the cover).
FIG. 49 depicts an embodiment of invention with water inlet and partial vacuum, radiation absorbing surfaces, and heat exchange to enhance the water evaporation rate.
FIG. 50 depicts an embodiment of invention with heating chamber for water and evaporation chamber having partial vacuum.
FIG. 51 depicts an embodiment of invention with multiple heating surfaces for water evaporation and water inlet(s) supplying water above the surfaces.
FIG. 52 depicts an embodiment of invention, with captured vapor pressurized and cooled via heat exchange with evaporator, geothermal, and/or cooled air from condensation tank.
FIG. 53 depicts an embodiment of invention with a water column maintained by partial vacuum for evaporation using heat from radiation and/or heat exchange.
FIG. 54 depicts an embodiment of invention with water column(s) maintained by partial vacuum for evaporation using heat from radiation and/or heat exchange and mixing reduction in water inlet and outlet.
FIG. 55 depicts an embodiment of invention with vapor storage tank (e.g., underground) cooled via geothermal, water storage (e.g., underground), and/or cooled air (from condensation tank staging compartment) and operated by an automatic control and monitoring system, e.g., remotely.
FIG. 56 depicts an example of the phases of operation for various modules of system in an embodiment of invention, e.g., for capture, storage, cooling, condensation, and distribution.
FIG. 57 depicts an example of various modules and their arrangement for optimizing cost and throughput within the system for example in continuous operation, e.g., for capture, storage, cooling, condensation, and distribution.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an example/embodiment for the structure or facility for capturing the air with high humidity from surface of the sea or river, e.g., usually in hot areas, e.g., in Africa or Middle East, with dry land, with multiple pipes or tubes, along the seashore or coast, e.g., in parallel with the coast line. The tubes or pipes can be flexible or rigid or semi-rigid or piecewise-rigid, with connectors or hinges or reducers or interconnects or junctions, in between the pieces or connecting them. The distance to shore may be, e.g., 5 m to 500 m, but it can be longer or shorter, as well. For longer connections, one needs extra motors or fans to suck the air or pull or push the air for longer distances, e.g., in different stages or different locations or intermediate spaces or locations. The tower or structure for capturing water or collection storage can be set of ground or shore, or based on a floating boat or structure, or anchored on the sea, or with columns or long legs in concrete or metal or floaters (e.g. light tubes or wood), e.g., in or near shore, e.g., in or near water.
FIG. 2 shows an example/embodiment for the structure or facility for capturing the air with high humidity from surface of the sea or river, e.g., with miles along the shore with high throughput.
FIG. 3 shows an example/embodiment for the flexible pipes, e.g., plastic or elastic or accordion-shaped or variable-volume or extendable or compressible, to be flexible for tide during the days or during variations for seasons or during storm or rough sea or the like, or for adjusting of the height or extension or length or stretch on sea, because of various parameters in the weather and others measured by our sensors on the pipes or near shore or on tower or by satellite or central HQ or controller module or main processor module or analyzer module or device or system, or for optimization or efficiency, by controller device, e.g. to reduce cost or for environmental footprint or emission gases or more or faster rate of water collection or less energy or less non-renewable energy or the like, based on a cost function to optimize or penalize, based on all parameters mentioned in this spec.
FIG. 4 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces, e.g., with the pump or fan near the end near or at the water source or humidity source near or on water surface, e.g. sea or river or pond or lake or ocean or pool or stream or underground lake or cave. This method, the 1 atmosphere pressure difference limit, as the maximum possible, is removed as a constraint.
FIG. 5 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces, e.g., with the pump or fan in the middle or somewhere between the 2 ends. FIG. 6 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces, e.g., with the pumps or fans or motors at multiple locations, e.g., in the middle and near the water source.
FIG. 7 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces, e.g., with the pumps or fans or motors at multiple locations, e.g., in the middle and near the water source and near the tower, e.g. on land for collection structure.
FIG. 8 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces, e.g., with one or more pumps or fans or motors all at one location near or at the tower, e.g. on land for collection structure. This configuration has a limit of max 1 atm pressure gradient or difference, which is a constraint. However, this configuration is closer to the tower and thus, easier to repair or maintain, and less susceptible or at risk with respect to rough sea or natural elements near the surface of the sea, thus, safer and less risky and more life expectancy and less repairs, in general, and thus, less costly for operation and maintenance/ to own. So, it is a trade-off. So, in one embodiment, for some applications, the configuration on FIG. 5 might be a good compromise for the 2 cases or extremes for FIG. 8 and FIG. 4 , or e.g. use multiple fans or pumps or motors in the whole stretch or pipes, in series, or staggered for different sections or distances, or at periodic locations.
FIG. 9 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces, e.g., with the pumps or fans or motors at multiple locations, e.g., near the water source and near the tower, e.g. on land for collection structure.
FIG. 10 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces, connected together in the middle or fanned out or distributed or T-shaped or aggregated for more throughput, as parallel inputs, accumulated, with one branch or line going to the tower or shore.
FIG. 11 shows an example/embodiment for the flexible pipes or non-flexible pipes or rigid or pieces, with multiple jackets inside each other, e.g. circular or elliptical or square shaped cross sections, e.g. concentric tubes, e.g. with insulation, vacuum, light reflector (such as metal, like mirror, coatings or materials), refrigerants, oil, inert gas, foam, plastic, metal, or air, or the like or combinations, in between or on or in the jackets, or filled up or partially, or coated, to e.g. control heat exchanged or lost, or keep humidity, or reduce heat exchange, or reduce cost, or reflect more light or less light depending on the situation and other parameters, to e.g. control for humidity and temperature or pressure inside the tubes or in between, e.g. to optimize or for more efficiency, based on the control system and rules/rules engine.
For example, in one embodiment, in a 3-layered system of concentric tubes (see FIG. 11 ), the outermost tube is coated with a reflective coating such as metal, or made of a reflective material (e.g., for most wave lengths, e.g. for invisible and visible spectrums), or made of metal material or metal alloy, e.g., aluminum, to reflect the Sun light, and not absorb too much radiation energy, to reduce the temperature inside the tube, for faster condensation of water vapor/humidity at a cooler temperature, to be more efficient. In one embodiment, the next layer, going inside the tube, is an insulation layer, e.g. fiberglass or plastic, for better insulation than air, so that less Sun light gets absorbed, to reduce (or keep lower) the temperature inside the inner-most tube. In one embodiment, the next layer, going inside the tube, is another/second insulation layer, e.g. fiberglass or plastic, or a different insulator material, for even better heat insulation, e.g. for conduction, to reduce (or keep lower) the temperature inside the inner-most tube, which carries the humid air or water vapor, e.g. to the tower at shore, at a cooler temperature, to be more efficient for water collection/condensation.
FIG. 11 also shows an example/embodiment for the circulation of air or other liquid or fluid back and forth in different/multiple M jackets or layers (1, 2, 3, . . . , n layers) between the pipes, for cooling/heating or transportation purposes. For example, the cold air generated or dry air generated, in the processes shown here, can be fed back to another place. For example, the dry air or cool air can be used/redirected/fed for forced air supply for cooling a house for humans, saving energy for the house consumption.
FIG. 12 shows an example/embodiment for the system with water coming or collected from humidity from sea, and the motors or fans are energized or powered by the solar or wind or ocean wave energy generators, as well as coal or gas generators, as a backup, and not as main source, which can also be stored on batteries, e.g. for nights, as backups, and the solar panels being e.g. on the roofs and sides of the structure or tower or buildings. Then, the water is collected and distributed to humans, animals, or plants, with some purifications for drinking purposes, or e.g. for green houses or land for agriculture.
FIG. 13 shows an example/embodiment for the system with water coming or collected from humidity from sea, with various distribution means, e.g., nozzles, or pipes to the green houses or closed enclosures, such as rectangular box housing, e.g. with glass or transparent wall(s) and/or roof, or non-transparent wall or roof, or translucent wall or roof, or reflective/mirror wall or roof, or solar panels on wall or roof, or insulating material wall or roof, e.g. with fiber glass material in between shingles/roof and ceiling surface, e.g. to keep the temperature lower at the enclosed housing, for more availability of liquid water for the plants inside the box or housing or enclosed garden.
FIG. 14 shows an example/embodiment for the system with e.g. the tube staying on sea surface, using a light weight floater, such as a tire tube with air in it, or wooden material, or hollow plastic floater, with overall average density of all assembly to be smaller density than the density of the water, at about 1 gm/cm 3 .
FIG. 15 shows an example/embodiment for the system with wire mesh or net or chains or cables or fabrics, holding the assembly together, from right side of the FIG. 15 , connected or attached to the tower, at the shore, hanging on the air, on top of the sea surface, which is controllable from the tower, in terms of reach or extension or length of the assembly, using the net or mesh to pull the assembly toward the tower or shore, when needed, or release it more, away from the shore, by loosening the grip on the net, which is flexible for the assembly and net, to get away from tower, and increases the length of the assembly and its reach. The same thing can be done with solid bars that hold the assembly, instead of net, with the control from the tower at the shore, to bend the bars at the hinges or elbows, to reduce the reach of the assembly/its effective length, as shown in FIG. 18 .
FIG. 15 also shows some embodiments related to connection to the tower or crane, for connecting to a motor, for push/pull operation on the arm or assembly, with options such as cable, chain, hook/ring, or bar, with flexible, solid, or elastic material, e.g., metal, alloys, or twisted metal strings/rope, e.g. rust-proof, stainless steel, coated, or painted. The motor can be installed on the tower or crane, working in both directions, rotating, for push/pull operations.
FIG. 16 shows an example/embodiment for the system with funnel collector with wide entrance or opening, for wider reach on sea surface. This can be hanging on air, like FIG. 15 , or floating, like FIG. 16 .
FIG. 17 shows an example/embodiment for the system with multiple or arrays of collectors on each floater, with multiple floaters (or hanging on the air, similar to FIG. 15 ), using both or any of the flexible piping or rigid piping (with elbows or hinges, shown in FIG.), to get the water/humidity to the tower, using e.g. various connectors or reduces or hinges in between.
FIG. 18 shows an example/embodiment for the system with metal bars for flexible pipes (or rigid pipes), to hold them intact, for strength/stability of assembly shown, holding on air or floating, similar to FIGS. 15-16 , attached to the tower, by metal or other types of bars or chains or cables, e.g. using a crane and a hook on the crane, which is on or attached to the tower, which is anchored to the ground or sea shore.
FIG. 19 shows an example/embodiment for the system with multiple metal bar systems or assemblies, attached to multiple cranes or towers (two or more), for better control on length or position or rotation of the collector tip near the water, for one or more of piping assemblies or collectors, or array of them, to control from tower by human or by computer, based on image of the assembly/analysis, and based on control system analyzing those images to position the collector tip's coordinate, e.g. height, from sea surface, length, or reach, away from tower or shore.
The camera(s) or sensors are on the floater, or pipes, or cranes, or towers, or at sea shore. They all can be connected by wire for power, or using battery, or solar panel powered, or wind mill powered, or other renewable methods, and they are also connected by cable for communications, or wirelessly, by antennas or satellite or dishes, or laser/optical communications, or other means of communications.
So, in one embodiment, each collector tip can be navigated or positioned or controlled separately by one or more cranes. In one embodiment, each floater with one or more collector tips can be navigated or positioned or controlled separately by one or more cranes, in all 3D coordinates, e.g. height, rotation, tilt, diagonal plane, or XY horizontal 2D coordinates, with respect to sea surface, assuming flat horizontal 2D plane.
For example, for transitional coordinate on 2D, or XY coordinate, or horizontal plane, if we have 2 cranes on left and right side of a single collector tip, and both connected to the same collector tip, then we have, from FIG. 19 , as an example:
If we pull from left crane, then the collector tip goes to the left side. If we pull from right crane, then the collector tip goes to the right side. If we pull from left crane, and push from right crane, then the collector tip rotates clockwise, with asymmetric positioning as shown e.g. in FIG. 19 . If we pull from right crane, and push from left crane, then the collector tip rotates counter-clockwise, with asymmetric positioning as shown e.g. in FIG. 19 .
In one embodiment, the crane can be connected to the assembly or arm/net for supporting the pipes, using cable, strings, chain, cable(s), and the like, and it can be pulled or pushed using e.g. a motor, rotating in 2 different directions, forward/reverse, attached to such cable or chain, as an example, as shown in FIG. 15 . Everything is controlled by server/computer/processor at central HQ, e.g. using wireless communications, for control/analysis/decisions/navigations.
In one embodiment, the crane or tower is land-based or sea-based or on sea-shore or anchored at sea or seashore or on land, with concrete blocks or metal anchors or the like, or floating near the shore.
In one embodiment, the high wind from sea, e.g. Red Sea, brings a lot of moisture from sea to the shore, which is seasonal or during some periods, without use of a fan or motor, which saves a lot of energy, as long as the weather forecast tells the controller to turn off the fans and get the collector tips vertical, and aligned in the direction of the wind at the seashore or land, to collect moisture, with min cost and effort. The local sensor and wind direction detector, locally, can do the same for controlling the collector tip's direction and orientation and location, attached to the controller device locally, or at HQ centrally, or distributed computation power. The tip of the collector is positioned by cranes, by cables or chains or strings or levers or bars, or by motors directly, e.g. using gear or gear box, to position in many different directions or angles in 3D coordinates. Some dedicated collector tips can also be stationed only for land based collection, permanently based there, as an example.
FIG. 20 shows an example/embodiment for the system with disengaging rod or chain, to fold down the assembly or arm, and pull back the floater by an extra cable or crane toward the shore, e.g., using a motor, for safety and storage, or e.g. push down by crane or its own weight to store the accordion shaped arm or assembly on floater or on shore/land, during rough sea or storm or high wind.
FIG. 21 shows an example/embodiment for the system with various sensors and their possible locations, so that we can get feedback to the controller and HQ or processor, so that it adjusts the cranes and collector tips. It uses various communication tools, such as antenna in different locations.
FIG. 22 shows an example/embodiment for the system with various/multiple stages for refrigeration, along the pipes. FIG. 23 shows an example/embodiment for the system with various/multiple stages for compressors, along the pipes, with an expansion chamber at the end, for rapidly cooling down the gas, to get the water from the humidity in air, with drain holes in the bottom of chamber, to collect and send the water into a main drain pipe, underneath the chamber, for distribution, e.g. by gravity/slope of the pipe, only, e.g. in one embodiment, without any pump or extra energy.
FIG. 24 shows an example/embodiment for the system with pipes exchanging heat with sea, or land, during different seasons, and day/night, at different temperatures, e.g. as body of water stored by pump, or water come by tide/gravity at a storage, or e.g. exchanging heat by block of metal, or underground land based reservoir, to adjust the temperature of the pipe, to cool down, to condense water from vapor/gas form/humidity.
FIG. 25 shows an example/embodiment for the system with floating or structure near the surface of the sea near the shore, with dark absorbing top surface, with grains to absorb more Sun light and energy, to cause the water near surface gets hotter than normal, and gets more humidity to the collector tip near the surface, for water. The structure under the water or floating can be permanent or temporary or moveable.
FIG. 26 shows an example/embodiment for the system with fan and radiator or heat exchanger, e.g. with coils carrying oil or liquid or the like, in which humid air passes through these coils, to cool down and get humidity condensed as water, with drain funneled at the bottom of chamber, to accumulate those for main pipe, for distribution of the water.
FIG. 27 shows an example/embodiment for the system with a structure with roof covered with solar panels or light reflectors, e.g. mirror material, and insulator for heat underneath the solar panels or light reflectors, to keep the shaded area and enclosure located below at a cooler temperature, away from heat or direct Sun, to get cooler temperature underneath on the shade provided, to condense water, from air passing by, through the pipe, with drain sloped to collect and direct the water by gravity/slope to the main pipe for distribution or storage or filtering or cleaning or purifying. The building structure can have any shape.
FIG. 28 shows an example/embodiment for the system with a horizontal fan or vertical fan axis, with collector tip opening located horizontally, parallel to the water or sea surface. FIG. 29 shows an example/embodiment for the system with a vertical fan, connected to a motor for rotation of the fan, with cable for electricity from tower, or from solar panels on the floater or boat. FIG. 30 shows an example/embodiment for the system with a angled fan, with plane between vertical and horizontal, 0 to 90 degrees, e.g. 45 or 60 degrees. The tip of the collector and its angle can be adjusted using cables or cranes or levers or rods or nets, as shown in previous FIGS., with controller adjusting, centrally or locally.
FIG. 31 shows an example/embodiment for the system with roof and heat exchanger with ground, plus insulation coverage, to cool down and extract water. FIG. 32 shows an example/embodiment for the system with various extensions or arms for different configurations for collector section, to collect water on the sea.
FIG. 33 shows an example/embodiment for the system with pipes connected by hinges, which are bent, or can be adjusted manually or by motor/gears/gear box, with flexible or solid pipes, which can be controlled by controller or HQ or processor device, with knee or elbow connected to the gear. The elbow is made of 2 spheres with near radius sizes one enveloping the other one, which can be moved with respect to each other in all 3 directions or angles for 3D space. The pipes can carry water or humid air or coolant or the like. The pipes can be used in various parts of our system, e.g. in arm assembly.
FIG. 34 shows an example/embodiment for the system which controls the operation for water extraction with various devices and components, for each section of the shore or water collection facility, as a separate module or division, controlled by the same processor or server or controller or HQ or microprocessor or central office or collection of servers or server farms or distributed computing devices or cloud-based devices or collection of local computers or network of computers or Internet-based processors or remote devices or device.
FIG. 34 is an example/embodiment for the system where the humidity sensor on or near the collector measures the humidity, and sends the information using the wireless communication/antenna to local unit/antenna or main unit/tower, directly, or via another leg, to HQ or main processor. Then, the controller at main unit or processor decides when the fan and collector should be on, and when it is inefficient, in terms of energy consumption per gallon or liter of the water collected, or based on available green energy at that time, e.g. no solar power during the night, forcing to use non-green energy sources, e.g. natural gas, to power the fan and assembly, which is less favorable for operation stand point. Or, it decides when it is damaging to use the fan or collector, to turn off the system or retrieve the whole arm and system, to avoid high wind or rough sea, as an example. All are based on database, and rules engine, with rules embedded there, plus the weather forecast/feed, in addition to the real weather data at any given time, as supplemental data. These are, in some embodiment, parts of the main HQ or central unit. The wind direction and temperature are also measured locally and transmitted to HQ, via sensors on collector unit or floater or crane or arm, as well as anemometer for speed of wind, and wind vane for direction of wind, plus barometer for pressure, e.g. as shown on FIG. 21 , in various locations, installed or attached. (see FIG. 34 .)
An example of rules engine is given here: (stored in rules database, and connected to the controller unit, as well as processor) (see FIG. 34 .)
Rule 1: If the relative humidity H r is below H r0 , then turn off the fan, crane, arm, and assembly system. (e.g., H r0 is 50 percent, or it is somewhere between 40 to 70 percent.)
Rule 2: If the temperature T below T0, then turn off the fan, crane, arm, and assembly system. (e.g., T0 is 20 C, or it is somewhere between 15 to 30 C.)
Next rule, Rule 3, R3: If the temperature T below T1, and the relative humidity H r is below H r1 , then turn off the fan, only. (standby situation) (e.g., T1 is 25 C, or it is somewhere between 20 to 35 C.) (e.g., H r1 is 40 percent, or it is somewhere between 30 to 60 percent.)
Next rule: If the speed of wind is more than V0, then turn off the fan, crane, arm, and assembly system, and fold the pipes, and pull back the arm toward the tower or shore, as shown in a previous figure. (e.g., V0 is 80 miles/hr, or it is somewhere between 50 to 100 miles/hr.)
Next rule: If the speed of wind is more than V1, but below V0, then for the direction of the wind in the direction of the 3D (dimensional) vector V w , lift the collector tip in vertical position, and align the collector tip axis in the direction of vector V w . That is, the wind or vector V w will be perpendicular to the plane/circular cross section of the collector tip (see FIG. 29 for orientation, and FIG. 19 for mechanism to do so). This is one of the most efficient ways of collecting air/humidity, with the largest cross section available for that wind direction, in some embodiments. (e.g., V0 is 80 miles/hr, or it is somewhere between 50 to 100 miles/hr.) (e.g., V1 is 30 miles/hr, or it is somewhere between 20 to 60 miles/hr.) (See FIG. 35 )
Next rule: If more than N percent of the energy for operation comes from non-green or renewable kinds (e.g. N=90 percent, or it is between 50 to 95 percent), then turn off the fan, only.
Next rule: If more than N1 percent of the energy for operation comes from battery (e.g. N1=80 percent, or it is between 40 to 85 percent), then turn off the fan, only.
Next rule (Rule Q, for efficiency): If less than G gallons e.g. per minute/unit time of water is extracted from/by the local unit (e.g. G=10 gallons, or it is between 5 to 100 gallons), then turn off the fan, only, for that local unit.
Next rule (Rule Q1, for efficiency): If less than G1 gallons of water is extracted from/by the local unit, per Z (J energy) used, or per Z1 (e.g. in J, Joule) non-renewable energy used (e.g. G1=1 gallon, or it is between 0.5 to 10 gallons), then turn off the fan, only, for that local unit. (e.g. Z=1 J, or it is between 0.001 J to 1000 kJ) (e.g. Z1=0.75 J, or it is between 0.00001 J to 500 kJ). This rule can also be expressed in terms of power, in Watt, for rate of energy used, per unit time.
The combinations of the rules above in any order are also used here. Any single rule is also used here. Any logical combination of the rules can be used here, in one embodiment, e.g., using OR, AND, XOR, and the like, for operation between rules, e.g. with parenthesis between operands, with multiple operands or rules, as an example. For example:
Final rule=(R1 OR R2) AND R3
Wherein Ri is rule number i, and i is an integer, positive, bigger than zero.
FIG. 36 is an example/embodiment for the system for the fan power and control wires and cables, which is related to other figures, e.g., FIG. 35 .
Other Embodiments
The enthalpy of water evaporation is about 44 kJ/mol at about 25° C. This enthalpy decreases by increasing temperature (e.g., about 41 kJ/mole at 100° C.) and it vanishes rapidly as the temperature is reaches its critical point (at about 647 K and 218 atm pressure). In the range of about 25-50° C. the enthalpy of evaporation is about 43 kJ/mole. The equilibrium water vapor partial pressure is approximated, e.g., by August-Roche-Magnus approximation, as follows:
P
WS
=
610.94
ⅇ
(
17.625
·
T
D
243.04
+
T
D
)
T
D
=
243.04
×
1
17.625
ln
(
P
WS
610.94
)
-
1
where T D is the Dew point temperature (in ° C.) and P wS is the equilibrium (saturated) water partial pressure in Pascal. This approximation is plotted in FIG. 37 . The partial pressure may be approximated as proportional to the negative exponential of enthalpy:
P
WS
∝
ⅇ
(
-
Δ
H
K
B
T
)
where K B is Boltzmann constant, ΔH is enthalpy of evaporation, and T is absolute temperature of the vapor. This implies (assuming small variation in ΔH within the temperature range):
ⅆ
ln
(
P
WS
)
ⅆ
T
=
Δ
H
K
B
T
2
≅
0.05
K
-
1
(
at
∼
50
°
C
.
)
This is in agreement with the exponential fit to the August-Roche-Magnus approximation for the equilibrium water vapor partial pressure depicted in FIG. 37 (depicted as dotted line with fitting exponent of 0.049 K −1 .
Saturation water partial pressure may also be approximated (in range of 0° C. and 373° C.) based on the critical point (see W. Wagner and A. Pruβ, “The IAPWS Formulation 1995 for the Thermodynamic Properties of Ordinary Water Substance for General and Scientific Use”, Journal of Physical and Chemical Reference Data, June 2002, Volume 31, Issue 2, pp. 387535):
ϑ
=
1
-
T
T
C
ln
(
P
ws
P
C
)
=
T
T
C
·
(
C
1
ϑ
+
C
2
ϑ
1.5
+
C
3
ϑ
3
+
C
4
ϑ
3.5
+
C
5
ϑ
4
+
C
6
ϑ
7.5
)
where T and T C (647 K=373° C.) are the vapor temperature and the critical temperature in Kelvin, respectively, and P ws (in hPa) and P C (220640 hPa) are the saturated water pressure at T and T C , respectively, and C 1 =−7.85951783, C 2 =1.84408259, C 3 =−11.7866497, C 4 =22.6807411, C 5 =−15.9618719, C 6 =1.80122502.
The relative humidity, R H , is the ratio of the partial pressure of water vapor in an air-water mixture to the saturated vapor pressure of water at a given temperature. R H contours are plotted in Dew Point—Vapor Temperature plot in FIG. 38 , based on the August-Roche-Magnus approximation. For example, point 1 is at R H of 60% at 50° C. Both Points 2 and 3 indicate saturated water-air mixture at different temperatures (50° C. and 40° C., respectively). Going from point 1 to 2, water is added to the mixture to reach saturation at the same temperature. This is accompanied with increase in volume if the total pressure is kept the same. Going from point 2 to 3, the temperature is (e.g., slowly) reduced and the saturated mixture would lose water as liquid. At point 3, the same amount of water added (from point 1 to 2) is reclaimed, because the absolute moisture between points 1 and 3 are the same, as reducing the temperature from point 1 to point 3 would not lose any moisture to liquid form until point 3 (a saturation point) is reached. Therefore, the horizontal lines indicate the equal absolute humidity, as the volume and temperature increase from point 3 to point 1 (assuming the same total pressure), given that the molar fractions and therefore the water partial pressure remain the same. Given that the water partial pressure of point 2 and 3 are the same, the relative humidity of point 1 (with respect to point 3, at the same vapor temperature) may be expressed based on partial pressure of saturated water-air mixture (i.e., points 2 and 3), as follows:
R
H
1
=
P
w
1
P
w
2
=
P
w
3
P
w
2
=
ⅇ
(
17.625
·
T
D
243.04
+
T
D
)
ⅇ
(
17.625
·
T
A
243.04
+
T
A
)
where T D is the Dew point temperature of the mixture (at point 1, e.g., 40° C.), T A is the temperature of the mixture in ° C. (at point 1, e.g., 50° C.), and T D is the Dew point temperature of the mixture in ° C. (at point 3, e.g., 40° C.). Similarly, T A or T D may be derived based on R H and the other:
T
D
=
243.04
×
ln
(
R
H
)
+
(
17.625
·
T
A
243.04
+
T
A
)
17.625
-
ln
(
R
H
)
-
(
17.625
·
T
A
243.04
+
T
A
)
T
A
=
243.04
×
(
17.625
·
T
D
243.04
+
T
D
)
-
ln
(
R
H
)
17.625
+
ln
(
R
H
)
-
(
17.625
·
T
D
243.04
+
T
D
)
Assuming near ideal gas, the ratio of the molar density of the water vapor for points 2 and 1, is the same as the ratio of the water vapor partial pressure for points 2 and 1, given that the temperatures of points 2 and 1 are the same:
R
H
1
=
(
n
w
1
V
1
)
(
n
w
2
V
2
)
=
(
P
w
1
T
1
)
(
P
w
2
T
2
)
=
P
w
1
P
w
2
·
T
2
T
1
=
P
w
1
P
w
2
The absolute water content (per volume) is a mixture is obtained from an ideal gas approximation as follows:
A
=
C
·
P
w
T
where
C = 18 g / mol R = 2.166 g K / J ,
and T is absolute temperature of the mixture in Kelvin, P w is partial pressure of water vapor in Pascal, and A is in g/m 3 . The water content per air content or mixture content is depicted in FIG. 39 for saturate mixture (at 1 atm total pressure), based on near ideal gas assumption:
Water
Content
to
Mixture
Ratio
=
n
w
·
M
w
n
w
·
M
w
+
n
a
·
M
a
=
P
w
·
M
w
P
w
·
M
w
+
(
P
t
-
P
w
)
·
M
a
=
1
1
+
(
P
t
P
w
-
1
)
·
(
M
a
M
w
)
Water
Content
to
Air
Ratio
=
n
w
·
M
w
n
a
·
M
a
=
P
w
·
M
w
(
P
t
-
P
w
)
·
M
a
=
1
(
P
t
P
w
-
1
)
·
(
M
a
M
w
)
=
1
1
+
(
P
t
P
w
-
1
)
·
(
M
a
M
w
)
where M w (18 gr/mole) and M a (29 gr/mole) are molar mass of water and air (with ¼ratio of O 2 and N 2 ), respectively, and P t is total pressure (e.g., 1 atm).
This also shows that increasing pressure causes the Dew point to occur at higher temperatures as the vapor is pushed into liquid phase. As depicted in FIG. 40 , the Dew point temperature (T D0 ) is used to determine the saturated water vapor partial pressure (P ws0 ), e.g., for a baseline total pressure (P t0 , e.g., 1 atm). For example, when the total pressure (P t ) is increased the Dew point temperature (T D ) should be increased to prevent the water vapor from condensing, so that the molar fraction of water vapor remains the same in the mixture. Therefore, the partial pressure of the saturated water vapor (P ws ) is proportionally increased (assuming ideal gas approximation), which results in higher Dew point temperature according to:
P
ws
0
=
610.94
ⅇ
(
17.625
·
T
D
0
243.04
+
T
D
0
)
P
ws
=
P
ws
0
·
P
t
P
t
0
T
D
=
243.04
(
17.625
17.625
·
T
D
0
243.04
+
T
D
0
+
ln
(
P
t
P
t
0
)
-
1
)
where T D0 and T D are in ° C.
For example, the Dew point for a vapor-air mixture at 25° C. at 1 atm with 60% relative humidity, is about 16.7° C. However, pressurizing the mixture at 2 atm, 3 atm, and 4 atm, increases the Dew point from 16.7° C. to 28° C., 35° C., and 41° C., respectively. In one embodiment, the captured mixture is pressurized to increase the Dew point of the mixture.
For a non-saturated water vapor at temperature T and relative humidity R H (and vapor partial pressure P w ), the total pressure in increased (by factor of r) to make the mixture saturated at temperature T D as follows:
P w =P ws ( T )· R H
T D =T D ( P W )= T D ( P w ·r )= T D ( P ws ( T )· R H ·r )
where in the above T D ( . . . ) and P ws ( . . . ) are used in functional form, as for example shown above via approximation.
The partial pressure of water vapor (from pure water source) may be corrected to the salinity of the water source, as the enthalpy of the evaporation increases with the salinity and less equilibrium water vapor pressure results from the liquid source. Salinity is generally expressed in mass fraction, i.e., the mass of dissolved material (e.g., salt) in unit mass of solution. Sea water has typically a salinity of around 35 g/Kg (or part per thousand (ppt or % 0 )). The salinity factor (see Turk, L. J. (1970), Evaporation of Brine: A Field Study on the Bonneville Salt Flats, Utah, Water Resour. Res., 6(4), 1209-1215, doi:10.1029/WR006i004p01209) has inverse logarithmic relationship with the evaporation reduction, as depicted in FIG. 41 . The correction is about 1-2% for typical high salinity bodies of water.
At high ambient pressures, an enhancement factor may be used to adjust P ws in presence of other gases, e.g., as proposed by Greenspan: J. of Research of the NBS vol 80A, No. 1 p 41-44.
In one example, the average surface water temperature of Red Sea is about 26° C. in the North and 30° C. in the South during the summer, with the annual evaporation in excess of 205 cm (81 in). In one embodiment, per 1 m 2 capture area, with 10% efficiency in vapor capture, and 50% condensation extraction, the annual water extraction is about 100 lit or 26 gal.
In one embodiment, the water evaporation rate is enhanced by one or combination of the followings: reducing the boundary layer over water by blowing air over the surface (by fan or wind), increasing the temperature of the water (and air) at the surface of water (e.g., by radiation absorption from sun, heat exchange, electrical energy (e.g., from grid or solar mirrors or panels), or fuel consumption), and pumping away the evaporated vapor to increase net evaporation from the surface. In one embodiment, the condensation of water is enhanced by one or combination of one of the followings: increasing the Dew point, increasing the vapor to air ratio (e.g., by creating partial vacuum over the surface of water), and exchanging heat with environment at various time of day (e.g., cooling during night time when the air temperature over land drops).
In one embodiment, the evaporation from the water surface is enhanced by blowing air over the surface (e.g., by reducing the boundary layer and/or replacing high humidity air mixture very close to the water surface. The forced convection and/or diffusion increase the rate of evaporation significantly. For example, for unoccupied pools of water, the evaporation rate due to natural convection is estimates by
Evap
.
Rate
=
290
D
w
·
(
D
r
-
D
w
)
1
/
3
·
(
W
w
-
W
r
)
in
pounds
hour
·
ft
2
where D w is the density of air saturated at water temperature (in pounds per cubic foot of dry air), D r is the density of air (in pounds per cubic foot of dry air), W w is humidity ratio of air saturated at water temperature (in pounds per pound), and W r is humidity ratio of air (in pounds per pound). (See Shah, M. M. (2008). “Analytical formulas for calculating water evaporation from pools”, ASHRAE Transactions, 114). Also the evaporation rate due to forced convection by air current is estimated as:
Evap
.
Rate
=
0.0346
(
p
w
-
p
r
)
in
pounds
hour
·
ft
2
where p w is water-vapor pressure in air saturated at water temperature (in inches of mercury), and p r is water-vapor pressure in air (in inches of mercury). The evaporation rate may be estimated as the larger of the two estimates. For the above evaporate rate formulas the range of area is few to 4500 square feet, range of water temperature is 45 to 201 degree Fahrenheit, the range of air temperature is 43 to 95 degree Fahrenheit, the range of air relative humidity is from 28% to 98%, the range of (p w -p r ) is 0.062 to 23.7 millimeter of mercury, the range of (D r -D w ) is 0.00025 to 0.062 pounds per cubic foot.
Another formulism for estimating the evaporation rate uses the velocity of air above the water surface. The rate of the evaporated water is estimated as:
Evap
.
Rate
=
(
25
+
19
v
)
·
A
·
(
W
s
-
W
a
)
in
kg
hour
where v is velocity of air above the water surface (in m/s), A is water surface area (in m 2 ), W s is the humidity ratio in saturated air at the same temperature as the water surface (in kg of H2O in kg of Dry Air), and W a is the humidity ratio in the air (in kg of H2O in kg of Dry Air). See for example, http://www.engineeringtoolbox.com/evaporation-water-surface-d — 690.html. The required heat of evaporation per hour is about
( 2270 k J kg ) × Evap . Rate .
For example, at low air speed, the evaporation rate from a 500 m 2 water surface with 20 g H 2 O saturated in kg of dry air (e.g., at 25° C. Dew point per FIG. 39 ), at 60% relative humidity (i.e., about 12 gr H 2 O in kg of dry air), is about 100 kg/hour, requiring about 64 kWhr. However, at about 1 mile/hr air speed (0.5 m/sec), the evaporation rate increases by 38% to 138 kg/hr, and at about 13 mile/hr, the evaporation rate is more than fivefold (i.e., about 556 kg/hr). At 10 m/sec (or 21.6 mile/hour), the evaporation according to the above formula is about 860 kg/hr, i.e., almost an order of magnitude higher. The intensity (power per area) for 860 kg/hr water from 500 m 2 area is about 1.1 kW/m 2 which is close to the sun radiation intensity at the Earth's surface. Therefore, the potential to harvest more water evaporation using the sun radiation as the heat source from a wide area is achieved in an embodiment by increasing the air velocity over the water surface (e.g., by using fans or blowers) and/or capture the water vapor mixture in the direction of the wind (e.g., high winds, for example, during monsoon).
In one embodiment, the evaporation of vapor from the source is enhanced by increasing the source temperature (e.g., water temperature) and/or increasing the vapor temperature above the Dew point to hold more moisture. In one embodiment, the water temperature is increased by radiation absorption from the sun, as for example depicted in FIG. 42 . The depth of radiation penetration is within few inches for infrared. Only blue portion of the spectrum penetrates to about 200 meters depth. In one embodiment, a platform immersed in water has a surface for absorbing sun radiation (e.g., dark surface). In one embodiment, the depth of immersion (e.g., as indicated by D in FIG. 42 ) is about 3-5 inches. In one embodiment, the radiation absorption surface is coated. In one embodiment, the platform has one or more holes and/or sloped surface for heavier and/or colder brine or high salinity water to exit. In one embodiment, the water flows from sides, e.g., via opening in the platform support or other channels. In one embodiment, the holes in the platform are at longer depths (as depicted by D′ in FIG. 42 ), e.g., to support the slope on the platform. In one embodiment, as for example depicted in FIG. 43 , the platform construction is modularized to connect multiple platforms together. In one embodiment, the patterns of the holes are alternated. In one embodiment, the holes are formed as elongated openings on the platform. In one embodiment, rails are used next to holes/openings to mark/protect people from falling through. In one embodiment, safety handles are installed next to openings to help people come up through opening, if for example fallen into the opening. In one embodiment, the platform is supported at its edges. In one embodiment, floaters are used to hold the platform on the body of water. In one embodiment, the floaters are adjusted or calibrated to allow the platform be immersed at a desired depth below water surface. In one embodiment, the floater is made of hollow container (e.g., made of aluminum, fiberglass, wood, or plastic). In one embodiment, the modular platforms may be attached by connector or links at their edges.
In one embodiment, as for example depicted in FIG. 44 , the water surface over the platform is fully or partially covered. In one embodiment, the cover or part of the cover is transparent or passes part or most of a portion of the radiation spectrum. In one embodiment, the cover allows the radiation reach the water and/or platform but prevents the evaporated water vapor from escaping to open air. In one embodiment, an air flow is provided (e.g., by use of fan or blower to collect the evaporation from the surface of water below the cover. In one embodiment, the air flow helps reduce the boundary layer over the surface of the water and increase the rate of evaporation. In one embodiment, the cover is made of glass, clear plastic, nylon, talc, and/or polymer. In one embodiment, the radiation is reflected from an array of mirrors onto the platform.
In one embodiment, as for example depicted in FIG. 45 , water and/or air is heated (e.g., over a platform with for example dark or radiation absorbing surface) by other or additional means such as heat exchange with a hot fluid to increase the temperature of water and hence increase the partial pressure of the vapor and the rate of evaporation. In one embodiment, the heat exchange is providing via pipes/fins to pass or circulate hot fluid (e.g., gas or liquid such as water or vapor-air mixture, Freon, Puron, molten salt, or alkyl halide). In one embodiment, the source of heat is the heat exhaustion portion of a cooling system. In one embodiment, the source of heat is the heat exchange with a pressurized tank. In one embodiment, the heat exchange surface is totally immersed in the water. In one embodiment, the heat exchange surface is exposed to both water and air above to increase the dew point and support higher vapor pressure.
In one embodiment, as for example depicted in FIG. 46 , a blower or fan creates or enhances air flow over the water surface to increase the evaporation rate. In one embodiment, a capture fan or opening captures the air-vapor mixture for later water extraction. In one embodiment, the direction and/or speed of wind are measured and the speed and direction of one or more fan is set to enhance the air flow and capture. In one embodiment, when the speed of the wind is above a threshold (e.g., a soft threshold such as about 15 miles per hour), the blowing fans are turned off automatically via a control module (e.g., with rules engine). In one embodiment, the capture fan or opening is automatically adjusted to face the wind (e.g., within a range of angles), for example, by pivoting about an axis of rotation.
In one embodiment, as for example depicted in FIG. 47 , the fan or blower is installed on an adjustable support or floater or a pier. In one embodiment, the fan/blower operation is controlled and/or monitored by a control module at a central location. In one embodiment, the floater or support is movable, e.g., on rail or via cable/chain/rope. In one embodiment, the direction/speed of the fan/blower is adjusted by control module. In one embodiment, sensors near (e.g., in front and back) the surface of water and blower/fan are used to determine the temperature, humidity, wind speed/direction. In one embodiment, the sensor data is transmitted to the central location and/or control module and used to determine the operation of the fan/blower based on the sensed data, weather forecast data, time of day (and season), the status of the system (e.g., the condition of the storage tanks and the phase in the production cycle), and historical/empirical data. In one embodiment, the capture assembly has an opening to capture the air/vapor mixture. In one embodiment, the capture is enhanced by a fan or pump to maintain the air flow. In one embodiment, the coating on the capture pipe/channel is coated by reflective material so to reduce or prevent the temperature of the mixture from rising during the transport. In one embodiment, the capture channel/pipe includes heat exchange (for cooling the captured air flow), e.g., via circulating a cooler air in a separate pipe inside, within the jacket of the capture pipe, or outside of the capture pipe.
In one embodiment, as for example depicted in FIG. 48 , an air flow over the water surface is confined by a cover, e.g., a transparent cover, to allow radiation reach the water surface for heating and evaporating the water vapor. In one embodiment, the platform creates or supplements the air flow using one or more blower, fans, or pumps, e.g., installed on the platform or along the air flow channel. In one embodiment, the supports are floating over the surface of water and adjusted to maintain a clearance over the surface of water and the cover for the air flow. In one embodiment, the clearance is in range of about 1 to 6 feet. In one embodiment, the covers are rotatable or removable for maintenance (e.g., washing/rinsing), e.g., from below the cover or above. In one embodiment, the platforms are modularized and connected to provide larger surface area or air flow channel.
In one embodiment, as for example depicted in FIG. 49 , the evaporation from the surface is enhanced by applying low pressure (e.g., using a vacuum pump) over the surface of water in a closed (e.g., by automatic controllable/programmable valves) chamber. In one embodiment, the chamber includes an air inlet to break the partial vacuum (e.g., for maintenance). In one embodiment, the radiation (e.g., from sun) is used to heat the water directly and/or via absorption by dark or radiation absorbing surface (e.g., on the chamber or inside chamber, for example, below water surface or covering parts of the chamber walls or various assemblies). In one embodiment, the surface of the water is agitated by a mixing or stirring mechanism (e.g., fan or a magnetic coupler) to provide heat to the surface of the water, since during the water evaporation, the latent heat of evaporation is carried away by the vapor. In one embodiment, the depth of the water in chamber (e.g., denoted as D l ) is in range of few inches to several feet, e.g., depending on the size of the system. In one embodiment, the clearance above the water surface (e.g., denoted as D g ) in n range of several inches to several feet, depending on the size of the system and the rate of evaporation. In one embodiment, the pump is reduces the pressure in the chamber below the saturated partial pressure of the water vapor to maintain the outflow of the vapor from the chamber. In one embodiment, an air outlet is provided for initial pumping out the chamber so that the initial air in the chamber (e.g., after a maintenance task) does not flow to the vapor outlet. In one embodiment, the valves for gas and liquid are controlled remotely by a control module. In one embodiment, supports are provided with the chamber (e.g., in the middle of the chamber) to support against the pressure difference on the cover and/or the chamber. In one embodiment, a heat exchange is used to heat the water and/or air within the chamber for faster evaporation rate and higher dew point. In one embodiment the bottom of the chamber is sloped to help with discharging of the water (e.g., after evaporation increase the salinity beyond a threshold) through a drain through a valve. In one embodiment, various sensors are used to monitor the temperature of gas and water, humidity, level of water, and/or salinity.
In one embodiment, as for example depicted in FIG. 50 , the preheating of the water is separated from the water evaporation in a partial vacuum. In one embodiment, the heating chamber operates at the same or similar pressure as the environment (e.g., 1 atm). In one embodiment, the heating chamber is filled mostly with water from a water inlet. In one embodiment, a bleed line lets the air or water overflow out. In one embodiment, the heat exchange and/or radiation (e.g., from sun) is used to heat the water in the chamber. In one embodiment, the heated water is moved to an evaporation chamber (e.g., via gravity flow and/or pump). In one embodiment, the construction of the evaporation chamber is strengthened to withstand higher vacuum. In one embodiment, a vacuum pump is used to pump the evaporated vapor through a vapor outlet. In one embodiment, the programmable valves are used to control the operation of the water and gas flow, e.g., letting air in the chamber and discharging the water from the drain. In one embodiment, the evaporation is done with additional heating, e.g., by heat exchange from the enclosure. In one embodiment, one or more evaporation chambers are used per one heating chamber, based on the rate of evaporation and the rate of the water heating. In one embodiment, one or more of evaporation chambers are fed from one or more heating chambers using programmable valves and connecting manifolds.
In one embodiment, as for example depicted in FIG. 51 , a chamber with one or more evaporation surfaces are sprayed, dripped, flowed by water inlet on top of the surfaces/plates. In one embodiment, the plates are vertically or in slop for water to flow over their surfaces by gravity. In one embodiment, an air flow is used to enhance the evaporation of the water, e.g., from heated plates (e.g., by heat exchange, radiation, electrical, or chemical reactions). In one embodiment, the water collects at the bottom of chamber and drained through a siphon (e.g., to regulate the level of the water. In one embodiment, a drain is provided at the bottom of the chamber for maintenance. In one embodiment, a fan or pump is used to flow the vapor through the outlet. In one embodiment, the modular design allows the scaling of production and reduction of the foot print.
In one embodiment, as for example depicted in FIG. 52 , water vapor evaporated off of a body of water (e.g., a pool, sea, or tray) is collected by one or more vapor-air collection fans/pumps. In one embodiment, the captured mixture is stored in a tank. In one embodiment, the tank is pressurized (e.g., by pump) to increase the dew point. In one embodiment the heat from the storage tank is exchanged with the evaporation module to help increase the evaporation rate or increase the partial pressure of water vapor at the evaporation module while cooling down the storage tank. In one embodiment, the storage tank is cooled, e.g., via heat exchange by geothermal or other cooling mechanism. In one embodiment, the storage tank is cooled via heat exchange with cooled air from condensation tank (e.g., by circulating the cooled air as the cooling fluid in the heat exchanger and/or by using a separate heat exchanger on the condensation tank). In one embodiment, the heat exchange with the storage tank is controlled automatically and/or remotely by a controlled module by switching the heat exchange paths with valves and pipes/manifolds, based on the status of the modules (e.g., temperatures and efficiencies of heat exchange with each module). In one embodiment, the vapor mixture from storage tank is let into condensation tank (e.g., through a valve), and water condensation is done via a cooling system and a condenser/refrigeration system to bring the temperature of the mixture below the dew point. In one embodiment, the pressure in the condensation tank is regulated via the pressure in the storage tank. In one embodiment, the condensed water liquid is extracted from the condensation tank for further processing and use, and the air (e.g., relatively dry air) is removed for release or distribution to residential or commercial buildings. In one embodiment, the storage tank is not pressurized and it is cooled by geothermal and/or circulation or heat exchange with the cool air from the condensation tank after the condensation cycle. In one embodiment, the extracted heat from the cooling system of the condensation tank is directed to the evaporation module (e.g., via heat exchange) to help with increase water evaporation. In one embodiment, multiple the heat exchange paths share same carrier fluid.
In one embodiment, as for example depicted in FIG. 53 , a water column is setup using a vacuum pump to create a partial vacuum over the surface of the water in the column. The height of the water column, e.g., based on 1 atm pressure difference is less than 10 meters. In one embodiment, the water on top of the water column is heated to increase the evaporation rate at the water surface, e.g., via radiation (e.g., on dark or radiation absorbing surface or coating) and/or heat exchange or heater close to the water surface above the water column. In one embodiment, water with high salinity (e.g., due evaporation) flows down to the bottom to be drained and replaced with a new batch or in a continuous mode (e.g., with a pump). In one embodiment, a bleed or release line/valve is provided, e.g., for letting air in the system for maintenance and/or between batch cycles. In one embodiment, as for example depicted in FIG. 54 , the paths for incoming water and heavier water, for example, with higher salinity (e.g., due to evaporation) is separated by sloping the evaporation platform toward the water drain. In one embodiment, multiple evaporation trays/pools/platforms are used in a modular construction. In one embodiment, one or more water inlets feed one or more evaporation platforms, and one or more drains are used to collect and discharge the water. In one embodiment, the drains are let into one or more water outlet. In one embodiment, the inlet and outlet water are positioned in a distance and/or in downstream to reduce the drained the amount of water getting back in the system without significant dilution in salinity.
In one embodiment, as for examples depicted in FIG. 55 , the evaporation is enhanced by blower or fan to reduce the boundary layer over a body of water (e.g., on sea, pool, tray). In one embodiment, the vapor-air mixture is collected (e.g., via a fan or pump) and let into a storage tank. In one embodiment, the storage tank is placed underground to heat exchange with surrounding environment for cooling down the vapor-air mixture. In one embodiment, a separate water storage (e.g., sourced from sea) is placed, for example, underground, and it is cooled by geothermal heat exchange. In one embodiment, the heat capacity of the water storage is significantly higher than the vapor-air mixture in the storage tank. In one embodiment, the vapor-air mixture in the storage tank is cooled by heat exchange with the water storage, e.g., by circulating water in pipes/fins within vapor/air storage tank or using other (e.g., more efficient) cooling fluid for heat exchange. In one embodiment, the evaporation and vapor collection occurs during the day when the evaporation rate is high. In one embodiment, the cooling cycles with water storage and/or geothermal occur during and after vapor collection. In one embodiment, the cooled vapor mixture is sent to condensation tank, e.g., with a refrigeration or cooling system to condense the vapor to water and extract water into a water collection and distribution system. In one embodiment, the condensation tank has an air outlet that provides low(er) humidity air for distribution to residential and/or business/commercial buildings and/or structures. In one embodiment, the cooled air after the condensation cycle is used for heat exchange with the vapor-air storage tank to cool the mixture for later condensation. In one embodiment, the heat captured by the cooling system is directed to water evaporation module/tray/platform to increase the evaporation rate. In one embodiment, a control module automatically directs the operation of the system by automatically manage the heat exchanges based on temperature, humidity, storage capacity, and time of day/season. In one embodiment, the condensation occurs, e.g., during the night time when the cooling system is more efficient in disposing the extracted heat from the condensation tank. In one embodiment, the condensation occurs, e.g., during day time, when the heat from the cooling system is directed to the evaporation module to increase the vapor evaporation. In one embodiment, the system's heat exchange is staggered between parallel units. In one embodiment, the cooling of the air-vapor mixture at the storage tank occurs in stages (via various heat exchangers) and/or at cooling compartments/tanks. For example, as the air mixture cools at one stage of cooling, it is moved (using pump, fan, or blower) to the next compartment/tank. In one embodiment, the chain of cooling stages are scheduled to reduce the bottleneck in the operation. In one embodiment, the content of a tank is partially replaced during a stage of cooling, for example, when the receiving tank or enclosure has less capacity or processes less volume of mixture batch at a time. In one embodiment, the operation is optimized and automated by matching the water/mixture/air flow throughput of the production at various stages of the process, e.g., by matching the number of active modules at each stage of processing with the throughput and using programmable valves, manifolds, sensors/detectors, and rules.
In one embodiment, as for example depicted in FIG. 56 , the operation of various modules are scheduled with dependency on other tasks. In one embodiment, the output of one or more evaporator modules is directed to one or more storage tanks. For example, during Capture 1 phase, the captured vapor mixture is directed to Storage Tank 1 (e.g., to the 1 st staging tank/compartment). In one embodiment, the existing content of this staging compartment is moved to a second staging compartment to further cooling. In one embodiment, the compartments are arranged in series so to reduce or prevent mixing of the incoming hotter air with already cooled air, as the cooling with heat exchangers require time to reduce the temperature of the air-vapor mixture. In one embodiment, the cooling in one stage is done by, for example, heat exchange with cool water (e.g., from an underground water storage) and/or geothermally. In one embodiment, the cooling in one stage is done, for example, by heat exchange with cooled (dry) air from the condensation tank (e.g., by circulating the cooled air or via another fluid). In one embodiment, the recycled air from a staging compartment is used to lower the temperature of the air-vapor mixture within the condensation tank (e.g., as a pre-condensation cooling) and/or to lower the temperature in a staging compartment of a storage tank/compartment. In one embodiment, the inside of the compartments are arranged in sub-compartments to allow the air flow to exchange heat with the heat exchangers with reduced mixing between the incoming and outgoing gas. In one embodiment, the intake of the dry air in the staging compartment following the condensation phase occurs at the same time as discharging of the existing air from the staging tank/compartment (e.g., for distribution lower humidity air to buildings). In one embodiment, while a condensation tank is used for cooling/condensing water, an staging compartment is used extract heat from air-vapor in a condensation tank or a storage tank, e.g., by recycling the cooled air.
In one embodiment, as for example depicted in FIG. 57 , the resources at multiple stage and phases in the production are matched automatically by directing the liquid/gas flow to available resource from one to next stage in the process. For example, the air-vapor captured from one or more capture modules may be directed to one or more storage tank concurrently, sequentially, and/or in staggered timing. In one embodiment, the tanks/compartments at different stages have one to one ratio and are arranged in sequential order in the process. For example, in one embodiment, each storage compartment feeds into a corresponding subsequent storage stage (for further cooling). However, in one embodiment, multiple storage modules share, for example, their 2 nd stage compartment. In one embodiment, sharing the compartment/tanks helps with maintaining a ready, high capacity resource for the next stages. For example, multiple condensation tanks may feed from a storage compartment concurrently, sequentially, or in staggered fashion. In one embodiment, multiple cool air recycling tanks/compartments are concurrently used to cool one or more condensation and/or storage tanks based on the temperature, capacity, phase and status of the units, e.g., automatically and/or remotely, via one or more controllers, e.g., by manipulating (e.g., via actuators) programmable valves and regulators.
Some Embodiments and Examples for Features:
In some locations, the humidity of the air on sea is still high to large heights, e.g. up to 5 or 10 meters, or even more, in some seasons or time periods. Those locations can accommodate large fans with big diameters. Areas with large coast lines would be useful for large scale operations. In some locations, the humidity of the air coming inland is still high for many meters inland, which can accommodate large fans located inland, which are cheaper to operate and maintain. In some locations, the oil is on water, which is not good for our operation. So, we filter or remove them from surface first, e.g. with spoon shaped devices on boats or floaters, as well as filters for oil. In one example, we use fan on or in or half-in or partially-in the water to splash and produce more vapor or humidity locally, to get sucked in by fans, near the fans. In one example, we use spray or nozzle with motor or pump, for water mist for more humidity for operation near the fans.
Some examples are 5 to 50 meters distance to the shore, for operation, but it can be lower or higher numbers, as well, for distance to the shore. Some examples for the arms are 5 to 50 meters, but it can be lower or higher numbers, as well. The cranes and towers are for example between 2 to 20 meters in length, but they can be lower or higher numbers, as well. Some examples for materials for pipes and assembly or arms, and cranes/towers are concrete, metal, plastic, fiberglass, clothing, glass, and wood.
Some Embodiments and Examples for Features:
Here are list of features for various embodiments:
A method of extracting water from the humidity collected from sea or river, said method comprising: a collector tip sucking up humidity from surface of said sea or river, using a fan; a processor device receiving weather data from weather authority and local data from a local unit; said processor device analyzing said weather data and said local data; a rules engine receiving rules from a rules database; said processor device communicating with said rules engine; said processor device applying said rules to said weather data and said local data; said processor device sending rules and data analysis to a controller; wherein said collector tip is connected to a first end of a flexible accordion-shaped tube; wherein said flexible accordion-shaped tube has a circular cross-section; wherein said flexible accordion-shaped tube is made of plastic or elastic material; wherein a second end said flexible accordion-shaped tube is connected to a tower; wherein said tower is located at a shore near edge of said sea or river; wherein a crane is connected to said tower; wherein said crane holds said flexible accordion-shaped tube, using multiple sets of connected bar pieces; wherein each of said multiple sets of connected bar pieces comprises two or more bar pieces; wherein each of said bar pieces is connected to another of said bar pieces, by a hinge or connector or elbow; wherein said fan is installed inside said flexible accordion-shaped tube; a first motor rotating said fan; wherein a second set of motors are connected to said multiple sets of connected bar pieces, using a set of main bars; wherein said second set of motors are located on said tower; wherein each of said set of main bars comprises holes, which are located periodically throughout each of said set of main bars' length; wherein there are N0 motors in said second set of motors, and there are N0 sets of connected bar pieces in said multiple sets of connected bar pieces, and there are N0 main bars in said set of main bars; wherein N0 is an integer number, equal or larger than 3; each of said N0 motors rotating a gear; said gear engaging said holes which are located periodically throughout each of said set of main bars' length, using said gear's pins; each of said N0 motors pushing or pulling each of said set of main bars; each of said set of main bars pushing or pulling each of said multiple sets of connected bar pieces; a first of said multiple sets of connected bar pieces moving said collector tip horizontally; said first of said multiple sets of connected bar pieces rotating said collector tip; said first of said multiple sets of connected bar pieces orienting said collector tip; said local unit receiving wind direction and wind speed information from a wind vane and an anemometer, respectively; wherein said wind vane and said anemometer are located on said crane; said processor device receiving said wind direction and wind speed information from said local unit; said processor device analyzing said wind direction and wind speed information; said processor device sending wind analysis to said controller; said controller communicating with said tower, said crane, said second set of motors, and said first motor; said controller adjusting direction and orientation of said collector tip to be same as said wind direction, using said multiple sets of connected bar pieces; said first of said multiple sets of connected bar pieces lifting said collector tip from one side in a vertical position; said controller adjusting operation of said tower, said crane, said second set of motors, and said first motor, based on said rules engine, according to said rules database; if relative humidity measured by said local unit is below Hr0, then said controller turning off said fan, said crane, said second set of motors, and said first motor; if air temperature measured by said local unit is below T0, then said controller turning off said fan, said crane, said second set of motors, and said first motor; if air temperature measured by said local unit is below T1, and relative humidity measured by said local unit is below Hr1, then said controller turning off said fan; if said wind speed is more than V0, then said controller turning off said fan, said crane, said second set of motors, and said first motor; said processor device receiving energy usage and consumption data from said local unit; if more than N percent of energy for operation comes from non-green or renewable kinds, then said controller turning off said fan; if more than N1 percent of the energy for operation comes from battery, then said controller turning off said fan; if less than G gallons per minute of water is extracted by said local unit, then said controller turning off said fan; if less than G1 gallons of water is extracted by said local unit, per Z energy used, then said controller turning off said fan; and if less than G2 gallons of water is extracted by said local unit, per Z1 non-renewable energy used, then said controller turning off said fan.
G1 is between 0.5 to 10 gallons, and G2 is between 0.5 to 10 gallons.
A floater station comprises two floaters on each side of said floater station, with a flat plate situated between and held by said two floaters; wherein said two floaters float on water, with relative density of said two floaters being lower than that of water; wherein said flat plate situated a distance DS below surface of water, submerged in water; wherein said flat plate has a dark non-reflective rough surface, for light absorption; placing said floater station under said collector tip; and collecting water in a cold chamber, from humidity collected from said floater station, through said collector tip.
Wherein said distance DS is 5 cm.
Wherein said distance DS is between 1-100 cm.
Wherein said flat plate has black color.
Said flat plate has bumpy surface with bumps about 1 cm.
Flat plate has bumpy surface with bumps between 1 mm to 10 cm.
wherein said two floaters are made of wood.
wherein said two floaters are made of hollow plastic.
wherein said two floaters are made of hollow metal.
wherein said floater station is rectangular-shaped.
wherein said floater station has a motor to move around.
wherein said floater station has two motors, placed perpendicular to each other, to move around in 2 different directions or axes.
wherein said floater station has an antenna for communication to said controller or said processor device.
wherein said multiple sets of connected bar pieces are made of metal.
wherein said multiple sets of connected bar pieces are made of plastic.
wherein said set of main bars are made of plastic.
wherein said set of main bars are made of metal.
wherein N0 is 3.
wherein N0 is between 3 to 10.
wherein said cold chamber has a drain on bottom to get water out of said cold chamber.
A floater station comprises two floaters on each side of said floater station, with a plate situated between and held by said two floaters; wherein said two floaters float on water, with relative density of said two floaters being lower than that of water; wherein said plate situated a distance DS below surface of water, submerged in water; a second floating fan, powered by a separate motor, located near said collector tip, pushing water toward said collector tip; wherein said second floating fan is half-submerged in water in vertical position, so that bottom blade of said second floating fan is in water; wherein said plate has a 2-dimensional array of holes, with sloped surface toward center of said 2-dimensional array of holes, for removal of remaining salt and debris from surface of said plate; placing said floater station under said collector tip; and collecting water in a cold chamber, from humidity collected from said floater station, through said collector tip.
wherein said second floating fan is located on a boat or floating device.
wherein said boat or floating device is made of wood.
wherein said boat or floating device is made of hollow plastic or elastic material.
General Variations and Teachings:
A user enters commands or information into the computer through input device(s). Input devices include, but are not limited to, a pointing device such as a mouse, trackball, stylus, touch pad, keyboard, microphone, joystick, game pad, satellite dish, scanner, TV tuner card, digital camera, digital video camera, web camera, and the like. These and other input devices connect to the processing unit through the system bus via interface port(s). Interface port(s) include, for example, a serial port, a parallel port, a game port, and a universal serial bus (USB). Output device(s) use some of the same type of ports as input device(s). Thus, for example, a USB port may be used to provide input to computer, and to output information from computer to an output device. There are some output devices like monitors, speakers, and printers, among other output devices, which require special adapters. The output adapter includes, by way of illustration and not limitation, video and sound cards that provide a means of connection between the output device and the system bus. It should be noted that other devices and/or systems of devices provide both input and output capabilities such as remote computer(s).
Computer can operate in a networked environment using logical connections to one or more remote computers, such as remote computer(s). The remote computer(s) can be a personal computer, a server, a router, a network PC, a workstation, a microprocessor based appliance, a peer device, a smart phone, a tablet, or other network node, and typically includes many of the elements described relative to computer. Remote computer(s) is logically connected to computer through a network interface and then connected via communication connection(s). Network interface encompasses wire and/or wireless communication networks such as local-area networks (LAN) and wide-area networks (WAN) and cellular networks. LAN technologies include Fiber Distributed Data Interface (FDDI), Copper Distributed Data Interface (CDDI), Ethernet, Token Ring and the like. WAN technologies include, but are not limited to, point-to-point links, circuit switching networks like Integrated Services Digital Networks (ISDN) and variations thereon, packet switching networks, and Digital Subscriber Lines (DSL).
Communication connection(s) refers to the hardware/software employed to connect the network interface to the system bus. The hardware/software necessary for connection to the network interface includes, for exemplary purposes only, internal and external technologies such as, modems including regular telephone grade modems, cable modems and DSL modems, ISDN adapters, and wired and wireless Ethernet cards, hubs, and routers.
The system, e.g., includes one or more client(s), which can include an application or a system that accesses a service on the server(s). The client(s) can be hardware and/or software (e.g., threads, processes, computing devices). The client(s) can house cookie(s), metadata and/or associated contextual information by employing the specification, for example.
The system also includes one or more server(s). The server(s) can also be hardware or hardware in combination with software (e.g., threads, processes, computing devices). One possible communication between a client and a server can be in the form of a data packet adapted to be transmitted between two or more computer processes where the data packet contains, for example, an audio sample. The data packet can include a cookie and/or associated contextual information, for example. The system includes a communication framework (e.g., a global communication network such as the Internet) that can be employed to facilitate communications between the client(s) and the server(s).
Communications can be facilitated via a wired (including optical fiber) and/or wireless technology. The client(s) are operatively connected to one or more client data store(s) that can be employed to store information local to the client(s) (e.g., cookie(s) and/or associated contextual information). Similarly, the server(s) are operatively connected to one or more server data store(s) that can be employed to store information local to the servers.
This may also be practiced in distributed computing environments where certain tasks are performed by remote processing devices that are linked through a communications network. In a distributed computing environment, program modules can be located in both local and remote memory storage devices.
The systems and processes described herein can be embodied within hardware, such as a single integrated circuit (IC) chip, multiple ICs, an application specific integrated circuit (ASIC), or the like. Further, the order in which some or all of the process blocks appear in each process should not be deemed limiting. Rather, it should be understood that some of the process blocks can be executed in a variety of orders that are not all of which may be explicitly illustrated herein.
Any variations of the above teaching are also intended to be covered by this patent application. | In one example, we describe reliable, flexible, low-maintenance, low-overhead, low-cost installation, practical, and easy-to-install structures and components or techniques (methods and systems) for water capture from high humidity sources, e.g., sea or river, for use or consumption by humans, animals, or plants/agriculture/food production. In one example, it is modularized. Thus, it is easier for transportation and maintenance, with less cost and down-time. For example, it can be used in some regions in the Middle East or Africa, with dry land with no or small amount of rain. In one example, we describe the use of renewable energy sources. In one example, we describe the control system for operation of water collection and distribution systems, e.g., for optimization and efficiency or cost. We also describe the mechanisms, techniques, components, and systems to implement various tasks and goals related to these. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for converting a tensile residual stress existing in an inside surface of a pipe constituting a piping system of a plant, into a compressive residual stress to suppress stress corrosion cracking.
[0003] 2. Description of the Related Art
[0004] In a welded portion of stainless steel or nickel-base alloy steel, chromium carbide is separated out at a crystal grain boundary due to heat of welding. As a result, a chromium-lack layer is produced near the pole of the grain boundary, and sensitization (a phenomenon that the sensitivity to corrosion increases) occurs in the chromium-lack layer. On the other hand, a high tensile residual stress is generally generated in the surface near a welded portion of a pipe constituting a piping system of a plant. Therefore, if the pipe is used in a severely corrosive environment in a state wherein the material has been sensitized, stress corrosion cracking occurs. That is, when three factors of sensitization of the material, a high tensile residual stress, and a corrosive environment, are superposed, the risk of stress corrosion cracking increases.
[0005] To suppress the generation of stress corrosion cracking, reduction of the tensile residual stress in the region exposed to the corrosive environment is cited as one of measures. As methods for reducing the tensile residual stress of the inside surface of a welded portion of an existing pipe of a plant, there are “Method for Heat Treatment of Piping System” described in JP-B-957324 and “Method for Improving Residual Stress in Steel Pipe” described in JP-A-55-110729. The former is a method in which a piping system of a plant is assembled; a coolant is then allowed to flow in a pipe constituting the piping system; in this state, the pipe is heated through its outside surface to make a difference in temperature between the inside surface of the pipe and the outside surface of the pipe; the outside surface is compressive-yielded and the inside surface is tensile-yielded; and thereby the tensile residual stress of the inside surface of the pipe is reduced. The latter is a method in which a pipe is heated in a state wherein no coolant exists in the pipe, to uniformalize the temperature distribution in the wall of the pipe; a coolant is then supplied into the pipe to make a difference in temperature between the inside surface of the pipe and the outside surface of the pipe; the inside surface is tensile-yielded and the outside surface is compressive-yielded; and thereby the tensile residual stress of the inside surface of the pipe is reduced.
[0006] In JP-B-957324 as described above, the difference in temperature generated in the wall of the pipe is gentle. JP-A-55-110729 has a characteristic feature that heating can be performed with a simple heater and a steep gradient of temperature can be obtained near the inside surface of the pipe. However, because the pipe is heated without cooling the inside surface of the pipe, it is required to take in/out a coolant on the whole of a piping system when applied to the piping system of an existing plant.
SUMMARY OF THE INVENTION
[0007] An object of the present invention is to suppress the generation of stress corrosion cracking of an inside surface of a pipe of an existing pipe welded joint for a long time by a simple method.
[0008] According to the present invention to attain the above object, a method for heat treatment of a pipe constituting a piping system of a plant, have a characteristic feature that an arbitrary portion of the outside surface of the pipe is heated in a state wherein a coolant is retained in the pipe, so as to make a gentle temperature gradient in the pipe wall; and then, by allowing the coolant to flow in the pipe, the temperature gradient in the wall of the pipe at the heated portion is changed into a steep temperature gradient near the inside surface of the pipe. After the pipe is heated, a difference in temperature is made in particular between the inside and outside surfaces of the pipe. By rapidly cooling the inside surface of the pipe, the inside surface of the pipe is tensile-yielded and the outside surface of the pipe is compressive-yielded. When the temperatures of the inside and outside surfaces of the pipe are equaled to each other, the tensile residual stress in the inside surface of the pipe is reduced.
[0009] Here, the coolant is preferably water because it is easy to use. In the case that the pipe constitutes a piping system of a reactor, the coolant may be reactor water. Thereby, a method for heat treatment can be provided in which a steep temperature gradient is made near the inside surface of the pipe in a state wherein the reactor water as the coolant is retained in the pipe, and thereby the residual stress in the inside surface is converted into a compressive stress. Further, the pipe may be heated by either induction heating or direct electrical heating.
[0010] The above-described method for heat treatment of piping can be realized by using an apparatus for heat treatment comprising a heating coil for induction heating as means for heating a pipe, a spacer for keeping the heating coil at a constant distance from the outside surface of the pipe in which a compressive residual stress is to be generated in the inside surface, the pipe attached to the heating coil and allowing the coolant to be circulated in the pipe, a transformer and a power supply for applying an electric current to the heating coil, and a coolant circulating mechanism for supplying the coolant in the pipe for coolant circulation attached to the heating coil; and a circulating pump provided in the piping system. Alternatively, the method can be realized by using an apparatus for heat treatment comprising a direct electrical heating terminal as means for heating the pipe, a transformer and a power supply for applying an electric current to the direct electrical heating terminal, and a coolant circulating mechanism for supplying the coolant in the pipe for coolant circulation attached to the direct electrical heating terminal; and a circulating pump provided in the piping system.
[0011] According to the present invention, after a piping system of a plant is assembled, a compressive residual stress can be generated in the inside surface of a pipe constituting the piping system, in particular, near a welded metallic portion. As a result, stress corrosion cracking in the piping system can be prevented.
[0012] Other objects, features and advantages of the invention will become apparent from the following description of the embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is an explanatory diagram of a case wherein a method for heat treatment of piping according to the present invention is applied to a nuclear power plant with a boiling-water reactor;
[0014] FIG. 2 is an explanatory view showing a first embodiment of a method for heat treatment of piping according to the present invention;
[0015] FIG. 3 is an explanatory view showing an attachment structure of a heating coil;
[0016] FIG. 4 is an explanatory view showing an example in which a heater of the first embodiment according to the present invention is attached to a pipe;
[0017] FIG. 5 is an explanatory view showing a state wherein the heater of the first embodiment according to the present invention is detached from the pipe by being divided into two parts;
[0018] FIG. 6 is an explanatory view showing a sectional structure of a holder;
[0019] FIG. 7 is an explanatory view showing a second embodiment of a method for heat treatment of piping according to the present invention;
[0020] FIG. 8 is an explanatory graph graphically showing a temperature gradient produced in a pipe wall;
[0021] FIG. 9 is an explanatory graph graphically showing a relation between temperature and time;
[0022] FIG. 10 is an explanatory representation showing a stress distribution in a pipe wall when a coolant begins to flow and a difference in temperature is produced between inside and outside surfaces of the pipe;
[0023] FIG. 11 is an explanatory representation showing a stress distribution in the pipe wall after heat treatment of the present invention is applied; and
[0024] FIG. 12 is an explanatory graph showing a relation of stress-strain.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0025] A first embodiment of the present invention will be described with reference to FIGS. 1 to 7 .
[0026] FIG. 1 shows the first embodiment in which the present invention is applied to a nuclear power plant with a boiling-water reactor.
[0027] A reactor pressure vessel 1 has therein an in core portion 2 to be charged with nuclear fuel; a steam water separator 3 ; and a core shroud 4 surrounding the in core portion 2 . A plurality of control rods 5 are inserted in the in core portion 2 . The control rods 5 are operated by a control rod driving system 7 under the control of a control rod drive controller 6 .
[0028] The interior of the reactor pressure vessel 1 is filled up with light water as cooling water to a somewhat upper portion of the in core portion 2 . When the reactor is in operation, by driving a circulating pump 9 provided for a pipe 8 , the cooling water in the reactor pressure vessel 1 passes through the pipe 8 and a riser tube 10 (connected to the pipe 8 ) of a primary loop recirculation piping, and reaches the interior of a jet pump 11 . One end of the riser tube 10 is inserted in the reactor pressure vessel 1 to the upper end of the jet pump 11 . A valve 12 provided in the pipe 8 is opened. The cooling water reaching the interior of the jet pump 11 passes through a lower plenum 13 to the in core portion 2 . While moving upward in the in core portion 2 , the cooling water draws heat from nuclear fuel and changes into steam.
[0029] The steam passes the steam water separator 3 , and then it is sent to a turbine 14 and condensed in a condenser 15 . The turbine 14 is driven, and a generator 16 connected to the turbine 14 is rotated. Water generated by condensation in the condenser 15 is sent to the interior of the reactor pressure vessel 1 by a feed water pump 17 .
[0030] As described above, the pipe 8 and the riser tube 10 constitute a primary loop recirculation piping as one piping system of the nuclear power plant with a boiling-water reactor.
[0031] Both ends of a heating coil 18 wound on the pipe 8 are connected to a high-frequency oscillator 19 . A high-frequency heating apparatus 20 as one kind of induction heating apparatus is made up of the heating coil 18 , the high-frequency oscillator 19 , and so on.
[0032] After the assembly of the primary loop recirculation piping connecting the reactor pressure vessel 1 and the upper end of the jet pump 11 is completed, the circulating pump 9 is driven, so that the cooling water flows in the recirculation system pipe. Afterward, the circulating pump 9 is stopped, so that the cooling water is allowed to stagnate in the pipe 8 . Next, the pipe 8 is heated through the outside surface of the pipe by the heating coil 18 of the high-frequency heating apparatus 20 . At this time, the temperature of the outside surface of the pipe 8 is controlled so as to exceed a temperature at which the stress of the outside surface of the pipe 8 is not less than the compressive yield stress. On the other hand, the temperature of the inside surface of the pipe 8 rises to 100° C. or more because the stagnating cooling water begins to boil. The temperature distribution in the wall surface of the pipe or the temperature of the inside surface of the pipe is estimated from an output value of not-shown temperature measuring means (e.g., a thermocouple or the like) for the outside surface of the pipe, and a heating time set in advance.
[0033] When the temperature distribution in the wall surface of the pipe is judged to become a predetermined distribution or the temperature of the inside surface of the pipe is judged to become a predetermined temperature, the circulating pump 9 is driven, and the cooling water in the reactor pressure vessel 1 is supplied into the pipe 8 and the riser tube 10 .
[0034] As described above, the pipe 8 is heated through its outside surface so as to make a state wherein the difference in temperature between the inside and outside surfaces of the pipe 8 is little. Next, by cooling the inside surface of the pipe 8 , a steep temperature gradient is formed near the inside surface of the pipe, and thereby the inside surface of the pipe 8 is tensile-yielded.
[0035] Afterward, heating by the heating coil 18 is stopped. When the temperature lowers, a compressive residual stress is generated in the inside surface of the pipe 8 and a tensile residual stress is generated in the outside surface of the pipe.
[0036] According to the present invention, after the primary lop recirculation piping is assembled, heat treatment for the pipe can be performed and a compressive residual stress can be generated in the inside surface of a necessary portion of the primary loop recirculation piping.
[0037] In addition, because the cooling water in the reactor pressure vessel 1 can be supplied into the primary loop recirculation piping, an apparatus for supplying the cooling water into the primary loop recirculation piping need not be newly provided.
[0038] The embodiment shown in FIG. 2 is to generate a compressive residual stress in the inside surface near a welded portion 22 of a pipe in which a pipe 21 a and a pipe 21 b are welded to each other.
[0039] A heating coil 25 is spirally attached to the pipe 21 with spacers 23 and holders 24 . An induction current generated in a power source 27 is supplied from a transformer 28 through cables 29 a and 29 b to end portions 26 a and 26 b of the heating coil 25 .
[0040] Further, the heating coil 25 has a structure to be supplied with the cooling water from the end portions 26 a and 26 b of the heating coil 25 through hoses 31 a and 31 b from a cooling water circulating pump 30 .
[0041] A thermocouple 32 for measuring the temperature of the surface of the welded portion is attached to the welded metallic portion of the outside surface of the pipe. The thermocouple 32 sends a voltage caused by thermoelectromotive force to a controller 34 through a cable 33 .
[0042] The cooling water is supplied into the pipe 21 by a not-shown feed system.
[0043] Next, the heating coil 25 as a component to be attached to the pipe, and a spacer 23 and a holder 24 for supporting the heating coil 25 , will be described in order.
[0044] FIG. 3 shows a supporting condition of the heating coil 25 . As the heating coil 25 used is a copper pipe. The heating coil 25 is supported by the holder 24 .
[0045] FIG. 4 shows a sectional view when hypothetically cut along a plane a normal line of which is coincide with the central axis of the pipe 21 . The heating coil 25 is held by a not-shown holder 24 and set around the pipe 1 with a spacer 23 made of an insulator.
[0046] FIG. 5 shows a state wherein the heating coil 25 is divided to be set around the pipe. The heating coil 25 can be divided into semicircular parts, and electrical connection and connection of flow passages for a coolant can be made by not-shown upper and lower holders 24 as connecting portions. Therefore, when setting, a proper space can be made between the pipe surface and the heating coil only by attaching the spacers in accordance with the pipe surface.
[0047] FIG. 6 shows a sectional structure of an upper or lower holder 24 as a connecting portion. An end of the heating coil 25 is connected to the holder 24 . A port 35 as a flow passage for the coolant is provided in an upper portion of the holder 24 . By connecting a heat-resistant hose or the like to the port 35 , a circuit for the coolant can be constructed.
[0048] Next, a procedure of a heat treatment operation using this apparatus will be described. In FIG. 2 , the apparatus is provided in the shown state, and then the interiors of the pipes 21 a and 21 b connected at the welded portion 22 are filled up with the cooling water by a not-shown circulating pump. The controller 34 starts the cooling water circulating pump 30 to start supplying the cooling water to the heating coil 25 . Next, the current is applied to the heating coil 25 . An induction current is induced in the pipe by the current which flows in the heating coil 25 , and thereby heat generation of the pipe occurs. The temperature of the outside surface of the pipe is measured by the thermocouple 32 , and the output of the thermocouple 32 is sent to the controller 34 . The controller 34 estimates the temperature distribution in the wall surface of the pipe or the temperature of the inside surface of the pipe from the output of the thermocouple 32 and a heating time set in advance.
[0049] When the temperature distribution in the wall surface of the pipe or the temperature of the inside surface of the pipe is judged to have become a predetermined value, the controller 34 drives a not-shown circulating pump, so that the cooling water is allowed to flow in the pipe. After a predetermined temperature gradient is obtained, the current supply to the heating coil 25 is stopped.
[0050] In the embodiment shown in FIG. 7 , the pipe heating means of the embodiment shown in FIG. 2 is changed to direct electrical heating.
[0051] Ring terminals 36 a and 36 b for direct electrical heating are attached to the pipe 21 . The current generated in a power source 38 is supplied from a transformer 39 through cables 29 a and 29 b to end portions 37 a and 37 b of the ring terminals.
[0052] Further, the ring terminals 36 a and 36 b have structures to be supplied with the cooling water from the end portions 37 a and 37 b of the ring terminals through hoses 31 a and 31 b from a cooling water circulating pump 30 .
[0053] A thermocouple 32 for measuring the temperature of the surface of the welded portion is attached to the welded metallic portion of the outside surface of the pipe. The thermocouple 32 sends a voltage caused by thermoelectromotive force to a controller 34 through a cable 33 .
[0054] The cooling water is supplied into the pipe 21 by a not-shown feed system.
[0055] Next, a procedure of a heat treatment operation using this apparatus will be described. In FIG. 7 , the apparatus is provided in the shown state, and then the interiors of the pipes 21 a and 21 b connected at the welded portion 22 are filled up with the cooling water. The controller 34 starts the cooling water circulating pump 30 to start supplying the cooling water to the ring terminals 36 a and 36 b . Next, the current is applied to the ring terminals 36 a and 36 b . The pipe 21 sandwiched by the ring terminals 36 a and 36 b is electrically heated, and thereby heat generation of the pipe occurs. The temperature of the surface of the pipe is measured by the thermocouple 32 , and the output of the thermocouple 32 is sent to the controller 34 . The controller 34 estimates the temperature distribution in the wall surface of the pipe or the temperature of the inside surface of the pipe from the output of the thermocouple 32 and a heating time set in advance.
[0056] When the temperature distribution in the wall surface of the pipe or the temperature of the inside surface of the pipe is judged to become a predetermined value, the controller 34 drives a not-shown circulating pump, so that the cooling water flows in the pipe. After a predetermined temperature gradient is obtained, the current supply to the ring terminals 36 a and 36 b is stopped.
[0057] Here, the reason why a compressive residual stress is generated in the inside surface of the pipe in the above-described embodiments will be described below.
[0058] When the pipe is heated in a state wherein the cooling water in the pipe does not flow, the cooling water which stagnates in the pipe begins to boil. Thus, the temperature of the inside surface of the pipe rises to 100° C., which is the boiling temperature of the cooling water, or more. As a result, the temperature distribution in the wall surface of the pipe has a tendency as shown by a curve A in FIG. 8 . To represents the temperature of the outside surface of the pipe. When the cooling water in the pipe flows after the temperature distribution as shown by the curve A is formed, the inside surface of the pipe is rapidly cooled and the temperature of the inside surface gets near to the temperature of the cooling water. As a result, the temperature distribution in the wall surface of the pipe becomes a state as shown by a curve B in FIG. 8 . When changes in temperature of the inside and outside surfaces of the pipe as the time elapses are graphically shown, it is as shown in FIG. 9 . For comparison, an example of the temperature distribution in the wall surface of the pipe by a conventional method in which the outside surface is heated while the inside surface is cooled, is shown by a curve C in FIG. 8 , and the relation between temperature and time is shown by a chain double-dashed line in FIG. 9 .
[0059] On the basis of the temperature gradient shown by the curve B according to the present invention, as shown in FIG. 10 , a large tensile stress σi is generated in the inside surface of the pipe and a compressive stress σo is generated in the outside surface of the pipe. When the tensile stress σi exceeds the yield strength of the material, the outside surface of the pipe is tensile-yielded. When cooling to the normal temperature, as shown in FIG. 11 , a compressive stress σri remains in the inside surface of the pipe and a tensile stress σro remains in the outside surface of the pipe.
[0060] FIG. 12 shows a relation between stress and strain. When the difference in temperature between the inside and outside surfaces of the pipe is little, either of the inside and outside surfaces of the pipe does not exceed its yield stress. Thus, in FIG. 12 , the stress-strain relation exists on the straight line of 0D2 in the outside surface of the pipe and on the straight line of 0D1 in the inside surface of the pipe. When heating is stopped, either of stress in the inside and outside surfaces of the pipe returns to zero, and the residual stress does not change. On the other hand, the difference in temperature between the inside and outside surfaces of the pipe is sufficiently large, the radial stress distribution of the pipe is as shown in FIG. 10 , and the stress in the inside surface of the pipe exceeds the tensile-side yield stress σy and that in the outside surface of the pipe exceeds the compressive-side yield stress −σy. The stresses in the wall surface of the pipe at that time are shown by B 1 and B 2 in FIG. 12 , respectively. When heating stops at this time, the stress in the inside surface of the pipe is changed in the course of B 1 to E 1 . When the temperature of the whole of the pipe lowers to the temperature of the atmosphere, the stress in the inside surface reaches the point C 1 . On the other hand, the stress in the outside surface of the pipe changed in the course of B 2 to E 2 and reaches the point C 2 . Therefore, a compressive residual stress is generated in the inside surface of the pipe because a positive strain is given, while a tensile residual stress is generated in the outside surface of the pipe because a negative strain is given.
[0061] The above-described stress-strain relation of FIG. 12 is in the case that no residual stress exists. However, even in the case that a tensile residual stress exists in the inside or outside surface, a similar method of thinking can be used and it may be thought that a stress generated due to the difference in temperature between the inside and outside surfaces of the pipe is superposed on the original tensile residual stress. Therefore, to yield the inside and outside surfaces of the pipe, a less difference in temperature suffices in comparison with a case wherein no initial residual stress exists.
[0062] It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims. | In a method for heat treatment of an existing pipe constituting a piping system, for converting the residual stress at a welded metallic portion and a welding heat influenced portion of the inside surface of the pipe, into a compressive stress and thereby generate the compressive stress in the inside surface of the existing pipe, a coolant is retained in the pipe; an arbitrary portion of the outside surface of the pipe is heated; thereby a temperature distribution little in temperature difference is produced in the wall surface of the pipe at the heated portion; and then the coolant is allowed to flow. By converting the residual stress at the welded metallic portion and the welding heat influenced portion of the inside surface of the pipe, into the compressive stress, stress corrosion cracking generated from the welded metallic portion and the welding heat influenced portion can be suppressed. | 2 |
THE FIELD OF THE INVENTION
Embodiments of the present invention relate to methods and systems for detection and delineation of text characters in images containing combinations of text and graphical content. More particularly, these methods and systems detect text by computing local evidence of character strokes without the resource-consuming global and regional analyses of existing techniques or the limitations of directional scan-line techniques.
BACKGROUND
Various components of images may be processed in order to optimize or otherwise modify the visual aspects of the image. Digital photographs may be processed in several ways to enhance the visual qualities of the image and add special effects or other modifications. Images containing text may also be enhanced by methods which increase legibility, character contrast, sharpness or other visual characteristics. While both textual and graphical images may be processed and enhanced, the methods for processing text and graphical images are not the same.
Graphical images such as digital photographs and scanned graphics may be processed using techniques that remove noise, adjust color and contrast, reduce aliasing and create special effects. These techniques adjust characteristics of the graphic while maintaining the integrity of the image. Because these images typically involve many colors, shades and contrast levels, the techniques used generally vary significantly from those used for textual processing.
Text may be processed to enhance legibility or modify its visual characteristics or to convert between formats. Visual modification may involve contrast adjustment, character sharpness and other visual characteristics. Text images may also be converted from an image file format to a text file format using character recognition methods such as raster-to-text methods. Furthermore, the compression algorithms used for text may differ from those used for photographs and other graphics. Higher compression ratios are available for text than for graphical elements and overall image compression may be improved when text elements are separated out and compressed at higher ratios.
Because text and graphical elements are processed very differently, an image which contains both text and graphical elements must be partitioned into segments for optimal processing of both elements. In order to make this partition, text-containing areas must be identified and distinguished from graphical areas which require different processing techniques.
Various methods have been used to identify text elements. Some of these methods employ scan-line techniques in which rows or columns of pixels are evaluated to determine intensity or luminance levels. Consecutive intensity levels are compared to whether the intensity has changed significantly from one pixel to the next. When significant intensity changes occur, the location is marked as an edge. Changes from light to dark and dark to light may be distinguished as rising or falling intensity levels and may be identified accordingly, for example, by opposite signs. As text characters typically involve high contrast edges of opposite sign within close proximity, this condition may be used to identify the presence of text in a document. Processing of single scan-line data can produce false-positive text in high-contrast graphical image areas. These methods may also produce false-negative results in areas with bold or large text. More particularly, false-negative results may arise when a scan-line crosses the top of a character such as a “T” which has a broad area between successive opposing edges.
Other methods involve the use of segmentation into successive windows in which a series of histograms are computed. In some methods, the image may be thresholded to black and white and length of run histograms may be generated for runs of black and white pixels. The frequency of runs of a specific length may be used to determine whether text or graphical content is present.
Another known method of distinguishing between textual and graphical areas involves image smoothing followed by comparison of each pixel with a threshold density. Each pixel is classified as textual or graphical. The length or area of each region is then compared to a reference length or area. Regions with values below the reference are designated as text.
Other known methods are used to find the edges of characters for text enhancement techniques and other modifications. One scan-line-based method locates oppositely signed pairs of curvature extrema along the scan-line. Curvature is estimated by computing local angular differences in the slope of the image function along a scan-line followed by computing the local changes in angle along the scan-line. Pairs of significant curvature-extrema are taken as edge boundaries. Edge points are computed as the intervening pixel closest in value to the average intensity. Edge points are then linked across neighboring scan-lines to form straight line segments.
Another method of text edge-detection performs edge detection at two scales on binarized image data. Gray-scale or intensity data may be thresholded prior to smoothing and edge filtering. Halftone dot detection using pattern matching is performed on the binary image data. Detection of solid areas near dotted areas is also performed via pattern matching. The detected dotted and solid areas are considered regions of halftone and are subtracted from the original edge data leaving edges classified as text only.
Known methods and apparatus suffer from false detection determinations, burdensome processing requirements and the necessity of evaluating complete images or large portions thereof.
SUMMARY AND OBJECTS OF THE INVENTION
Embodiments of the present invention provide improved methods and systems for detecting and delineating text in scanned or otherwise digitized images with mixed-content. These systems and methods are particularly useful for digital copying, compression and optical character recognition applications especially those involving mixed-content color documents where speed and image quality are paramount.
In some embodiments of the present invention, text detection and localization is computed on the grayscale or intensity information of an image or portion thereof. These methods may be used for processing of color images when the grayscale or other intensity information inherent in the color image is utilized. This grayscale or intensity information may be represented as a three-dimensional diagram, map or two-dimensional functional surface.
Because characters are based on curvilinear segments originally derived from pen or brush strokes, these curvilinear segments typically appear as valley or ridge structures on the intensity map. Each character segment, either curved, linear or some curvilinear combination may be referred to as a “stroke.” Text may be detected by the presence of strokes rather than complete characters or groups of characters thereby reducing detection time and resources.
Using the methods of embodiments of the present invention, strokes may be detected in small, localized areas or over larger areas. Edges which exist between high-contrast areas are detected and identified. This may be achieved using a variety of edge detection techniques known in the art. First derivative techniques such as, but not limited to, Sobel edge detection are preferred as they provide intensity gradient information. Using these techniques, high-contrast edges and vector data identifying the direction of the local maximum intensity gradient may be identified.
Methods of embodiments of the present invention may also comprise techniques for identifying valleys and ridges of character strokes. Character strokes may be plotted on a three-dimensional map having pixels mapped with their intensity plotted as a third dimension perpendicular to a plane designating location coordinates. In this manner, the terrain of the map rises and falls with varying intensity. The cross-section of a character stroke displayed in this way shows a prominent rising or falling slope at the leading edge of a character and a corresponding inverse slope at the trailing edge. The region between these cross-sectional slopes or edges typically forms one or more ridges or valleys which correspond roughly to an axis of the character stroke. These ridges and valleys may be identified so that their relationship to character edges or other image attributes may be examined. These ridge and valley determination processes may be performed simultaneous to edge detection processes or at some other time either before or after edge detection.
In a preferred embodiment, ridges and valleys are detected by progressively analyzing the intensity differential of adjacent pixels. Each successive pixel is analyzed to determine whether the curvature of the intensity reaches a maximum absolute value at the same point that the curvature of the intensity map in another direction, such as a roughly perpendicular direction, is close to zero. In this document, the term “transverse” is used to describe a direction which is substantially or roughly perpendicular to the longitudinal axis of a shape or object. Because the intensity gradient defines a direction transverse to the character stroke, this condition typically indicates that the shape of the character stroke has “peaked” in a valley or ridge while the character stroke intensity is relatively constant in the longitudinal direction of the stroke. Smoothing processes may be used on the image before ridge or valley detection procedures to tailor specific detection results.
Once edges and ridges and/or valleys have been identified, the methods of some embodiments of the present invention calculate spatial relationships between edges and adjacent ridges and/or valleys. The proximity of an edge to an adjacent ridge or valley may be determinative of the presence of text characters in the image. Typically, an image with edges in close proximity to valleys or ridges is a strong indication of the presence of text in the image.
Because the width or thickness of text characters often vary widely when measured in a single direction (i.e., the horizontal width of the top of a “T” relative to the bottom), errors are introduced when these wider character components are identified as graphical components. These errors are inherent in unidirectional techniques such as scan-line methods. The methods and systems of embodiments of the present invention are capable of measuring the distance between an edge and an adjacent valley or ridge in the direction of the intensity gradient. In this manner, dimensions are measured perpendicular to a character's stroke axis across its shortest dimension. This can be achieved for characters with strokes of any curvilinear shape.
In preferred embodiments, the distance between a pixel identified as an edge and an adjacent valley or ridge is measured in the direction of the intensity gradient when measuring to a ridge and in a direction opposite to the intensity gradient when measuring to a valley. In this manner, the distance between an edge and an adjacent valley or ridge is measured in a direction roughly perpendicular to the character stroke axis when a character is present.
When a valley or ridge is found within a specified proximity to an edge, the pixel, group of pixels or some other associated region or neighborhood may be designated as being related to text. In some embodiments, each edge pixel is analyzed to determine its proximity to a valley or ridge. When the proximity is within specified parameters, the pixel is labeled as a text edge. This process is repeated for each pixel which has been identified as an edge.
When character contrast and sharpness enhancement methods are employed, this identification of character edges may be sufficient for identification of text edges for further treatment, however some embodiments of the present invention may further identify regions of text for segregation and selective processing. Some embodiments may identify regions of text for OCR processing, compression or other processing and treatment.
Accordingly, it is an object of some embodiments of the present invention to provide systems and methods for detecting text, line art and similar graphical structures in mixed-content documents.
It is another object of some embodiments of the present invention to provide systems and methods for detecting and verifying edges of text, line art and similar graphical structures in images.
These and other objects and features of the present invention will become more fully apparent from the following, description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the manner in which the above-recited and other advantages and objects of the invention are obtained, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
FIG. 1A shows an image with dark text characters on a light background;
FIG. 1B depicts an image intensity map of the image in FIG. 1A ;
FIG. 2A shows an image with light text characters on a dark background;
FIG. 2B depicts an image intensity map of the image in FIG. 2A ;
FIG. 3 shows the results of using a first derivative edge detection method to identify text edges and edge intensity gradient information;
FIG. 4 shows a cross-sectional view of the intensity map surface of a typical character stroke;
FIG. 5 shows a plan view of a character from FIG. 4 with multiple ridge axes;
FIG. 6 shows a cross-sectional view of the intensity map surface of a character stroke after substantial smoothing has been performed;
FIG. 7 shows a plan view of a character from FIG. 6 with a single axis; and
FIG. 8 depicts an image intensity map of the characters shown in FIG. 2A showing the substantially perpendicular axes of minimum and maximum curvature.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The figures listed above are expressly incorporated as part of this detailed description. It will be readily understood that the components of the present invention, as generally described and illustrated in the figures herein, could be arranged and designed in a wide variety of different configurations. Thus, the following more detailed description of the embodiments of the system and apparatus of the present invention, as represented in FIGS. 1 through 8 is not intended to limit the scope of the invention, as claimed, but it is merely representative of the presently preferred embodiments of the invention.
The currently preferred embodiments of the present invention will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
Embodiments of the present invention may detect and delineate text in digital images. These images are generally represented by image components or picture elements which may be referred to as pixels, pels or other nomenclature. Each pixel typically defines a location and one or more visual characteristics of an image at that location. Naturally, color images with a wide spectrum of colors and monochrome images with a wide variety of grayscale variations can contain a large amount of data in addition to pixel location data. Many digital image encoding formats or color spaces exist including RGB, HSV, Lab, YIQ, and many others. While these formats include color information and other data, they are generally easily converted to a grayscale format comprising two-dimensional coordinates and a luminance or intensity value. While color attributes may be lost in the converted format, the contrast between adjacent pixels is generally well preserved. Because conventional text is typically displayed in high-contrast situations, it is well preserved when converted to a simple grayscale image format.
Grayscale images may be visualized as a three-dimensional map or plot with the X, Y location coordinates defining a horizontal plane and the intensity value being plotted in the Z direction perpendicular to that plane. These intensity maps may be used to visualize image characteristics and to analyze the image based on geometric relationships on the map. Geometric analysis and techniques of differential geometry may be used to establish relationships between pixels or groups thereof.
As text characters are typically displayed as symbols with a high-contrast background, they generally show up as significant rises or drops in the “terrain” of an intensity map as may be seen in FIGS. 1B and 2B . FIG. 1A shows a typical text character “p” 2 with dark text symbols on a light background 6 . Accordingly, the corresponding intensity map, as shown in FIG. 1B shows a dark character as a depression 8 and the light background as an elevated surface 12 . The edges of the characters have a steep slope 14 representing the abrupt transition from light background to dark character.
In reference to FIG. 2A , a light character “p” 20 is shown against a dark background 24 . The intensity map corresponding to FIG. 2A is shown as FIG. 2B where the light character “p” 20 is shown as elevated surface 26 . Dark background 24 is shown as depressed surface 30 . The edges of these characters also have a steep slope 32 representing the abrupt transition from dark background to light character.
The variation in intensity between adjacent pixels along these edge slopes 14 , 32 is pronounced in relation to those within the character or background. This significant intensity differential is typically used to detect these high-contrast text edges in a digitized image. Many known techniques may be used for this process. These edge detection processes will typically identify an edge similar to that shown in FIG. 3 for the image shown in FIG. 1A . Edge pixels 42 along the high-contrast edge between character and background are identified.
In addition to the identification of edge pixels 42 , some edge detection techniques or related techniques also identify intensity gradient information comprising a maximum intensity gradient direction 44 which points toward the direction of highest intensity change. This vector information can be used to increase method speed, efficiency and reliability as will be discussed below. Preferred embodiments of the present invention employ first derivative edge detection techniques, for example, but not limited to, Sobel techniques.
As well as edge detection, the methods and systems of embodiments of the present invention also comprise character stroke axis identification. Because characters are based on curvilinear segments originally derived from pen or brush strokes, these curvilinear segments have narrow, elongated signatures which typically appear as channels or berms on the luminance or intensity map with valleys or ridges along their axes. These character segments, either curved, linear or some curvilinear combination may be referred to as “strokes.” The ridges or valleys of these strokes typically form substantially longitudinal axes along which the surface of the stroke reaches a maximum curvature in a transverse cross-sectional view.
In reference to FIG. 4 , a transverse cross-section of a character stroke 50 , identified by reference lines 50 in FIG. 3 , shows a rising edge 52 where the image transitions from dark background to light character and a descending edge 54 where the character transitions back to a dark background. As the rising edge 52 transitions to the plateau 60 of the high-intensity stroke of the character, the cross-sectional surface forms a point of maximum curvature 56 which can be detected through the methods of embodiments of the present invention. Likewise, as the plateau 60 transitions into the descending edge 54 another point of maximum curvature 58 may be formed. The summation of these points of maximum curvature 56 , 58 define longitudinal stroke axes 62 as shown in cross-section in FIG. 4 and in plan view in FIG. 5 .
In some embodiments of the present invention, the raw intensity data may be processed by smoothing techniques, which may transform the cross-sectional shape of the character stroke. In reference to FIG. 6 , the transverse cross-section as delineated in FIG. 3 at 50 may take the form of surface cross-section 76 when the raw intensity data has been smoothed. Section 76 has a rising slope 70 and a descending slope 72 . The rounded or smoothed transition between these two slopes 70 , 72 has a point of maximum curvature 74 which forms a ridge between the two slopes 70 , 72 . The summation of these points of maximum curvature, for a smoothed character, may form a single ridge along a longitudinal axis 78 of the character stroke. In many cases, the axis 78 will be somewhat centralized in the character stroke. However, multiple axes and off-center axes may be accommodated in many embodiments of the present invention.
Points of maximum curvature 56 , 58 , 74 may be found using differential geometry operations on the surface of the intensity map. Neighborhood-oriented mask operations may be used to effectuate these calculations. In preferred embodiments, a pixel is analyzed, using methods of differential geometry, to determine the curvature of the intensity map in each direction around the pixel. A simple 3×3 mask is preferred for its decreased processing time, however, larger masks yield more stable results and may be used when time constraints are relaxed or processing power is increased. When the curvatures around the subject pixel have been calculated, a maximum curvature and a minimum curvature may be determined. These curvatures may be coupled with directional information to establish a maximum curvature direction and a minimum curvature direction. Points of maximum curvature 56 , 58 , 74 may be identified when the maximum curvature of a pixel meets specific criteria while the minimum curvature of a pixel meets other specific criteria.
Due to the geometric nature of character strokes, ridge and valley points, also called axis points, along these strokes will typically have a maximum curvature within a specific range while the minimum curvature is near zero. Therefore, these axis points may be identified as points which have a maximum curvature greater than a given threshold value while the minimum curvature is near zero or below some minimum curvature threshold value.
The axes of text strokes correspond to topographic features of the image surface—specifically valleys and ridges. These features are distinguished by their principal curvatures (κ 1 , κ 2 ), which are measured at each pixel location of the image surface. In particular, for valleys and ridges, the largest of these curvatures is significant, |κ max |≧θ, and the smallest is relatively small—in fact, it is close to 0, |κ min |≦ε. Valleys are further distinguished from ridges by the sign of the largest curvature, which is positive for valleys, κ max >0, and negative for ridges, κ max <0.
It is well know from differential geometry that at each point of a functional surface such as an image the principal curvatures are approximately equal to and proportional to the eigenvalues of the Hessian matrix—i.e., (κ 1 , κ 2 )=(λ 1 , λ 2 ). Thus, in order to efficiently compute the principal curvatures of an image surface, it is sufficient to solve for these eigenvalues (λ 1 , λ 2 ) of the Hessian at each pixel location, where the Hessian is defined in terms of the local 2 nd -derivatives as follows:
H = [ d xx d xy d xy d yy ] .
Techniques for solving such a 2×2, symmetric eigensystem are well documented in the linear-algebra literature, and we will not discuss its solution herein. Anyone skilled in the arts can solve such a system.
With respect to computing the individual entries of the Hessian, it can be shown, in terms of a least-squares approximation, that the preferred 3×3 2 nd -derivative operators are defined as follows:
d xx = 1 3 1 - 2 1 1 - 2 1 1 - 2 1 , d xy = 1 4 1 0 - 1 0 0 0 - 1 0 1 , d yy = 1 3 1 1 1 - 2 - 2 - 2 1 1 1
Convolving the smoothed image with each of these, produces a Hessian system at each pixel location. Once the eigenvalues at a pixel location are computed, one can determine whether or not that point corresponds to an axis feature (a valley or a ridge) by applying the following predicate.
λ max = (|λ 1 |≧|λ 2 |)? λ 1 : λ 2 ; λ min = (|λ 1 |≧|λ 2 |)? λ 2 : λ 1 ; Significant = (|λ max |≧θ)? TRUE : FALSE; Small = (|λ min |≦ε)? TRUE : FALSE; if(Significant && Small) { if(λ max >0) featureType = VALLEY; else if(λ max <0) featureType = RIDGE; }
The above methods have successfully detected text using values for θ of around 15 and values for ε of around 1.5, however other values can be used successfully as text size, font and other attributes vary.
The geometric nature of character strokes also dictates that these maximum and minimum curvatures will generally have directions that are roughly perpendicular to each other. This occurs as the maximum curvature slopes in a transverse direction across the cross-section of the stroke while the minimum curvature follows the relatively flat contour of the longitudinal length of the stroke. In reference to FIG. 8 , a point of maximum curvature 80 is shown with a maximum curvature in a transverse direction 82 while the minimum curvature falls in a perpendicular longitudinal direction 84 along the character stroke. Another point of maximum curvature 86 lies along a curvilinear axis, but continues to have a maximum curvature in a transverse direction 88 while the minimum curvature lies in a roughly perpendicular direction 90 . Consequently, pixels which meet this condition may be identified as partial axes of character strokes or pixels to be evaluated for further text relationships based on geometric relationships or other criteria.
Once character edges and stroke axes have been identified, the methods and systems of embodiments of the present invention analyze the edge and axis data to determine whether relationships between these data support a likelihood that text is present in the image. Some embodiments of the present invention analyze the proximity of edge features to axis features. Other embodiments may also utilize the geometric relationships of edge features to axis features. Preferred embodiments analyze the relationships between edge and axis features using a geometrically-directed analysis. These methods generally begin with an edge pixel for which intensity gradient information has been obtained and examine adjacent pixels in the intensity gradient direction or an opposite direction depending on whether the background is darker than the text. If the text is lighter, a ridge axis will be found in the direction of the intensity gradient and if the text is darker, a valley axis will be found in a direction opposite to the intensity gradient direction. Both directions may be analyzed when text/background intensity is not known as in a general purpose scanner or copier application.
These preferred embodiments may determine relationships by beginning at a subject pixel that has been identified as an edge pixel and progressively analyzing adjacent pixels in a direction parallel with the intensity gradient of the subject pixel. Pixels may be analyzed to determine whether they have been identified as edge or axis pixels. In this manner, the distance and geometric relationship between edges and axes may be established without the unidirectional constraints of scan-line methods. By following the intensity gradient 44 , as shown in FIG. 3 , the analysis path typically runs transverse to the character stroke rather than horizontal or vertical to the image. This transverse directional approach will generally locate an adjacent axis or edge along the shortest distance to that feature.
The transverse directional methods of embodiments of the present invention eliminate false-negative text search results which result from vertical scan-lines through vertical text strokes such as at line 46 in FIG. 3 or horizontal scan-lines through approximately horizontal strokes such as at line 48 in FIG. 3 . These known scan-line methods fail to detect as text the wide contrasting areas at these locations despite their location on text characters whereas the transverse-stroke methods of embodiments of the present invention consistently measure across the stroke thereby detecting the true proximity of the character stroke edges.
Once the geometric relationships between character edges and axes has been established, methods of embodiments of the present invention may be used to identify text for selective processing. Text may be identified by the presence of one or more axes in close proximity to an edge or to each other. Text may also be identified by a geometric relationship between axes and edges, between adjacent axes, between adjacent edges or between axes, edges and other character structures. Using these methods, text may be detected by the presence of strokes and their associated edges and axes rather than complete characters or groups of characters thereby reducing detection time and resources. These methods may also yield fewer false-negative results because a character may be resolved over a smaller spatial extent.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope. | Embodiments of the present invention relate to methods and systems for detection and delineation of text characters in images which may contain combinations of text and graphical content. Embodiments of the present invention employ intensity contrast edge detection methods and intensity gradient direction determination methods in conjunction with analyses of intensity curve geometry to determine the presence of text and verify text edge identification. These methods may be used to identify text in mixed-content images, to determine text character edges and to achieve other image processing purposes. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to pressure-sensitive adhesive bonding tapes, and more particularly to a bonding tape having a layer of a primary pressure-sensitive adhesive material coated with a film of a secondary pressure-sensitive adhesive material.
Pressure sensitive adhesive tapes are commonly employed in adhesive fastening in a wide variety of application. However, in situations were a bond must be made to or between low energy surfaces, adequate adhesion is difficult to achieve. A low energy surface may be defined for purposes of this specification as a surface having a critical surface tension low enough so that there will not be sufficient wetting by an adhesive. An example of adhesive bonding between low energy surfaces is the bonding of an automobile windshield to a car body. The surfaces to be joined are glass and painted metal (especially the newer acrylic high solids enamel paints), both low energy surfaces.
The principal problem in obtaining adequate adhesion to low energy substrates is poor surface to surface contact between adhesive and substrate because the adhesive cannot properly spread and wet the substrate. This may result in adhesive failure during use. Moreover, the difficulties in achieving good adhesion to a low energy surface are increased when excess moisture is present and/or during application of repeated cyclic stresses such as vibrations. Both conditions are common in the bonding of windshields to automobile bodies.
One method practiced by the prior art in attempting to overcome poor adhesion to low energy surfaces is to apply a primer to the low energy surface prior to bonding. The primer is usually applied as a liquid and possesses a surface tension low enough to promote wetting of the substrate. Upon solvent release, or other suitable mechanisms, the primer sets up to form a continuous film over the surface of the substrate. With the film of primer in place, suitable bonding of the adhesive to the substrate can be achieved. Although the use of primers overcomes the poor adhesion characteristics of pressure-sensitive adhesive tapes to low energy surfaces, the need to apply a primer prior to bonding increases the time, costs, and labor to perform such operations. Significant time, labor and material costs are required to apply and then cure or dry primer layers on one or more of the low energy substrate surfaces to be bonded.
The use of energy-absorbing bonding tapes coated with pressure-sensitive adhesives, such as the energy-absorbing bonding tapes disclosed in commonly-assigned U.S. Pat. Nos. 3,896,245 and 4,061,805, is also known for adhering automotive trim strips and the like to painted metal substrates. However, where it is desired to bond two low energy surfaces together, it has been found that with the pressure-sensitive adhesives heretofore utilized with such bonding tapes that bonding performance is often inadequate, especially where the bond is subjected to moist conditions and/or cyclic stresses.
Accordingly, the need exists in the art for a pressure-sensitive adhesive bonding tape which overcomes the problems of prior art tapes and yet achieves adequate bonding without the need for the application of a separate layer or layers of primer to the substrate(s) to be bonded. By achieving adequate adhesion without the use of primers, the user would realize both time and cost savings.
SUMMARY OF THE INVENTION
The present invention meets that need by providing a self-priming pressure-sensitive adhesive bonding tape having a layer of a primary pressure-sensitive adhesive material coated on one or more surfaces with a film of a secondary pressure-sensitive adhesive material. Both the primary and secondary pressure-sensitive adhesives are modified by the addition of adhesion promoters to enhance the wetting characteristics of the tape. Additionally, the film thickness of the secondary pressure-sensitive adhesive is reduced so that the film has discontinuities which enable at least a portion of the primary pressure-sensitive adhesive layer to be directly exposed to the substrate. This permits both the primary and secondary pressure-sensitive adhesives in the tape to participate in the bonding process to the low energy substrate. Heretofore, prior art tapes have relied upon the adhesive characteristics of the coated pressure-sensitive adhesive film alone to achieve bonding and have not used the adhesive properties of the underlying support.
Bonding tapes of the present invention are applicable to a wide variety of uses which require the bonding together of low energy surfaces such as glass and painted or polymer coated substrates. In particular, the bonding tapes of the present invention may find use in adhering automobile windshield glass to automotive bodies and automotive trim strips or body side moldings to automobile bodies.
The self-priming bonding tapes of the present invention may be formulated from a number of suitably compounded pressure-sensitive adhesive systems or modifications thereof. The invention is not restricted to the specific composition of either the primary pressure-sensitive adhesive base layer or the secondary pressure-sensitive adhesive film over the base layer. Rather, I have discovered that by proper selection of adhesion promoters which are compounded with the primary and secondary adhesives in combination with a reduction of the film thickness of the secondary adhesive to expose portions of the primary adhesive directly to the substrate, a primerless bonding tape results which has superior adhesion characteristics and which can be used without preapplication of a separate primer layer. The bonding tape is especially useful to bond substrates together which are exposed to moist conditions and/or cyclic stresses.
Suitable tacky pressure-sensitive adhesives of the rubber resin type may be employed in the practice of the present invention. Suitably compounded, they may be used to form either the primary pressure-sensitive adhesive base layer or the secondary pressure-sensitive adhesive film. Examples include natural rubber adhesives, block copolymers, butyl rubber, polyisobutylene, halobutyl rubbers, acrylic adhesives, vinyl ether polymers, silicone pressure-sensitive adhesives, styrene-butadiene rubber, butadiene-acrylonitrile rubber, polychloroprene, polyurethanes, polyvinyl pyrrolidone, and ethylene vinyl acetate.
Many known tackifiers and adhesion promoters may also be used in the practice of the present invention. They may be compounded with either the primary pressure-sensitive adhesive base layer or the secondary pressure-sensitive adhesive film layer, or two or more promoters may be combined for use. Examples of suitable adhesion promoters include wood rosin and its derivatives, terpene resins, petroleum-based resins, polyolefinic tackifiers, coumarone-indene resins, hydroabietyl alcohol esters, polyisobutylenes, polyamide resins, phenolic resins, epoxy resins, petroleum-based oils, pine tars, acrylic monomers and polymers, polyester resins, malamine resins, and silanes, including mercaptosilanes and epoxysilanes.
Accordingly, it is an object of the present invention to provide a pressure-sensitive adhesive bonding tape which will bond to low energy surfaces without the need for the application of a separate primer layer. This and other objects and advantages of the invention will becomes apparent from the following detailed description, illustrative examples, and appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The primary pressure-sensitive adhesive material utilized in the adhesive bonding tape of the present invention can be any of a number of suitably compounded adhesives. (For example, tacky pressure-adhesives of the rubber resin type such as natural rubber adhesive, block copolymers, butyl rubber, polyisobutylene, halobutyl rubbers, acrylic adhesives, vinyl ether polymers, silicone pressure-sensitive adhesives, styrene-butadiene rubber, butadiene-acrylonitrile rubber, polychloroprene, polyurethanes, polyvinyl pyrrolidone, and ethylene vinyl acetate may all be utilized.) Additionally, suitable adhesive materials such as those disclosed in commonly-assigned U.S. Pat. No. 3,896,245 may also be utilized in the practice of the present invention. Other suitable commercially available adhesives include Hycar 2100×20 acrylic polymer from B.F. Goodrich Co., the Gelva acrylic polymers from Monsanto Corp., or the Aroset acrylic resins from Ashland Chemical Co. Preferably, the primary pressure-sensitive adhesive in in the form of a tape 0.10 to 1.00 inches thick, and of varying width and length (or varying diameter when the tape has a circular cross-section).
The secondary pressure-sensitive adhesive is preferably a film coated on the tape. The secondary pressure-sensitive adhesive film layer may also be selected from the above group of pressure-sensitive materials. This secondary pressure-sensitive adhesive material is applied as a thin film to the primary pressure-sensitive adhesive layer. It has been found that a film thickness of approximately between 0.00005 and 0.005 inches is suitable for the practice of the present invention. This can be achieved by application of the secondary pressure-sensitive adhesive material at a dry coating weight of between 0.1 to 10.00 grams/ft 2 .
The film thickness on the primary pressure-sensitive adhesive layer is controlled by adjusting the solids and viscosity level of the secondary adhesive through dilution with one or more known solvents. The more solvent that is added, the lower the solids content of the secondary adhesive and the lower its viscosity. Consequently, the lower the coating weight applied for a given set of conditions, the lower the final film thickness. For many applications of the present invention, a solids level of approximately 1% to 10% by weight has been found to be useful.
The thin film of the secondary pressure-sensitive adhesive may be applied by any of a number of known procedures. These procedures include dip coating, spray coating, adhesive film transfer, roll coating, or any other suitable method.
The thickness and/or method of coating of the layer of secondary pressure-sensitive adhesive must be controlled so that at least a portion of the film contains discontinuities which expose the underlying layer of primary pressure-sensitive adhesive directly to the substrate to be bonded. These discontinuities which may be pinhole discontinuities or larger, and which are controlled by the coating weight and thickness of the film of the secondary pressure-sensitive adhesive which is applied, permit both pressure-sensitive adhesives to participate in the bonding to the substrate.
Another important feature of the present invention is the use of a tackifier or adhesion promoter in both the primary and secondary pressure-sensitive adhesives. The tackifier or adhesion promoter may be chemically or physically admixed with the adhesives or adhesion could be promoted by a physical treatment, such as corona discharge, of the adhesive. Additive-type tackifers and adhesion promoters which have been found useful in the practice of the present invention include wood rosin and its derivatives, terpene resins, petroleum-based resins, polyolefinic tackifiers, coumarone-indene resins, hydroabietyl alcohol esters, polyisobutylenes, polyamide resins, phenolic resins, epoxy resins, petroleum-based oils, pine tars, acrylic monomers and polymers, polyester resins, melamine resins, and silanes, including mercaptosilanes, epoxysilanes. gamma-glycidoxypropyltrimethoxysilane and gamma-mercaptopropyltrimethoxysilane. It has been found that addition of adhesion promoters in amounts of from about 0.05% to 10% by weight produce a useful pressure-sensitive adhesive bonding tape.
The invention may be further illustrated by the following non-limiting example.
EXAMPLE
A standard butyl automobile window tape composition such as 22% butyl rubber, 21% silicate filler, 20% asbestos fibers, 12% carbon black, and 25% paraffinic oil was used as the primary pressure-sensitive adhesive layer. To that standard butyl composition, approximately 0.3% by weight of a mercaptosilane adhesion promoter was added. The mercaptosilane adhesion promoter is commercially available as Silane A-189 from Union Carbide Company.
The butyl compound with adhesion promoter was extruded into a 0.480 inch diameter round shaped tape and then dip coated through an acrylic adhesive and dried prior to winding. The acrylic adhesive is a Gelva RA-1753 acrylic adhesive commercially available from Monsanto Corporation. The acrylic adhesive was compounded with an epoxy silane adhesion promoter available commercially from Union Carbide Company and identified as Silane A-187. Approximately 0.3% by weight of the epoxy silane adhesion promoter was added to the acrylic adhesive.
The adhesive coating level was controlled by diluting the acrylic adhesive with methyl acetate solvent. A 6% solids acrylic pressure-sensitive adhesive. solution was used for the dip coating operation. This resulted in a final film thickness of approximately 0.0003 inches.
The effectiveness of the self priming adhesive bonding tape compared to systems requiring a primer layer and prior art tapes without primers was evaluated by a laboratory fatigue testing system as set forth in specification ESB-M3G-95-D Part 3.3 of the Ford Motor Company. The fatigue testing system determined the bonding durability of the tapes tested under simulated road vibrations.
The fatigue tester put an oscillating shear force on each tape which bonded a glass and metal test cell together. Water was continuously applied to the test cell during application of the shear force.
The metal and glass portions of the test cell were 2"×8" in size and were bonded to each other with the three tapes tested. The cell had a bonded overlap area of 6"×3/4".
During the test, the metal and glass portions of the cell were pulled apart in shear with an oscillation amplitude of ±0.30" and a frequency of 660 cycles per minute. The test cells were periodically evaluated for adhesive failure. Failure was taken as either complete delamination of any or all of the glass or metal surface at any point on the cell, excluding the ends. Failure was also considered as a 1/4" delamination at any of the four end interfaces. The results of the fatigue tests are reported below.
TABLE 1______________________________________Fatigue Testing Comparison Cell No. 3 Cell No. 1 Cell No. 2 Self-PrimingNo. of Standard Tape Standard Tape Tape WithoutCycles With Primer Without Primer Primer______________________________________100,000 Pass Pass Pass200,000 Pass Failed Pass300,000 Pass -- Pass1,000,000 Pass -- Pass______________________________________
The standard tape utilized in cell 1 is a butyl based pressure-sensitive adhesive tape having a composition of 22% butyl rubber, 22% silicate filler, 20% asbestos fibers, 12% carbon black, and 25% paraffinic oil. The primer layers were applied to both the glass and metal test surfaces and was aminosilane based for the glass and hydrocarbon based for the painted metal. The same standard butyl based pressure-sensitive adhesive tape was used in cell no. 2, but without the primer layers. Finally, cell no. 3 utilized the self-priming tape of the present invention described above which contained a primary pressure-sensitive adhesive layer of butyl rubber modified by a mercaptosilane adhesion promoter and a secondary pressure-sensitive adhesive film thereon which had been modified by an epoxy silane adhesion promoter.
As can be seen, cell no. 2 demonstrates the need for primer layers when standard pressure-sensitive adhesive tapes are utilized so that adequate adhesion of glass to painted metal can be obtained. Comparison of the results of cell no. 1 versus cell no. 3 show the ability of the self-priming pressure-sensitive adhesive tapes of the present invention to perform as well as prior art tapes but without the need for primer layers.
While the methods and compositions herein described constitute the preferred embodiments of the invention, it is to be understood that the invention is not limited to these precise methods and compositions, and that changes may be made in either without departing from the scope of the invention, which is defined in the appended claims. | A self-priming pressure-sensitive adhesive bonding tape is provided having a layer of a primary pressure-sensitive adhesive material coated onto one or more surfaces with a film of a secondary pressure-sensitive adhesive material. Both the primary and secondary pressure-sensitive adhesives are modified by the addition of adhesion promoters to enhance the wetting characteristics of the tape. The film thickness of the secondary pressure-sensitive adhesive is such that the film has discontinuities which enable at least a portion of the primary pressure-sensitive adhesive layer to be directly exposed to the substrate. Bonding is accomplished with the participation of both the primary and secondary pressure-sensitive adhesives. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to robot arms and wrist assemblies therefor.
2. Description of the Prior Art
In the prior art there have been various robots designed for use. For example, in Machine Design Magazine, of Aug. 12, 1982, on Page 55, there is an illustration of a robot sold by the Bendix Corporation, Robotics Division of Southfield, Mich. utilizing bevel gear drives for a wrist. The details shown are not extensive, but it does show bevel gears in an arrangement that moves the tool holder shaft through a differential action.
Likewise, U.S. Pat. No. 4,068,536 shows a type of a manipulator hand that provides for three axis movements in a wrist, as well as drives for mounting a robot arm on which the wrist is mounted.
U.S. Pat. No. 4,047,448 shows a robot head that provides for movement of a wrist member about three mutually perpendicular axes, utilizing three separate hydraulic motors for drive and gear trains for accomplishing such drive.
U.S. Pat. No. 4,332,147 shows an adjustable power transmitting device having an input and output shaft which are coupled together by drive gears, and which includes a housing that is rotatably mounted and is adjustable to a plurality of different positions.
A drive is shown in U.S. Pat. No. 3,922,930, requires few drive motors but substantial gear and shafting, and typical manipulator hand operators are shown in U.S. Pat. Nos. 4,188,166; 2,861,701; and 3,817,403.
U.S. Pat. Nos. 4,360,886, and 4,367,532 show devices for providing a program sequence of motions with a robot, and include controller systems for controlling the mechanical construction of the robot.
In addition, another type of manipulator hand is shown in U.S. Pat. No. 3,247,978, but which has its drive motors up near the end of the arm. The hand is driven through various gear drives. This hand, however, does show the use of electromagnetic clutches, which also form part of the present device. The grip operating motor is located down near the hand in this device.
Another type of arm used in manipulators for handling workpieces is shown in U.S. Pat. No. 4,064,656.
An industrial robot utilizing complex gear and shaft drives for obtaining the required motion is further described in U.S. Pat. No. 3,985,238.
None of these, however, have very simple drives for providing a plurality of joint motions in a wrist, shoulder or elbow assembly with gear drives and selectively operable brakes for controlling motions about a plurality of axes for a robot arm and wrist using a minimum number of motors and very simple controls.
SUMMARY OF THE INVENTION
The present invention relates to industrial robots, and more particularly to robot controls utilizing brakes and gear drives that reduce the number of motors that are necessary for operating the robot about its operational axes.
In particular, as illustrated, a robot arm is mounted on a base and has a shoulder joint supporting an upper arm and a forearm connected to the upper arm at an "elbow" joint. A wrist is connected to the forearm. The wrist is operable about three independent axes. The upper arm is connected to the base at the shoulder through an axis parallel to the "elbow" axis, and is also connected to the base about a vertical axis. The upper arm can be rotated about an axis mutually perpendicular to the elbow and shoulder axes to provide seven axes of operation for the robot.
In the form shown, only two motors are necessary, and in particular the operation of the movable joints is through a unique arrangement to provide a compact, easily operated assembly that can easily be controlled through the use of drive motors and clutches that in turn control the operation about the various axes.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a robot made according to the present invention;
FIG. 2 is a fragmentary vertical sectional view taken generally along the section line 2--2 in FIG. 1 with the upper arm in its dotted line position;
FIG. 3 is a sectional view taken generally along line 3--3 in FIG. 1 with parts in section and parts broken away; and
FIG. 4 is a sectional view of the wrist assembly made according to the present invention taken with parts removed for sake of clarity with parts in section and parts broken away.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An industrial robot illustrated generally at 10 made according to the present invention includes a support base 11 that is mounted onto a support floor 12, or on an overhead bridge, a trolley or the like which comprises the main support. The base 11 has a support sleeve 13 fixed to the top wall of the base. The axis of sleeve or housing 13 is vertical as shown and mounts a motor which is shown schematically at 20 in FIG. 1. The motor 20 is mounted on the base and powered through suitable controls.
The motor 20 has an output shaft that drives through a suitable speed reducing drive 20A to drive an elongated coupling 22 coupled to a drive shaft 23 having an axis 21 called a neck axis which is rotatably mounted through a center bore of the hub 30 of an electric brake 24 having a housing 25 fixedly mounted on the interior of the sleeve 13 and rotably mounted on hub 30 through a large bearing 29. The hub 30 has a flange 30A that carries a brake armature 30B through an annular, flat spring 30C. The spring 30C is a ring fastened at three annularly spaced locations to the flange 30A and to the armature 30B at three different annular locations so the armature will rotate with the flange 30A but can move axially toward housing 25 under spring load. The spring acts as an axially flexible, rotationally driving member. The structure is a conventional flexible coupling and the coupling springs used for driving the armatures of each brake assembly herein are supplied with the brakes when purchased from a supplier.
The housing 25 houses a coil 25A, which, when energized, magnetically locks the housing 25 and armature together to prevent rotation of hub 30 relative to the brake housing 25. The armature is magnetically clamped against a matching steel plate.
The hub 30 has a gear housing 32 fixed thereto on the end opposite from flange 30A. The shaft 23 passes into the interior of the gear housing 32 and has a gear 65 driveably mounted thereon, as will be explained.
A thrust bearing 26 is positioned between the end of the brake housing 25 and a drive sprocket 27 which is drivably mounted on shaft 23. Sprocket 27 comprises a typical rotating encoder drive means to provide signals indicating position of the shaft 23. A nut 28 threads onto the shaft 23 to permit adjustment. The hub 30 and the gear housing 32 are prevented from rotating relative to the sleeve 23 when the brake 24 is energized. The brake housing 25 is fixed to the sleeve 13 with a flange 25B that fastens to the end of the sleeve.
The brake assembly shown at 24 is a conventional commercially available unit. The KEB-E brake, Model 02.320 made by Karl E. Brinkmann GmbH, Forsterweg, West Germany, is satisfactory. Other types of brakes or locks may be used as well.
At the top of the sleeve 13 a main shoulder pivot assembly illustrated generally at 36 is rotatably supported on the hub 30 and through the bearing of the brake assembly to sleeve 13. The shoulder assembly 36 is used for supporting and driving an upper arm tube 37 about the axis 40A of a generally horizontal pivot shaft 40 that is perpendicular to the axis 21. Upper arm 37 is a tube which has a support assembly at its lower (outer) end for supporting a forearm assembly 38, with a wrist assembly 39 at the outer end of the forearm.
The shoulder assembly 36 includes drive gearing for controlling rotation of the upper arm tube 37 about its longitudinal axis 37A, which is perpendicular to the axis 40A and for driving the gear housing 32 about the neck and axis 21. The vertical axis 21 or neck axis and axis 40A are perpendicular to each other and intersect to form a reference plane. The axis of upper arm tube 37 and the axis 40A also intersect.
A drive motor 43 is mounted on a support which moves about axis 40A with the upper arm tube 37. Motor 43 provides power to drive the forearm assembly 38 about the elbow pivot axis indicated generally at 44 as well as powering the motions of the wrist assembly. The elbow pivot axis is perpendicular to the longitudinal axis of the upper arm tube 37 and parallel to the axis 40A.
The gear housing 32 includes a pair of parallel plates 45 and 46 which are fixed to a base wall 47 of the gear housing 32. Base wall 47 is securely mounted on hub 30. The wall 47 and the gear housing 32 are free to rotate about the neck axis 21 when the brake 24 is released. The base wall 47 supports the gear housing 32 for rotation about neck axis 21. Shaft 40 is mounted on and extends between the plates 45 and 46 and does not rotate relative to the plates 45 and 46.
The upper arm tube 37 is carried on a support assembly 48, which includes a main mounting plate 49 that is positioned along one side of the gear housing 32, and specifically adjacent to the outer side of the plate 46. An annular thrust bearing 49A spaces plate 49 and plate 46. The plate 49 is connected to an L shaped yoke 50 that has a yoke base 51, and a support leg 52. The support leg 52 has a suitable bushing 53 and bushing 53 is mounted onto an outer end of the shaft 40, as can be seen in FIG. 2. The yoke base 51, which is at right angles to the support leg 52, spans across the ends of the plates 45 and 46. The plates 45 and 46 have rounded end surfaces, so that the yoke 50 can rotate around the axis 40A of the shaft 40.
A shaft 54 is rotatably mounted in suitable bearings 55 in the yoke base 51, and the shaft 54 has an axis that lies along the axis 21 when the yoke is in its position as shown in FIG. 2, and the axis of shaft 54 is coplanar with the axis 21 and the axis of shaft 54 intersects the axis 40A at the same point as where axis 21 intersects axis 40A. As the shaft 54 is moved with the yoke 50 around the axis 40A of the shaft 40 it moves in a plane with the axis 21. The plate 49 also will rotate about the axis of the shaft 40, and is mounted on the shaft with a suitable bushing 56. The shaft 40 has a retaining ring 57 at the end adjacent the bearing 56, and this retains a thrust bearing assembly 59 to hold the plate 49 on the shaft 40, and permits the plate 49 to rotate relative to the shaft 40.
At the other end of the shaft 40 there is an adjustment nut 60 threaded onto the end of the shaft and bearing against a suitable thrust bearing assembly 61 to provide for adjustment and for retaining the yoke 50 in position on the shaft, and also holding the support assembly 48 on the shaft.
It should be noted that the yoke base 51 is fixed to the plate 49 with suitable cap screws, and the plate 49 will rotate relative to an outer housing or cover 62 (removed in FIG. 1) that is positioned around the sleeve 13, the gear housing 32, and yoke 50. The shafts and bearings can be sealed in a suitable manner if desired. A thrust bearing 64 may be provided between the leg 52 of the yoke 50 and the plate 45.
Plate 47, which is the base of the gear housing 32, is mounted on the hub 30, and is fixed from rotation relative to the hub 30. The input shaft 23 is also rotatable relative to plate 47 on suitable bearings, and the end of the input shaft 23 on the interior of the plate 47 has the bevel pinion gear 65 drivably mounted thereon, and held in place with a suitable nut 65A. The bevel gear 65 drives a bevel gear 66 that in turn is rotatably mounted on the shaft 40. Bevel gear 66 is mounted with suitable bushings on the shaft 40, and a thrust bearing 67 is mounted between the base or hub of the gear 66 and the inner surface of the plate 45. For adjustment purposes, there are a plurality of threaded openings 70 into which set screws can be adjustably threaded to bear against the thrust bearing 67 and provide for gear backlash adjustment. There are access openings in the yoke leg 52 so that set screws in threaded opening ,70 can be accessed for adjustment.
The shaft 54 has a bevel gear 71 drivably mounted thereon, and a nut 72 is used for adjusting this gear. Likewise, a suitable thrust bearing 73 is used between the back side of the hub of gear 71 and the inner surface of the yoke base 51.
A second electric brake assembly 75 is mounted in a recess on the outer surface of the plate 46 forming part of the gear housing 32, and this brake 75 has a housing 76 fixed to the plate 46 with an annular metal ring 76B bearing against a snap ring 76C in a bore in housing 76. The ring 76B is held with cap screws which thread into the gear housing plate 46. The housing 76 may also be pinned to plate 46 to prevent rotation. An armature 77 is coaxially mounted with the housing 76. The armature 77 is coupled to the mounting plate 49 for the support assembly 48 with an annular spring 77A forming a flexible coupling so the armature and plate 49 will be in annular driving relationship to each other, but the armature can move axially relative to plate 49. When the brake 75 is energized in a conventional manner, a coil 76A in housing 76 will form a magnetic field to clamp the armature 77 tightly to the housing 76 and prevent rotation of the plate 49 relative to the housing 76 and gear housing 32 and therefore relative to shaft 40. A KEB brake model 02.130 made by Karl E. Brinkmann, GmbH of Forsterweg, West Germany, is satisfactory for use.
The shaft 40 provides support for the entire arm assembly including the upper arm tube 37, and the rest of the components attached to it.
The plate 49 has a motor mounting plate 48A attached thereto and extending alongside the sleeve 13, and this is for mounting the motor 43, and includes a support 49B as shown. Additionally, the arm support has an annular hub 78 adjacent to the end of the plate 49, and extending at right angles thereto. The hub 78 has a central opening for supporting the upper arm tube 37, as shown, and a plurality of rollers 79 are mounted in provided pockets on the hub 78, and these rollers in turn then roll against a inner bearing race 80 that surrounds and is fixed to the upper arm tube 37 with suitable screws. The race 80 will rotate on the rollers 79, which comprise a bearing support, that gives adequate support for permitting the tube to rotate. A large circular roller bearing could also be used.
At the inner or back end of the upper arm tube 37, a support ring 81 is fixed to the plate 49. The ring 81 supports an electromagnetic brake assembly 82 which includes a hub 82A, a housing 82C and an armature 82B mounted with an annular spring member 82D to a radial flange formed on hub 82A. The armature rotates with the hub 82A but can move axially a short distance. When the brake 82 is energized, a coil 82E acts to clamp the armature to the housing 82C and the hub 82A will be held from rotation relative to housing 82C.
Bearings 83 are provided on the interior of the hub 82A for rotatably mounting a shaft 84 which extends through a bore in the hub 82A. An end closure plate 85 is positioned on the interior of the upper arm tube 37 forming the upper arm and is fixed to the tube 37. This end plate 85 is also fixed to the end of hub 82A, and thus the end of the upper arm tube 37 is supported on the hub 82A and through a large bearing to the brake housing 82C. The upper arm tube is thus supported for rotation relative to the ring 81 and the plate 49.
When the brake 82 is energized the upper arm tube 37 is prevented from rotation about its axis, but when the brake 82 is deenergized, the upper arm tube 37 can rotate on the rollers 79 and on the bearing forming part of the brake assembly 82. The brake 82 is the same construction as brake 24.
It can thus be seen that rotation of the support assembly 48 and the upper arm tube 37 about the shoulder pivot axis 40A, which is the axis of the shaft 40, will depend upon the condition of the brake 75, which, when energized, will prevent such rotation. The ability to rotate the upper arm tube 37 about its longitudinal axis will depend upon the state of the brake assembly 82. When the brake 82 is energized the upper arm tube 37 cannot rotate about its axis.
The upper arm tube 37 may be driven rotationally about its axis while supported on the rollers 79 and the hub 82A through the use of a chain and sprocket drive assembly 88. This includes a sprocket 89 which is drivably mounted onto the shaft 54, which is on the yoke base plate 51. Suitable thrust bearings can be used behind the sprocket 89. A sprocket 90 is drivably mounted onto the upper arm tube 37 between the plate 78 and the brake 82. This sprocket 90 has a large center bore so that it slips over the upper arm tube 37 and it is fixed with respect to the upper arm tube 37. Then, a chain 91 drives between these two sprockets, through provided openings in the plate 49 (shown in dotted lines) so that when the shaft 54 is driven and brake 82 is released, the upper arm tube 37 can be rotated, which will in turn also rotate the forearm 38 and wrist 39.
Thus, in summary, brake 24, when energized, will prevent rotation of the hub 30 and plate 47 and thus the gear housing 32 relative to the main support sleeve 13, and when released will permit such rotation; when brake 75 is energized it will prevent rotation of the plate 49, and thus the housing 48 which supports the upper arm, about the axis 40A of shaft 40, and when released will permit such rotation; and brake 82, when energized, will prevent rotation of the upper arm tube 37 about its longitudinal axis, and when released will permit such rotation.
A suitable slip ring indicated generally at 92 is provided on the underside of the plate 47 of the gear housing 32, to carry control signals for the various brake members, including those which are provided in the arm assembly. The slip ring 92 of course will have suitable contacts acting against it, which contacts will be mounted on the sleeve 13 in a conventional manner.
The shaft 84, which is driven from the motor 43 has its inner end, on the interior of the upper arm tube 37, drivably coupled to a drive shaft 95. A suitable coupling shown at 96 can be used for making this drive connection, and it is made so that it is adjustable and will telescope in longitudinal length if there is a slight shift in position. The drive coupling can be any conventional design, so that whenever the motor 43 is powered the shaft 95 will rotate. It can be seen that the tube 37 can be rotated independently of the shaft 95, and that the shaft 95 does not power any components in the shoulder assembly. Shaft 84 is hollow, so that suitable air lines can be provided through the center of the shaft and through the center of the drive shaft 95, which is tubular to other parts of the robot arm assembly.
The motor 20 provides for control of motion of the complete arm assembly about the axis 21 and drives through the gears 65, 66 and 71 as controlled by the brakes 24 and 75. The motor 20 drives bevel gear 65, which in turn drives the ring gear 66 that is rotatably mounted onto shaft 40 and which gear meshes with gear 71.
Encoders are utilized for determining the rotational position of the shaft 23, as well as the rotational position of assembly 48 about shaft 40 and the rotational position of shaft 84. The amount of rotation of the upper arm tube 37 also can be determined by sensing the rotation of shaft 23 through resolver drive sprocket 27 by simultaneously sensing which electric brake or brakes are energized.
When the magnetic brake 82 is energized it will hold the hub 82A from rotation relative to ring 81 and prevent rotation of the upper arm tube 37. When this rotation is prevented, and the electromagnetic brake 75 is released with brake 24 energized, the shaft 54 and gear 71 can rotate relative to the gear housing 32, and the gear 65 will cause the gear 66 to rotate and this will drive the plates 46 and 47, and all the connected parts, including the arm 37 and connected parts about the axis 40A for forming the shoulder pivot or rotation of the arm.
When the tube 37 is to be rotated, brake 82 is released, so that the tube 37 and hub 82B can rotate and the brakes 24 and 75 are also energized. Then the gear 66 will be rotated by the drive gear 65, which in turn will rotate the gear 71, driving the shaft 54 and sprockets 89 and 90, thereby rotating the upper arm tube 37 about its axis.
When both brakes 75 and 82 are energized and brake 24 is released, driving the motor 20 will cause the entire arm assembly to rotate about the vertical axis 21 because as gear 65 is rotated, gears 71 and 66 are prevented from rotating. The gear housing 32 will be driven around the axis of gear 65.
Table I is a summary of action occurring when the operable combinations are in effect.
TABLE I______________________________________ Result when motor 20Brakes 24 75 82 is powered______________________________________ X O X Arm rotates about 40A O X X Arm rotates about 21 X X O Rotates 37 about its axis______________________________________ X = locked O = Open
ELBOW ASSEMBLY
The elbow assembly controlled at elbow axis is driven operated from the motor 43 and operated by the shaft 95, and is shown in FIGS. 1 and 3.
The elbow assembly 119 has a pair of side plates 120,120 which carry counterweights 121 at the outer ends of the plates. The side plates are used for supporting the forearm assembly 38 in a suitable holding bracket, and as can be seen in FIG. 3, the lower or outer end of the upper arm tube 37 has a block 122 therein which is fixed to a housing 123. The housing 123 has a first side plate 124, and a second side plate 125 which are fixed to a base 126 of the housing. The walls 124 and 125 mount the elbow axis shaft 130. The mounting plates 120 are mounted in suitable bearings at 131 on the shaft 130.
The plates 124 and 125 of the housing 123 are spaced apart at the outer end portion shown at to provide for pivotal movement of the forearm 38 relative to the housing.
The wall 124 is made to mount an electromagnetic brake 135, with the brake housing 135A attached to the wall plate 124 in a provided recess. Cap screws pass through openings in a collar 135C and are threaded into wall 124 and bears against a snap ring in the housing 135A to hold the housing 135A clamped in position. The housing 135A is also pinned to the wall 124 to prevent rotation. A brake armature 135B is drivably mounted in a suitable recess in the one side plate 120 through an annular flexible coupling spring 135D that permits axial movement, so that when the magnetic brake assembly is energized, the brake holds that side plate 120 from rotation relative to the housing 123. When the brake 135 is released, the side plates 120 can rotate relative to housing 123 about elbow axis 44, which is the axis of shaft 130.
The lower or outer ends of the side plates 120 are bolted to a mounting block 136 that has an annular hub 137 fixed thereto on which a tube 138 is fixedly mounted. The tube 138 is the tube forming the forearm 38.
The block 136 is spaced from the outer ends 140 of the housing walls 124 and 125, so that the side plates 120 are able to move about the elbow axis 44, which is the axis of the shaft 130. As the block 136 moves around the axis 44 the tube 138 will also move about this axis.
An input bevel drive gear 145 is drivably mounted on the shaft 95. A thrust bearing 146 is used between gear 145 and wall 126. The shaft 130 has a bevel gear 147 rotatably mounted thereon. Gear 147 engages the gear 145. The shaft 95 is tubular, so that air conduits can be passed through the shaft 95. The base wall 126 of housing 123 and the mounting block 122 have bearings for supporting the shaft 95.
Block 136 has suitable bearings or bushings 150 therein which in turn rotatably mount a shaft 151, which has an end positioned between the side wall plates 124 and 125 of the housing 123. A suitable thrust bearing 152 is mounted over the shaft to back up and position a bevel gear 153 that is drivably mounted onto the shaft 151 and engages the bevel gear 145. The thrust bearing 152 reacts thrust loads from the bevel gear 153 onto the block 136. Because the block 136 is held with the side plates 120 through the use of suitable bolts such as that shown at 155, and the shaft 130 holds the side plates 120 in place, the gear 153 will be driven by bevel gear 147 whenever the bevel gear is rotating, and the shaft 151 is free to rotate.
The brake 135 when energized will hold the forearm assembly 38 from pivoting, and thus hold the side plates 120 in a fixed rotational position. Holding shaft 151 from rotation (with brakes in wrist assembly 39) while releasing the brake 135 so that plates 120 can rotate, will permit changing the angular position of the forearm assembly about the elbow axis 44.
The shaft 151 does not have to be hollow, because air lines and the like can come out from the shaft 95 in the elbow assembly and then pass through provided openings in the block 136 into the interior of the tube 138, and then carried on down to the wrist assembly 39.
WRIST ASSEMBLY
The wrist assembly 39 is shown in FIG. 4 in detail, and it can be seen that the forearm tube 138 is fixed to an outer sleeve housing 170, and housing 170 in turn has an electromagnetic brake 171 mounted at the interior end thereof and fixed relative thereto. This is a conventional electromagnetic brake similar to brake 24 having an annular coil housing 172 for housing the energization coil 172A. Housing 172 is held in place on the housing 170 with a flange 172B attached to the end surface of sleeve housing 170, and a hub 173 of the brake 171 is mounted through a suitable bearing 174 relative to the housing 171. The hub 173 has an annular flange plate 175, which, when the brake is energized, will be held relative to the housing 171 through an armature ring 175A which is attached to the flange 175 through an annular spring 175B that provides a rotational drive between the flange 175 and the armature 175A but permits the armature 175A to move axially to be magnetically held on the housing 172 when coil 172A is energized and thus lock the brake.
When the brake 171 is not energized the hub 173 will be free to rotate on the bearing 174 relative to housing 172.
The shaft 151, which extends through the interior of the tube 138, has a drive coupling end indicated generally at 176 thereon which in turn drives a first or input wrist drive shaft 177. Drive shaft 177 is rotatably mounted on the interior hub 173 of the brake 171 on suitable bearings 180.
A mounting flange 181 is drivably mounted on the inner end of brake hub 173. The drive shaft 177 passes through an opening in flange 181. The flange 181 forms a base for a gear housing 182 that includes a pair of generally parallel plates 183 and 184 mounted on the flange 181 to form a space therebetween. Housing 182 is the wrist drive and support housing and on the interior of the housing there is a drive bevel gear 190 drivably mounted onto the shaft 177.
A thrust bearing 187 is used between a nut 187A on shaft 177 and flange 175 and thrust bearing 188 is between gear 190 and plate 181. A nut 188A holds the gear 190 on shaft 177 and permits adjustment of the bearing loads. The plates 183 and 184 in turn retain a cross shaft 191 that is at right angles to the axis of the shaft 177, and is nonrotatably mounted in the plates 183 and 184. Shaft 191 has a bevel gear 192 rotatably mounted thereon, which meshes with the gear 190 as shown to form a right angle drive. Bevel gear 192 is backed with a thrust bearing 193 which is backed up on the backside of the gear 192 through the use of adjustable set screws 194 threadably mounted in the plate 193. On the opposite plate 184, a coil housing portion 195 of an electromagnetic brake assembly 189 is mounted in place on the plate 184 through the use of cap screws 196 acting through a collar and threaded into plate 184 to bear against a snap ring. The brake 189 is the same construction as brakes 135 and 75.
The shaft 191 has a wrist joint yoke 200 rotatably mounted thereon. This wrist joint yoke 200 includes a side plate 201 rotatably mounted on one end of the shaft 191 through the use of a bearing 202, and a plate 203 that is rotatably mounted on the opposite end of the shaft 191 through the use of a bearing 204. Plate 203 is held spaced from the plate 183, and parallel thereto, and a suitable thrust bearing 205 can be utilized in wall 203 for taking any thrust loads. The plates 201 and 203 are supported on a base plate 206 shown at the right end in FIG. 4.
A brake armature ring 210 of the electromagnetic brake member 189 is mounted with an axially movable, rotationally driving, flexible coupling spring ring 211 to the plate 201. When the coil 195A of brake 189 is energized, the plate 201 is held from rotation through the brake armature 210 which is clamped against the housing 195 under magnetic force. The plate 201 is also held from rotation about the shaft 191. Brake 189 and brake 171 will provide for control of movement of the wrist as will be explained.
The end or base plate 206 of wrist joint assembly 200 has hub section 216 fixed thereon which extend outwardly from the plate and which rotatably mount a shaft 217 in suitable bearings 218. The shaft 217 has a bevel gear 220 drivably mounted thereon and positioned between plates 183 and 184. A suitable thrust bearing 221 is used to back the gear 220. The gear 220 drivably engages the gear 192.
The opposite end of the shaft 217 extends outwardly from the hub portion 216, and has a flange 223 drivably mounted to its end surface. A brake plate 222 is in turn mounted on the flange 223. The plate 223 carries the armature 228 of an electromagnetic brake 225. The armature 228 is driveably coupled to plate 222 through an annular flexible coupling spring 229 which permits axial movement of the armature but which drives rotationally. A brake housing 230 is fixed to the plate 206 with suitable cap screws 231. A thrust bearing 224 is provided between plate 223 and the outer hub portion 216. When coil 230A of brake 225 is energized the plate 222 will be held from rotation because the armature 228 will be pulled against the housing portion 230 by magnetic force and held clamped together. Brake 225 is the same as brake 189 except the housing has a mounting flange 230B for attaching the housing to the plate 206.
A suitable slip ring assembly illustrated generally at 240 near the plate 181 is provided carrying electrical connections that are necessary for operation of the electromagnetic coils that are in the brake portions 195 and 230, so the control for such brakes is back at a central controller.
A suitable tool or grip can be mounted onto the plate 222, and perform the functions necessary for robots. These grips can be conventional, and include automatic tools or the like.
When the brakes 171, 189 and 225 are energized, the shaft 151 will be held from rotation, and this will provide the braking action necessary so that when the input shaft 95 is rotated, and the brake 135 (in the elbow, see FIG. 3) is released, the forearm assembly 38, including the wrist assembly 39 will be forced to rotate, through the driving of gear 145 and 147, about the axis 44 of shaft 130 in the elbow.
When the elbow brake 135 is energized, and shaft 95 is rotating, with the brake members 171 and 189 energized and the brake member 225 deenergized, the shaft 151 will be driven by rotation of the gear 145, 147 and gear 153. This in turn will drive the shaft 177, gear 190, gear 192 and gear 220 to rotate the shaft 217 and rotate the tool held on the plate 222.
If the brake members 171 and 225 are energized, and the brake member 189 deenergized, with the brake 135 energized to hold the plates 120 in position, gear 190 again will be driven as shown, and this will rotate the gear 192, but because gear 220 is held from rotation by brake 225, the gear 192 will rotate and drive the gear 220 and the robot wrist yoke 200 about the axis shaft 191 and control movement about this axis.
With the brake member 171 deenergized, and the three brake members 135, 189 and 225 energized, rotation of the shaft 151 will cause the driving of gear 192 about the axis of the shaft 177, because there cannot be any other movement in the wrist and this will give full rotation of the wrist. Again, the slip rings 240 will accommodate this movement and still carry power to the brakes and also position signals from the movable parts.
The axes of movement of the wrist all intersect at a common point on the axis of shaft 191 so the actions are easily controlled. The gear drive and brakes operate reliably with a minimum of power sources.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention. | A robot assembly includes a support for mounting at least two arm portions and a wrist portion about an upright axis. The wrist has three axes of movement that are mutually perpendicular, and they are controlled by a single motor through an arrangement of electromagnetic clutches and gears so that one motor controls movement about all three axes of movement of the wrist. Additionally, gear drives are used for other movements on the robot arm to provide movement about seven independent axes in the arrangement shown with only two drive motors. | 1 |
FIELD OF THE INVENTION
[0001] This invention relates to filtration media that is made of nonwoven meltblown or spunbond fibers that are comprised of polybutylene naphthalate.
BACKGROUND OF THE INVENTION
[0002] Nonwoven webs of meltblown or spunbond fibers are frequently utilized as filtration media for utilization manufacturing filters for liquids and/or gasses. Such meltblown nonwoven webs can be made by a meltblowing process that involves extruding a thermoplastic resin through a row of closely spaced orifices to form a plurality of polymer filaments (or fibers) while converging sheets of high velocity hot air impart drag forces on the filaments and draw them down to microsized diameters. The microsized fibers are blown onto a collector screen or conveyor where they are entangled and collected, forming the integrated nonwoven web. The average diameter size of the fibers in the web typically ranges from about 0.5 microns to about 20 microns. The integrity or strength of the web depends upon the mechanical entanglement of the fibers as well as fiber bonding.
[0003] A wide variety of thermoplastic resins are known to be useful in manufacturing such meltblown and spunbond nonwoven webs for filtration media. These thermoplastic resins include polyamides, polyesters, polycarbonates, polyarylates, polyolefins, polyurethanes, polyethers, and polyacrylates. U.S. Pat. No. 6,322,604 reports that it is desirable for such filter media to be comprised of a thermoplastic polyester such as, polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polytrimethylene terephthalate. The selection of the particular polymer or polymers will vary with the intended application of the filter as well as other factors.
[0004] Meltblown nonwoven fabrics have been used in a variety of filtration applications. For instance, nonwoven webs of polyester fiber have been used in bag filters and vacuum cleaner filters as described in U.S. Pat. No. 5,080,702, U.S. Pat. No. 5,205,938, and U.S. Pat. No. 5,586,997. Nonwoven webs of polyester fiber have also been used for filtering biological fluids as described in U.S. Pat. No. 5,652,050.
[0005] One shortcoming of meltblown nonwoven fiber webs is that they often lack the strength and/or tenacity required for utilization in certain uses or applications. To overcome this problem one or more durable fabrics are sometimes laminated to the meltblown nonwoven fiber web to attain a laminate structure with improved overall characteristics. For example, U.S. Pat. No. 4,041,203 describes a nonwoven fabric-like material comprising a web of substantially continuous and randomly deposited, molecularly oriented filaments of a thermoplastic polymer having an average filament diameter in excess of about 12 microns and an integrated mat of generally discontinuous, thermoplastic polymeric microfibers having an average fiber diameter of up to about 10 microns. This nonwoven fabric-like material is reported to be useful as a sterile wrapper or containment fabric for surgical or other health care procedures and for used in garments and wipes. U.S. Pat. No. 5,667,562 describes a durable spunbond/meltblown nonwoven laminate structure which takes advantage of the filtration or barrier properties of the meltblown fabric and the improved strength and durability of the spunbond fabric.
[0006] While many nonwoven polyester fabrics exhibit excellent strength and durabilty, polyester meltblown nonwovens fabrics generally do not exhibit high strength and durability since the meltblowing process does not adequately draw the fibers so as to significantly promote crystallization of the polymer. Thus, it is likewise known in the art to improve the strength and durability of meltblown polyester materials by laminating a separate durable fabric thereto such as, a spunbond fiber web or other suitable supporting fabric. As a particular example, meltblown polyester nonwoven webs can be laminated with durable fabrics such as high strength polyester filaments. The polyester filaments have improved strength since they have undergone separate drawing steps which orient the polymer thereby improving the strength and tenacity of both the fibers and the fabric made therefrom. The meltblown fiber web and the drawn fibers may be thermally point bonded to one another. However, it should be noted that utilizing one or more support layers can significantly increase the overall cost of the laminate.
[0007] Multilayer laminates can offer excellent strength and durability. However, the means for permanently bonding the individual layers together can adversely impact the efficiency and service life of the filtration media. For instance, spunbond and meltblown nonwoven fiber webs are often thermally point-bonded. The bonded areas are highly fused areas which allow little, if any, penetration of the fluid to be filtered. Thus, the bond areas reduce the effective area of the filter and increase pressure drop across the filter media. In addition, use of adhesives and other bonding methods can likewise negatively impact filter efficiency and/or life. Thus, improved abrasion resistance and/or laminate integrity achieved in this manner often comes at the expense of overall permeability and/or filtration efficiency. Consequently, the ability to achieve such improved properties without sacrificing other desired attributes of the filter media has proven difficult.
[0008] It would be commercially beneficial to have a filter media that exhibits improved strength, durability, and filtration efficiency that can be manufactured with meltblown or spunbond fibers. The development of a nonwoven filter media that was resistant to organic liquids, such as gasoline, gasohol, kerosene, diesel fuel, jet fuel, motor oil and the like would be even more desirable.
SUMMARY OF THE INVENTION
[0009] This invention is based upon the discovery that polybutylene naphthalate resin (PBN) having an intrinsic viscosity which is within the range of 0.3 to 0.7 dl/g can be easily processed into a nonwoven web of meltblown or spunbond fibers that exhibit excellent characteristics for utilization in making filtration media, such as strength, durability and filtration efficiency. Additionally, such a nonwoven web of meltblown or spunbond fibers offers outstanding resistance to organic liquids, such as gasoline, gasohol, kerosene, diesel fuel, jet fuel, motor oil and the like. Filtration media manufactured utilizing such polybutylene naphthalate also offers excellent heat resistance, chemical resistance, acid resistance, alkali resistance, and hydrolysis resistance. The filtration media also offers outstanding capability to hold an electrostatic charge for extended time periods. This is a valuable benefit in manufacturing air filters since dirt in air carries an electrical charge.
[0010] The present invention more specifically discloses a filtration media that is comprised of a nonwoven web of fibers having an average diameter which is within the range of about 0.5 microns to about 35 microns, wherein the fibers are comprised of polybutylene naphthalate having an intrinsic viscosity which is within the range of 0.3 to 0.7 dl/g as measured in o-chlorophenol at 35° C.
[0011] The subject invention further reveals a filter comprising a rigid frame having a filtration media fixedly attached thereto, wherein the filtration media is comprised of a nonwoven web of fibers having an average diameter which is within the range of about 0.5 microns to about 35 microns, wherein the fibers are comprised of polybutylene naphthalate having an intrinsic viscosity which is within the range of 0.3 to 0.7 dl/g as measured in o-chlorophenol at 35° C. It is desirable for the frame to also be comprised of polybutylene naphthalate. This makes the filter more easily recyclable into other articles of manufacture that can be made employing polybutylene naphthalate. The polybutylene naphthalate utilized in making the frame can be identical to the polymer used in making the nonwoven web of fibers or it can be of a higher molecular weight.
[0012] The present invention also discloses a filter comprising: a frame having a nonwoven filter material fixedly attached thereto; said nonwoven filter material comprising (i) a first layer of polybutylene naphthalate microfibers having an average fiber size of less than about 8 micrometers and (ii) a second layer comprising polybutylene naphthalate fibers having fibers having an average fiber size in excess of 12 micrometers and wherein said second layer is autogenously bonded to said first layer, wherein said second layer has a basis weight of less than 34 g/m 2 , and wherein the polybutylene naphthalate has an intrinsic viscosity which is within the range of 0.3 to 0.7 dl/g as measured in o-chlorophenol at 35° C.
[0013] The subject invention further reveals a process for manufacturing filter media which comprises (1) extruding molten polybutylene naphthalate through a plurality of die capillaries as molten filaments into converging high velocity gas streams that attenuate the filaments to reduce their diameter to within the range of about 0.5 microns to about 35 microns, wherein the polybutylene naphthalate has an intrinsic viscosity which is within the range of 0.3 to 0.7 dl/g as measured in o-chlorophenol at 35° C., (2) collecting the filaments on a conveyor wherein they become entangled to form a nonwoven web, and (3) allowing the entangled nonwoven web to solidify to produce a nonwoven web of the filter media.
DETAILED DESCRIPTION OF THE INVENTION
[0014] In the practice of this invention filtration media and filters made with such media can be manufactured utilizing standard techniques with polybutylene naphthalate having an intrinsic viscosity which is within the range of 0.3 to 0.7 dl/g, as measured in o-chlorophenol at 35° C., being utilized to produce the meltblown or spunbond fibers employed in the filtration media utilized therein. For instance, the manufacturing techniques described in U.S. Pat. No. 5,273,565 and U.S. Pat. No. 6,322,604 can be employed in producing the meltblown or spunbond fibers that are employed in making the filter media and filters of this invention. It is, of course, necessary to substitute polybutylene naphthalate having an intrinsic viscosity which is within the range of 0.3 to 0.7 dl/g for the thermoplastic resins described in these conventional techniques. In any case, the teachings of U.S. Pat. No. 5,273,565 and U.S. Pat. No. 6,322,604 are incorporated herein by reference in their entirety.
[0015] The polybutylene naphthalate used in the practice of this invention has an intrinsic viscosity which is within the range of 0.3 to 0.7 dl/g as measured in o-chlorophenol at 35° C. and will more typically have an intrinsic viscosity which is within the range of 0.4 to 0.6 dl/g. The polybutylene naphthalate will have an intrinsic viscosity of at least 0.3 dl/g to provide the nonwoven web with sufficient strength to be useful as filtration media. On the other hand, the polybutylene naphthalate becomes difficult or impossible to meltblow into continuous fibers at intrinsic viscosities of greater than 0.7 dl/g.
[0016] The intrinsic viscosity of the polybutylene terephthalate is determined as follows. The viscosity, η, of a series of dilute solutions of the polybutylene naphthalate in o-chlorophenol at 35° C. is compared to that of the o-chlorophenol solvent, η 0 , by the equation:
η sp /c =((η−η 0 )/η 0 )/ c
wherein the specific viscosity, η sp , divided by the concentration, c, is termed the viscosity number. Intrinsic viscosity is defined as η sp /c at infinite dilution (zero concentration). Since η sp /c increases linearly as a function of concentration, it is possible to determine the value of η sp /c at infinite dilution by extrapolation to zero concentration.
[0017] The polybutylene naphthalate is generally prepared by reacting dimethyl 2,6-naphthalate with 1,4-butanediol through ester-interchange and polycondensation reactions. In this preparation, a third component or a mixture of third components in an amount of not more than 20 mole percent can be added before completion of the polycondensation. Suitable third components that can be utilized in the synthesis of the polybutylene naphthalate resin include dicarboxylic acids such as terephthalic acid, isophthalic acid, 2-methylterephthalic acid, 4-methylisophthalic acid, dichloroterephthalic acid, dibromoterephthalic acid, 5-sodiumsulfoisophthalic acid, naphthalate-2,7-dicarboxylic acid, diphenyldicarboxylic acid, diphenyl ether dicarboxylic acid, diphenylsulfonedicarboxylic acid, diphenoxyethanedicarboxylic acid or sebacic acid, hydroxy acids such as p-.beta.-hydroxyethoxybenzoic acid, fumctional derivatives of these acids, dihydroxy compounds such as ethylene glycol, diethylene glycol, propylene glycol, trimethylene glycol, hexamethylene glycol (tetramethylene glycol when the glycol component is hexamethylene glycol), decamethylene glycol, neopentylene glycol, cyclohexanedimethylol, hydroquinone, bis(β-hydroxyethoxy)benzene, bisphenol A, bis(p-hydroxyphenyl)sulfone, bis (p-β-hydroxyethoxy phenyl)sulfone, polyoxyethylene glycol, polyoxypropylene glycol, or polyoxytetramethylene glycol, or functional derivatives of these dihydroxy compounds. A compound having at least three ester-forming functional groups, such as glycerine, pentaerythritol, trimethylol propane, trimellitic acid, trimesic acid or pyromellitic acid, can also be incorporated in such quantities as will maintain the polymer in substantially linear polymer chains (that is to say, as will not cause cross-linkage). A monofunctional compound such as benzoic acid or naphthoic acid can also be incorporated in order to adjust the degree of polymerization of the polymer.
[0018] The polybutylene naphthalate used in this invention may also contain a delusterant such as titanium dioxide, a stabilizer such as phosphoric acid, phosphorous acid, phosphonic acid or an ester of any of these, an ultraviolet absorbent such as a benzophenone derivative or benzotriazole derivative, an anti-oxidant, a lubricant, a pigment or a filler. As the filler, other polymers such as polyethylene terephthalate, poly(ethylene-2,6-naphthalate), polytetramethylene terephthalate can also be used.
[0019] The polybutylene naphthalate used in accordance with this invention is typically comprised of repeat units that result from the condensation reaction of butylene glycol with naphthalene-2,6-dicarboxylic acid. Such polybutylene naphthalate is of the structural formula:
[0020] It is preferred for the filters of this invention to be comprised of at least two layers as depicted in U.S. Pat. No. 6,322,604. These layers include a first layer of fine fibers or microfibers and a second layer of larger fibers or macrofibers. The first layer is desirably a relatively thicker layer having a small average pore size and good filtration and/or barrier properties. The filter material is typically made in the form of a sheet and can readily be stored in roll form. Thus, the filter material can be subsequently converted as desired to provide a filter specifically tailored to meet the needs of the end user. However, the filter material can also be cut to the desired dimensions and/or shape as needed via in-line methods. The filter media of the present invention provides a meltblown fiber nonwoven web which exhibits good abrasion resistance without significantly degrading the strength and/or filtration properties of the same. The term “nonwoven” fabric or web means a web having a structure of individual fibers or threads which are interlaid, but not in an identifiable manner as in a knitted or woven fabric. Nonwoven fabrics or webs have been formed by many processes such as for example, meltblowing processes, spunbonding processes, hydroentangling, air-laying, carded web processes, and so forth.
[0021] The first layer desirably comprises a nonwoven web of fine fibers or microfibers having an average fiber diameter of less than about 8 micrometers and more desirably having an average fiber diameter between about 0.5 micrometer and about 6 micrometers and still more desirably between about 3 micrometers and about 5 micrometers. The first layer desirably has a basis weight of at least 12 grams/square meter (g/m 2 ) and more desirably has a basis weight between about 17 g/m 2 and about 175 g/m 2 , and still more desirably between about 34 g/m 2 and about 100 g/m 2 . Fine fibers can be made by various methods known in the art. Desirably the first layer comprises a nonwoven web of fine meltblown fibers.
[0022] Meltblown fibers are generally formed by extruding a molten thermoplastic material through a plurality of die capillaries as molten threads or filaments into converging high velocity air streams that attenuate the filaments of molten thermoplastic material to reduce their diameter. Thereafter, the meltblown fibers can be carried by the high velocity gas stream and are deposited on a collecting surface (collector screen) where they become entangled to form a web of randomly laid meltblown fibers. The collecting surface will preferably be a conveyor to facilitate continuous production of the meltblown fibers. Meltblown processes are disclosed, for example, in Naval Research Laboratory Report No. 4364, “Manufacture of Super-fine Organic Fibers” by V. A. Wendt, E. L. Boon, and C. D. Fluharty; Naval Research Laboratory Report No. 5265, “An Improved Device for the Formation of Super-fine Thermoplastic Fibers” by K. D. Lawrence, R. T. Lukas, and J. A. Young; U.S. Pat. No. 3,849,241; U.S. Pat. No. 4,100,324; U.S. Pat. No. 3,959,421; U.S. Pat. No. 5,652,048; and U.S. Pat. No. 4,526,733. The teachings of these references are incorporated by reference herein in their entirety for the purpose of teaching suitable methods for manufacturing nonwoven webs of polybutylene naphthalate fiber by meltblowing. The meltblown fiber layer can be formed by a single meltblown die or by consecutive banks of meltblown fiber dies by consecutively depositing the fibers over one another on a moving forming surface. Thus, although the term “layer” is used, one layer may in fact comprise several sublayers assembled to obtain the desired thickness and/or basis weight.
[0023] The macrofiber layer comprises larger fibers of sufficient number and size so to create an open structure having improved strength relative to the first fine fiber layer. Desirably the macrofiber layer has a significant number of fibers in excess of about 15 micrometers and still more desirably has a substantial number of fibers in excess of about 25 micrometers. In this regard, it is noted that the coarse fibers can comprise a plurality of smaller fibers having diameters between about 10 and about 35 micrometers and still more desirably an average fiber diameter of between about 12 micrometers and about 25 micrometers wherein the individual fibers “rope” or otherwise become length-wise bonded so as to collectively form large, unitary fibers or filaments. In calculating average fiber size, the length-wise bonded fibers are treated as a single fiber. The macrofiber layer desirably has a basis weight less than about 100 g/m 2 and more desirably has a basis weight between about 10 g/m 2 and about 70 g/m 2 , and still more desirably between about 15 g/m 2 and about 35 g/m 2 . In a further aspect, the basis weight ratio of the first layer of fine fibers to the second layer of macrofibers desirably ranges from about 2:1 to about 10:1 and in a preferred embodiment the ratio of the first layer of fine fibers to the second layer of coarse fibers is about 3.3:1.
[0024] The second layer of macrofibers can be made by meltblown processes and, desirably, the macrofibers can be deposited directly onto the fine fiber web in a semi-molten state such that the macrofibers bond directly and autogenously to the fine fiber web. The deposition of the macrofibers is such that they have sufficient latent heat to more effectively bond to each other as well as to the previously deposited fine fibers thereby creating a filter media having overall improved strength and/or abrasion resistance. Conventional meltblowing equipment can be used to produce such larger, coarse fibers by properly balancing the polymer throughput, diameter of the die tip orifice, formation height (i.e. the distance from the die tip to the forming surface), melt temperature and/or draw air temperature. As a specific example, the last bank in a series of meltblown fiber banks can be adjusted whereby the last meltblown bank makes and deposits a layer of macrofibers over the newly formed fine fiber nonwoven web. With regard to making larger thermoplastic polyester fibers, by reducing the primary air temperature and/or lowering the formation height, production of larger, coarse fibers is achieved. The thickness or basis weight of the macrofiber layer can be increased as desired by increasing the number of consecutive meltblown banks altered to provide larger, coarse fibers. It is noted that alteration of other parameters alone or in combination with the aforesaid parameters may also be used to achieve macrofiber layers and/or webs.
[0025] Methods of making such larger, coarse fibers are described in more detail in U.S. Pat. No. 4,659,609 and U.S. Pat. No. 5,639,541. The teachings of these references are incorporated herein for the purpose of describing suitable methods for manufacturing coarse fibers that are suitable for utilization in manufacturing the filters of this invention. Desirably, the macrofiber layer is deposited co-extensively with the fine fiber layer and adheres directly thereto. In this regard, it will be appreciated that the macrofibers are not significantly drawn and/or oriented nevertheless, since the macrofibers are deposited upon the fine fibers in a semi-molten state they form good inter-fiber bonds with the fine fibers as well as other coarse fibers and thereby provide a composite structure which has improved strength and resistance to pilling during handling, converting and/or use. Moreover, despite the formation of a layer having increased irregularity, polymeric globules and/or shot, the macrofiber layer forms an open structure that does not significantly decrease the filtration efficiency. It is possible and frequently advantageous to deposit more than one macrofiber layer on the fine fiber layer.
[0026] The multilayer nonwoven web of the present invention is autogenously bonded and does not necessarily require additional binding. The term “autogenous bonding” refers to inter-fiber bonding between discrete parts and/or surfaces independently of mechanical fasteners or external additives such as adhesives, solders, and the like. However, after the deposition of the layers, the layers can, optionally, be further bonded together to improve the overall integrity of the multilayer structure and/or to impart stiffness to the same. Whenever further bonding is desired it is preferred to employ a bond pattern affecting a minimal surface area of the material since filtration efficiency typically decreases as the bonding area increases. Thus, desirably the bond pattern employed does not bond more than about 10% of the surface area of the sheet and still more desirably the bond area comprises between 0.5% and about 5% of the surface area of the fabric. The multilayer laminate can be bonded by continuous or substantially continuous seams and/or discontinuous bonded regions. Preferably the multi-layered filter media materials are point bonded. As used herein “point bonded” or “point bonding” refers to bonding one or more layers of fabric at numerous small, discrete bond points. For example, thermal point bonding generally involves passing one or more layers to be bonded between heated rolls such as, for example, an engraved patterned roll and an anvil roll. The engraved roll is patterned in some way so that the entire fabric is not bonded over its entire surface, and the anvil roll is usually flat. Numerous bond patterns have been developed in order to achieve various functional and/or aesthetic attributes, and the particular nature of the pattern is not believed critical to the present invention. Exemplary bond patterns are described in U.S. Pat. No. 3,855,046, U.S. Design Pat. 356,688, and U.S. Pat. No. 5,620,779. These and other bond patterns can be modified as necessary to achieve the desired bonding area and frequency.
[0027] Meltblown filter laminates of the present invention are well suited for fluid filtration applications including liquid and gas filtration applications. The filter material will most commonly be employed as part of a filter assembly which can comprise the filter media, a flame and housing. As used herein the term frame is used in its broadest sense and includes, without limitation, edge frames, mesh supports, cartridges, and other forms of filter elements. The filter media will commonly be secured and/or supported by a frame. Often the frame is slideably engaged with the housing. The frame can be designed so as to be capable of being releasably engaged in the housing element such that the frame and corresponding filter media can be readily replaced as needed. As examples, the frame and/or housing can be adapted so that the frame can be manually rotated, screwed, bolted, snapped, slid or otherwise secured into position
[0028] The nonwoven filtration material can be used alone or as part of a laminate structure in combination with additional materials. As a particular example, the nonwoven fabric can be laminated with an additional filter material such as, for example, paper, other polyesters, membranes, battings, nonwovens, woven fabrics, cellular foams, and other filter and/or reinforcement filter material. Paper filter materials are available in a wide variety of grades and forms. As an example, the filter paper can comprise a cellulose-based paper containing a phenol-formaldehyde resin. The filtration efficiency of the filter paper can be modified as desired by selecting the amount and type of resin binders, cellulose fiber size or furnishings, processing parameters and other factors known to those skilled in the art.
[0029] In one embodiment of this invention polybutylene naphthalate fibers are used in conjunction with fibers of another polymer to make the nonwoven fiber web. For instance, such a nonwoven fiber web can contain fibers of polyolefins or other polyesters in addition to the polybutylene naphthalate fibers. Some representative examples additional fibers that can be used in making the nonwoven web include polypropylene fibers, polybutylene fibers, polyethylene terephthalate fibers, polyethylene naphthalate fibers, and polybutylene terephthalate fibers. The additional fibers will typically be polypropylene fibers or polybutylene terephthalate fibers. Such nonwoven fiber webs will normally contain from about 35 weight percent to about 95 weight percent polybutylene naphthalate fibers and from about 5 weight percent to about 65 weight percent fibers that are made from the other polymer. Such nonwoven fiber webs will typically contain from about 40 weight percent to about 90 weight percent polybutylene naphthalate fibers and from about 10 weight percent to about 60 weight percent fibers that are made from the other polymer. Such nonwoven fiber webs will more typically contain from about 50 weight percent to about 85 weight percent polybutylene naphthalate fibers and from about 15 weight percent to about 50 weight percent fibers that are made from the other polymer.
[0030] Melt blends of polybutylene naphthalate with other polyesters can also be utilized in manufacturing the nonwoven web of fibers. Some representative examples of other polyesters that can be blended with the polybutylene naphthalate include polyethylene terephthalate, polyethylene naphthalate, and polybutylene terephthalate. Polybutylene terephthalate is normally preferred for utilization in such blends. Melt blends of this type will normally contain from about 35 weight percent to about 95 weight percent polybutylene naphthalate and from about 5 weight percent to about 65 weight percent of the other polyester. Such melt blends will typically contain from about 40 weight percent to about 90 weight percent polybutylene naphthalate and from about 10 weight percent to about 60 weight percent of the other polyester and will more typically contain from about 50 weight percent to about 85 weight percent polybutylene naphthalate and from about 15 weight percent to about 50 weight percent of the other polyester.
[0031] The additional filtration material can be fixedly attached to the nonwoven filter media via one or more methods known to those skilled in the art. Desirably the paper filter is laminated to the nonwoven filter material via an adhesive. In this regard, the nonwoven material can be sprayed with an adhesive and then the paper filter and nonwoven filter superposed and pressed together such that they become permanently attached to one another. By applying the adhesive to the nonwoven the filtration efficiency of the paper filter material is not substantially degraded since only adhesive upon the fiber surface will contact the paper filter material thereby minimizing any loss in filtration efficiency. Alternately, the adhesive can be sprayed onto the filter paper and then the treated side of the filter paper and the nonwoven can be permanently attached to one another. In a particular aspect of the invention, depending on the grade of filter paper, the nonwoven/paper laminate can have a filtration efficiency of at least about 98% for 10 μ/m particles and in a further aspect can have a filtration efficiency of at least about 98% for 2 μm particles.
[0032] In some cases it is desirable for the filter media to be comprised of a fine fiber layer that is positioned between a macrofiber layer and a filter paper sheet. As a specific example, a paper filter sheet can be adhesively laminated to a 65 g/m 2 layer of fine fibers, comprising polybutylene naphthalate meltblown fibers, such that the paper filter adheres directly to one side of the fine fiber layer and the macrofiber layer adheres to the second or opposite side of the fine fiber layer. The macrofiber layer is also preferable comprised of polybutylene naphthalate and can have a basis weight of approximately 20 g/m 2 . The filter material of this configuration is particularly well suited for use as a coalescing filter such as used in diesel engines and marine applications. The laminate prevents passage of both water and particles while allowing fuel to pass therethrough. The nonwoven fabric of polyester substantially prevents passage of water through the media and as well as large particles. The paper filter media further filters finer particles from the liquid being filtered, such as motor oil or fuel. Coalescing filter media are commonly employed within a frame and housing located either upstream or downstream of the liquid hydrocarbon pump.
[0033] The filter material of the present invention can optionally include various internal additives and/or topically applied treatments in order to impart additional or improved characteristics to the nonwoven fabric. Such additives and/or treatments are known in the art and include, for example, alcohol repellence treatments, wetting agents (i.e. compositions which improve or make a surface hydrophilic), anti-oxidants, stabilizers, fire retardants, disinfectants, anti-bacterial agents, anti-fungal, germicides, virucides, detergents, cleaners and so forth.
[0034] Air filters such as those described in U.S. Pat. No. 5,273,565 can be manufactured utilizing polybutylene naphthalate in accordance with this invention. The teachings of U.S. Pat. No. 5,273,565 are incorporated herein by reference. The meltblown nonwoven web used in manufacturing such air filters typically has the following characteristics: (1) an average fiber size diameter of 3.0 μm to 10 μm, (2) a coefficient of variation of the web fiber size diameter of 15 percent to 40 percent, (3) a packing density of 5 percent to 15 percent, and (4) a ratio of packing density to average fiber size diameter of 1.3 to 1.75.
[0035] This invention is illustrated by the following examples that 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
[0036] Polybutylene naphthalate (PBN) that is suitable for use in manufacturing the filter media of this invention was synthesized in this experiment. A 50-gallon (189 liter) batch reactor with a helical agitator was employed in the synthesis of the PBN in this experiment. In the procedure utilized 42.3 kg 1,4-butanediol, 82 kg of dimethyl 2,6-naphthalate, and 19.34 g of tetra-n-butyl titanate were charged into the reactor while the reactor was purged with dry nitrogen. The reactor was heated to a temperature of 215° C. The ester-interchange reaction was considered to be complete when more than 95% of the theoretical methanol had been collected. Then, the reactor temperature was increased to 255° C. while the reactor pressure was gradually reduced to 0.1 mm Hg over a period of 50 minutes. The polymerization mass was agitated at 250-260° C. at a pressure of 0.04 mm Hg until a specific agitator torque was reached. The polymer melt mass was subsequently extruded and cut into pellets. About 90 kg of PBN having an intrinsic viscosity of 0.54 dl/g was obtained.
EXAMPLE 2
[0037] In this experiment the filtration efficiency of air filters made utilizing a nonwoven web of polybutylene naphthalate (PBN) and a blend containing 50 weight percent PBN and 50 weight percent PBT were compared to an air filter made utilizing a nonwoven web of polybutylene terephthalate (PBT) that was otherwise identical. The nonwoven webs utilized in manufacturing these filters were made by a meltblowing procedure that was operated utilizing the conditions shown in Table 1.
TABLE 1 Meltblow Parameter Setting DCD (Die to Collector 3-10 in (7.5 to 25 cm) for fine fiber Distance) diameter (0.5 to 3 micrometers) Quench Air As Necessary Output Up to 1.0 grams/hole/minute Extruder Profile Zone 1 250° C. to 260° C. Zone 2 260° C. to 270° C. Zone 3 270° C. to 285° C. Zone 4 285° C. to 290° C. Zone 5 290° C. to 295° C. Die Melt Temperature 295° C. to 310° C. Process Air Temperature 310° C. to 360° C. Process Air Flow Rate 1100-2400 lbs./hour (2420-5280 kg/hour) Conveyor Vacuum 10-20 inches (25.4-50.8 cm) of H 2 O Extruder Outlet Pressure 500-600 p.s.i. (3400-4100 kPa)
[0038] The air filters made were then evaluated to determine filtration efficiency. The filter media s made with the PBN, PBT, and the blend of PBN and PBT were tested for filter efficiency at three stages: (1) as made (uncharged), (2) after charging, and (3) after heat treatment of the charged media in hot air at a temperature of 130° C. for 1 hour. Table 2 reports the filter efficiency retention after exposure to the hot air treatment. The filtration efficiency retentions are reported as a percentage of the charged filter efficiency before being exposed to the hot air. The filtration efficiency of the filters evaluated was also determined in the uncharged state and after being charged. Table 2 also reports the ratio of charged heat-treated efficiency to uncharged efficiency.
TABLE 2 Condition 50%/50% PBN PBN/PBT Blend PBT Filtration Efficiency 83% 60% 44% Retention After Heat Treatment Ratio of Charged 3.42 1.46 1.17 Heat Treated Efficiency to Uncharged Efficiency
[0039] As can be seen from Table 2, the filter made with the PBN nonwoven web retained a much higher of filtration efficiency after the heat treatment process than did the filter made with the PBT nonwoven web. It should also be noted that the filter made with the PBN nonwoven fiber web also exhibited a much higher ratio of charged to uncharged filtration efficiency after being subjected to the heat treatment procedure. This experiment accordingly shows the unexpected benefit that PBN offers over PBT in making nonwoven fiber web for air filters.
[0040] The filter made with the blend of PBN and PBT also offered improved filtration efficiency over the filter made using pure PBT. Accordingly, this experiment also shown that blends of PBN and PBT can be used in making nonwoven fiber webs for air filters for use in less demanding applications.
EXAMPLE 3
[0041] In this experiment PBN was evaluated to determine its resistance to various fuels and was compared to the fuel resistance of PBT. In the procedure used PBN and PBT was injection molded into tensile test bars. The tensile test bars were then soaked in various fuels at 65° C. for either 2000 hours or 5000 hours. The yield strength and modulus of the PBT and PBN test bars were then determined and are reported in Table 3 and Table 4, respectively.
TABLE 3 Fuel A Fuel B Fuel C Fuel D % % % % Soak Time Retention Retention Retention Retention Hours at Yield Yield Yield Yield Polymer 65° C. Strength Strength Strength Strength PBN 2000 109 82 102 107 5000 105 12 88 95 PBT 2000 73 59 61 69 5000 43 53 63 71
[0042]
TABLE 4
Fuel A
Fuel B
Fuel C
Fuel D
Soak Time
%
%
%
%
Hrs, at
Retention
Retention
Retention
Retention
Polymer
65 C.
Modulus
Modulus
Modulus
Modulus
PBN
2000
107
83
95
109
5000
104
1
89
102
PBT
2000
26
15
16
19
5000
10
22
20
23
[0043] Soak Fuels:
1) Fuel A: 50% Toluene+50% Isooctane, 2) Fuel B: Fuel “A”+15% Methanol+Aggressive Water 3) Fuel C: Fuel “A”+22% Ethanol+Aggressive Water 4) Fuel D: Fuel “A”+85% Ethanol+Aggressive Water
The water used in this series of experiments was deemed to be “aggressive” by virtue of the fact that it contained peroxides.
[0048] As can be determined from Table 3, the PBN test bars exhibited good resistance to ethanol based fuels. In fact, the resistance of the PBN to ethanol based fuels proved to be superior to that of PBT after being soaked in the fuel for either 2000 hours or 5000 hours. This experiment shows that PBN offers good fuel resistance for utilization in fuel filters that are used for filtering ethanol based fuels.
[0049] While certain representative embodiments and details have been shown for the purpose of illustrating the subject invention, it will be apparent to those skilled in this art that various changes and modifications can be made therein without departing from the scope of the subject invention. | This invention is based upon the discovery that polybutylene naphthalate resin (PBN) having an intrinsic viscosity which is within the range of 0.3 to 0.7 dl/g can be easily processed into a nonwoven web of meltblown or spunbond fibers that exhibit excellent characteristics for utilization in making filtration media, such as strength, durability and filtration efficiency. Additionally, such a nonwoven web of meltblown or spunbond fibers offers outstanding resistance to organic liquids, such as gasoline, gasohol, kerosene, diesel fuel, jet fuel, motor oil and the like. Filtration media manufactured utilizing such polybutylene naphthalate also offers excellent heat resistance, chemical resistance, acid resistance, and alkali resistance. The present invention more specifically discloses a filtration media that is comprised of a nonwoven web of fibers having an average diameter which is within the range of about 0.5 microns to about 35 microns, wherein the fibers are comprised of polybutylene naphthalate having an intrinsic viscosity which is within the range of 0.3 to 0.7 dl/g as measured in o-chlorophenol at 35° C. | 3 |
This application is a continuation of application Ser. No. 762,463 filed Aug. 5, 1985, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to method and apparatus for preparing the end of a coaxial cable for termination.
Coaxial cable of the type comprising a signal conductor, a surrounding layer of primary insulation, a braided shield, and an outer insulative jacket is well known. Such cable is typically terminated to a coaxial terminal of the type described in U.S. Pat. No. 3,323,098 and sold by AMP Incorporated as its COAXICON contact. Such contacts have a pin or socket portion which is terminated to the signal conductor and an outer tubular metal shell which is terminated to the braided shield. Before termination, the cable must be prepared by stripping the outer jacket to a second distance from the end of the cable to expose the shield, and stripping away the shield to a first distance less than the second. Additionally, the signal conductor must be exposed toward the end and the shield must be flared to facilitate termination.
U.S. Pat. No. 3,555,672 discloses apparatus and method for accomplishing a coaxial cable termination as described above. According to the method, two sets of blades engage the cable simultaneously at the first and second distances from the end, and are rotated about the cable to cut through the outer insulation and braid at said first distance and to cut the outer insulation at said second distance. The cable is then withdrawn while both sets of blades remain engaged, and the outer insulation between said second distance and said end and said braid between said first distance and said end are removed as a unit. The exposed primary insulation is subsequently cut circumferentially between the first distance and the end and the slug of primary insulation is pulled off to expose the signal conductor. The shield is then flared by gripping the end of the signal conductor and twirling it, the outer jacket being firmly clamped proximate the exposed shield. Alternatively, the end of the primary insulation is gripped and twirled prior to stripping, and the slug is subsequently cut and stripped. Either way, the rotary motion of the primary insulation imparts a flare to the shield.
The above described method works well enough where the primary insulation is polyethylene or other relatively hard material. Recently, however, foamed tetraflouroethylene (TFE), sold under the trademark Teflon by DePont Corporation, has seen increased use due to its good dielectric properties. W. L. Gore & Associates, Inc., makes a coaxial cable for foamed TFE primary insulation, which is in the form of a continuous strip helically wrapped about the signal conductor. TFE insulation is difficult to cut, though, which causes several problems if the cable is prepared by known methods. In order to completely sever the shield, it is necessary for the blades which cut it to penetrate the primary insulation. If the blades making the first cut remain engaged while the outer insulation and braid are removed from TFE primary insulation, the blades will pull the helical wrap out of the shield. An additional problem is the difficulty in cutting completely through TFE primary insulation without severly scoring the signal conductor; an incompletely severed slug likewise leads to pulling out the helical wrap.
SUMMARY OF THE INVENTION
According to the invention, a method for preparing coaxial cable involves first making the circumferential cut at the first distance, then withdrawing the cutting blades before engaging a second set of blades to make the cut at the second distance, which cut is not sufficiently deep to impinge the braided shield. The cable is then withdrawn while the second blades remain engaged, thus removing the slugs of secondary insulation and braid as a unit. Since the TFE primary insulation is "slippery", and not impinged by any blades, the helical wrap remains intact.
According to another aspect of the invention, the method for preparing coaxial cable for termination as descrribed above is further characterized by compressing the primary insulation to expose the signal conductor. This is accomplished by axially aligning a tubular tool with the end of the cable, the tool having an inside diameter just sufficient to accommodate the signal conductor. The tool and the cable are then moved relatively axially together to compress the primary insulation toward the shield as the signal conductor is received in the tool.
According to yet another aspect of the invention, the braided shield is initially flared after removal of the secondary insulation and braid by clamping the outer insulation adjacent the exposed shield and rotating a tool against the cable about a circumferential path. If the tool is rotated against the exposed shield, it compresses the insulation underneath to flare the shield to a generally conical configuration. If the flaring tool is rotated against the exposed primary insulation, the axis of the cable must be displaced, twirling the end, to impart the flare. Additional flaring is provided by compressing the primary insulation as described, and further by a second, conically nosed tubular tool slidable coaxially over the first tool.
The inventive flaring method is advantageous compared to the method described in U.S. Pat. No. 3,555,672 insofar as less stress is imposed on the signal conductor, and the apparatus is simpler.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A to 1C are sequential schematics showing cutting of the braid.
FIGS. 2A to 2D are sequential schematics showing the cutting of outer insulation.
FIG. 3 is a partial side view of the radial braid flaring tool and clamp.
FIG. 3A is a schematic end view of the braid flaring operation.
FIG. 4 is a side view of an alternative radial braid flaring scheme.
FIG. 5 is a partial top view of the axial tooling and clamp.
FIG. 5A is an end view of the vee guides.
FIG. 6 is a partial top view of the axial tooling as it engages the cable.
FIG. 7 is a partial side view of the axial tooling as it fully compresses the primary insulation.
FIG. 8 is a partial side view of the axial tooling as it die forms the braid.
FIG. 9 shows the retreat of the axial tooling.
FIGS. 10-13 show the terminal application sequence.
FIG. 14 is a side view of the radial braid flaring apparatus.
FIG. 15 is a perspective of the radial braid flaring apparatus.
FIG. 16 is a top section view of the axial tooling.
FIG. 17 is an end section view of the vee guide actuating mechanism.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1A depicts a coaxial cable 2 inserted between a first pair of opposed hinged blades 10 of a rotary wire stripper. The stripper is of the type described in U.S. Pat. No. 3,361,016, which is hereby incorporated by reference. Referring to FIG. 1B, the blades 10 are hinged down and rotated about the axis of cable 2 to make a first circumferential cut 12 through the outer or secondary insulation 8 and braided shield 6 (FIG. 2D) at a first distance from free end 3 of the cable 2. Subsequently, the blades 10 are hinged apart and the cable 2 is removed, as shown in FIG. 1C. The cable 2 is then inserted between the hinged apart blades 14 of a like wire stripper (FIG. 2A), which blades 14 are hinged down and rotated to make a second circumferential cut 16 in the insulation 8 at a second distance from free end 3 (FIG. 2B). The cable 2 is then withdrawn while the blades 14 are hinged down to remove the slugs of insulation and shield as a unit (FIG. 2C) to leave the inner or primary insulation 5 and shield 6 exposed (FIG. 2D). The first blades 10 are set to cut more deeply than the second blades 14, so that the first cut 10 achieves circumferential severing of the braided shield 6 by slightly penetrating primary insulation 5, while the second cut affects only the outer insulation 8. Since the primary insulation 5 is helically wrapped, it is important that blades 10 be removed before attempting to pull free the outer slugs, otherwise the TFE would be pulled from within the braid. The blades 14, though, needn't penetrate shield 6 as any incompletely severed insulation 8 will readily pull free.
Having prepared the cable 2 as shown in FIG. 2D, a crimp ferrule 18 is slid onto outer insulation 8 and the cable is clamped as shown in FIG. 3, the ferrule 18 being received in a cavity 45 formed by clamps 44, 46. A wheel 40 freely journaled to the end of arm 35 is brought into interfering contact with exposed braid 6 and rotated therearound. Since the primary insulation 5 is foamed TFE, it compresses readily, allowing the braid 6 to flare. FIG. 3A shows the flaring operation from the end. FIG. 4 shows the alternative braid flaring method, where wheel 40 contacts the primary insulation 5 of cable 2 beween the braid 6 and free end 3, substantially displacing the cable laterally of its axis during rotation to flare the blaid 6 as shown. This alternative method is suitable also where the primary insulation 5 is relatively incompressible.
After braid flaring, the cable 2 is removed from the clamps 44, 46 and then clamped between upper cup clamp 89 and lower cup clamp 91, the ferrule 18 being received in cavity 90 formed thereby (FIG. 5). The cup clamps 89, 91 form a conical mouth 92 about the flared braid 6. The cable 2 is captured between V-guides 68 toward free end 3, assuring positive axial alignment thereof with compression tube 83, which is mounted to slide coaxially in flare tube 85. Referring to the end view of FIG. 5A, the axial centering of the signal conductor 4 by V-guides 68 is apparent. Being so centered, the conductor 4 is readily received in compression tube 83, as shown in FIG. 6. The inside diameter of tube 83 is just sufficient to accommodate the signal conductor 4, so that the tube 83 axially compresses the foamed TFE primary insulation 5 therearound. The V-guides 68 are then withdrawn and the tube 83 is advanced to further compress the insulation 5, as shown in FIG. 7.
Referring to FIG. 8, the flare tube 85 is then advanced coaxially over the compression tube 83. The flair tube 85 has a conical nose which further flares the exposed portion of braided shield 6 and ultimately die forms it in cooperation with conical mouth 92 of the cup clamps. This advance also axially compresses the foamed TFE primary insulation 5 to substantially its original diameter. The tooling 83, 85 is then withdrawn, as shown in FIG. 9, and the V-guides 68 return to capture the exposed signal conductor 4, as shown in FIG. 10. A coaxial electrical contact 100 is then advanced in axial alignment with the cable 2 and received thereon as the guides 68 are again withdrawn (FIGS. 11 and 12). The contact 100 is of the type described in U.S. Pat. No. 3,323,098 and comprises an inner signal pin 102 which receives signal conductor 4, an insulator 104, and an outer shield 106. Referring to FIG. 13, the clamps 89, 91 are withdrawn and the ferrule 18 is slid forward to trap the braid 6 against the shield 106 to provide shielding continuity between the cable 2 and the terminal 100.
Apparatus for practicing the above described method will now be described. Referring to FIG. 14, the braid flaring tool 20 is a bench tool comprising a base 22, a first upright 24, and a second upright 42. A main shaft 26 journaled through upright 24 is turned by an electric motor (not shown) to effect rotation of wheel 40 as shown schematically in FIGS. 3 and 3A. An arm 35 is pivotably mounted in body 28, which is fixed on shaft 26. The arm 35 is spring loaded toward the position shown in phantom, and is moved into the active position by sliding collar 30 rightward on body 28. This is accomplished by manually pivoting link 32, which link has a follower 33 journaled thereto, which follower rides in annular channel 31 on collar 30. The arm 35 comprises an extension 37 with an ell 38 fixed thereto, which ell carries the wheel 40.c
Referring still to FIG. 14, a platform 43 on upright 42 provides support for the various fixtures which align the cable 2 relative to wheel 40. The cable 2 is fixed in a clamping block 54, which block is received slidably on rail 53 and slid against index block 52. The block 52 is adjustably positioned on the rail 53 and provides means for positively positioning the end of cable 2. A toggle link 48 mounted on bracket 49 serves to urge upper clamp 46 toward lower clamp 44 to clamp the cable toward the end thereof to position it laterally relative to wheel 40.
FIG. 15 is a perspective of the braid flaring tool 20, which, taken with FIG. 14, clarifies features referred to above. The arm 35 has a ramped surface 36 against which collar 30 rides to pivot the arm 35 to the position shown. The body 28 incorporates a counterweight 29 which is balanced against the mass of arm 35 and wheel 40 during rotation. The cable 2 is held between clamps 44, 46 with the exposed braid 6 impinged by wheel 40 as shown. Index block 52 on rail 53 serves an axial positioning function as previously described.
FIG. 16 is a top section view of the bench tool 60 which provides the final flaring for termination (shown schematically in FIGS. 5 to 9). A clamp block 96 on rail 95 is slid against index block 94 to axially position the cable 2. The cup clamp 89 is then applied so that the braid 6 is situated in conical mouth 92. The compression tube 83 is shown compressing the primary insulation 5 (corresponding to FIG. 7) after the V-guides 68 have retracted. The V-guides 68 are fixed to blocks 66 which in turn are fixed to respective slides 67. The guides 68 are urged apart by springs 70 and urged together by downward travel of a cam block 72 which acts on followers 69 journaled to respective slides 67 (see also FIG. 16). Axial movement of the compression tube 83 as a unit with the flare tube 85 is effected by pushing extension 84, which is supported at the rear by bracket 87 fixed to main upright 64. Independent advance of the flare tube 85 is achieved by bearing on extension 86 thereof.
FIG. 17 depicts the mechanism of urging the slides together; applicaton of finger 73 by a toggle mechanism above (not shown) urges cam block 72 down against springs 75, so that cam surfaces 74 urge followers 69 together. The compression tube 83 and flare tube 85 are accommodated by slot 76. The block 72 rides in upright 64, which is adjustably mounted to base 62.
Subsequent to cable preparation, known apparatus having crimping dies as described in U.S. Pat. No. 3,555,672 is used to terminate a coaxial contact to the cable.
The foregoing is exemplary and not intended to limit the scope of the claims which follow. | Apparatus and method for preparing end of coaxial cable having foamed TFE primary insulation comprises steps of engaging first blades to make a first cut completely through the outer insulation and braid, then withdrawing the blades before making a second cut which penetrates only the outer insulation, then pulling the cable against the second blades to remove slugs of outer insulation and braid as an unit. Braid is subsequently flared by rotating a tool against the exposed braid, and primary insulation is axially compressed to expose the signal conductor. | 7 |
BACKGROUND OF THE INVENTION
Field of the Invention
This invention relates to an illuminating module for mounting in a domestic appliance with a housing which is designed for receiving an illuminating element, and in which is arranged a first light conductor which has a light admission surface through which light escaping from the illuminating element enters the first light conductor, and which has a light exit surface from the light escapes from the illuminating module.
Such an illuminating module is disclosed in DE 100 64 118 A1, which describes a domestic appliance with a trademark in which the trademark consists of a structural element or an assembly of a transparent or translucent material, and which is connected to at least one light source fitted on the inside of the housing in such a manner that the outer surface of the trademark radiates light in the forward direction when the light source is switched on. The illuminating module of prior art must be produced specially for the application, which in a multiplicity of domestic appliance variants results in an equally large number of illuminating module variants to be specially produced.
SUMMARY OF THE INVENTION
The object of this invention is to indicate a universally low cost illuminating module for mounting in a domestic appliance.
This object is achieved by an illuminating module with the features of Claim 1 .
The illuminating module has a housing which is designed for receiving an illuminating element. In the housing is arranged a first light conductor of transparent or translucent material which has a light admission surface and a light exit surface. Light escaping from the illuminating element enters the light admission surface and is admitted to the first light conductor, and the light escapes from the light exit surface and from the illuminating module. Because the housing is designed for alternately receiving a first illuminating element and a second illuminating element that is different from the first element, the illuminating module can be equipped with an illuminating element that is optimised to the situation without its housing having to be modified.
In the illuminating module the first illuminating element may have at least one second light conductor. The illuminating module may therefore be used as a passive illuminating module on positions in a domestic appliance on which an electrical power supply is not desirable or not possible.
Furthermore, the second illuminating element may have a support plate, in particular a circuit circuit board, with at least one light source, so that light can be generated directly in the illuminating module. The illuminating module may therefore be used as an active illuminating module on positions on which a power supply is possible without problem.
At least one functional element is formed on the housing of the illuminating module. The functional element can be formed easily and inexpensively on the housing. The functional element can be formed particularly easily and inexpensively on the housing if the housing and the functional element are produced in one piece from the same plastic.
In particular, the functional element as a stop element with which the first light conductor and/or the first illuminating element and/or the second illuminating element is releasably secured in the housing and/or with which the illuminating module can releasably secured with a module receiving device. The illuminating module may therefore be equipped extremely easily with different first light conductors to enable different indications to be displayed. For example, the first light conductors are distinguished by differently designed light exit sides which display different symbols or letters which can be moulded into the light exit side, formed on the light exit side or impressed upon the light exit side. The different symbols or letters may also be formed at other points on the first light conductor instead of on the light exit side, e.g. on a side opposite the light exit side or in the volume of the first light conductor. On the insides of the housing at least one further stop element can be formed with which the first and/or the second illuminating element can be secured in the housing. The stop element is designed particularly advantageously so that both a circuit board with one or a plurality of light emitting diodes and, as an alternative to this, a second light conductor can be secured in the housing. On the one hand the illuminating module can be designed as an active illuminating module with its own light source, and on the other it can be designed as a passive illuminating module with light from a remote light source directed into the illuminating module. On the outside of the housing can be formed at least one further stop element with which the illuminating module can be secured in a module receiving device of the domestic appliance. The connection between the illuminating module and the module receiving device may therefore easily be loosened again and the illuminating module can be removed from the module receiving device so that it can be exchanged, for example, for another module or so that individual components of the illuminating module can be replaced.
The functional element is advantageously designed so that it is spring-mounted. In particular, the housing has a spring mounting for the first and/or second illuminating element so that the first and/or the second illuminating element can easily be mounted in the housing by bending the spring mounting from its position of test.
In a preferred embodiment the housing has at least one light reflecting inner surface. The luminosity of the illuminating module can therefore be increased since light which falls onto the reflecting inner surface of the housing is reflected instead of absorbed by it and is therefore continues to be available for radiation from the illuminating module.
The first light conductor is advantageously designed in the shape of a parallelepiped and, in particular, has a light exit surface which is perpendicular to the light admission surface. The first light conductor can therefore be manufactured inexpensively and assembled in the housing particularly easily.
According to a preferred embodiment the first illuminating element and/or the second illuminating element has direct contact with the light admission surface of the first light conductor, as a result of which the position of the coupling of the light from the first or second illuminating element into the first light conductor is extremely high.
In order to achieve as uniformly distributed light radiation over the light exit surface of the first light conductor as possible, the light exit surface and/or the surface of the first light conductor opposite the light exit surface has a structured surface. It is also possible to equip the light exit surface with a diffuser foil or to manufacture the first light conductor from diffuse material in order to obtain uniform light radiation.
The illuminating module can be secured releasably in a module receiving device of the domestic appliance, wherein the module receiving device is preferably arranged behind a screen of the domestic appliance. However, the module receiving device may also be arranged in front of or behind any other parts of the domestic appliance which are to be illuminated. For example, the module receiving device may be formed by stop hooks which are formed on the back of the screen and which engage in stop lugs of the illuminating module for mounting the illuminating module, which lugs are in turn formed on the housing of the illuminating module.
In particular, the screen may be a grip plate for an object that is movable on the domestic appliance, e.g. a detergent drawer or a door or a hood or flap of the domestic appliance. An optical display can be provided on these moving parts of the domestic appliance by using a second light conductor for feeding light into the illuminating module. An electrical connection for the illuminating module is difficult to obtain on these parts.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention and its embodiments are explained in greater detail in the following with reference to drawings,
in which
FIG. 1 a shows a perspective view of an illuminating module without an illuminating element obliquely to the light exit surface;
FIG. 1 b , 1 c each show an enlarged section of the illuminating module according to the invention from FIG. 1 a;
FIG. 2 a shows the illuminating module from FIG. 1 a with a second light conductor as illuminating element;
FIG. 2 b shows the second light conductor according to FIG. 2 a;
FIG. 3 a shows the illuminating module from FIG. 1 a with a circuit board fitted with four light emitting diodes as the illuminating element, and with a diffuser foil above the light exit surface;
FIG. 3 b shows the circuit board according to FIG. 3 a;
FIG. 4 a shows a perspective view of the rear side of a screen of a domestic appliance with the assembled illuminating module according to FIG. 3 a viewed obliquely from the rear side of the illuminating module;
FIG. 4 b shows a front view of the screen according to FIG. 4 a;
FIG. 5 a shows a front view of a domestic appliance with an assembled illuminating module according to FIG. 2 a;
FIGS. 5 b, 5 c each show a perspective view of a detergent dispenser tray of the domestic appliance according to FIG. 5 a, viewed oblique from above.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 a shows an illuminating module 1 according to the invention, with a housing 2 and with a first light conductor 3 arranged in housing 2 . The first light conductor 3 is designed in the shape of a parallelepiped, and has a light admission surface 4 and a light exit surface 5 , wherein light exit surface 5 is essentially perpendicular to light admission surface 4 . Housing 2 comprises the first light conductor 3 with a rear wall 6 opposite light exit surface 5 of the first light conductor 3 , with a first longitudinal wall 7 arranged adjacent to light admission surface 4 , with a second longitudinal wall 8 opposite this first longitudinal wall 7 , with a first transverse wall 9 connecting the first longitudinal wall 7 and the second longitudinal wall 8 , and with a second transverse wall 10 opposite the first transverse wall 9 . Housing 2 is designed so that it is open on light exit surface 5 of the first light conductor 3 . The internal sides of housing 2 , in particular that of rear wall 6 and the second longitudinal wall 8 , may be designed so that they are light reflecting.
On the first transverse wall 9 and on the opposite second transverse wall 10 are formed stop elements 11 with which the first light conductor 3 is retained in housing 2 . Furthermore, guiding elements 12 are formed on the first or second transverse wall 9 , 10 for exact positioning of the first light conductor 3 in housing 2 , and rear wall 6 has pins 13 formed on it which engage through recesses of the first light conductor 3 , thereby determining the exact position of the first light conductor 3 . Stop elements 11 , guiding elements 12 and pins 13 are, in particular, formed in one piece on housing 2 .
Inside housing 2 a receiving region 14 for receiving an illuminating element is formed between light admission surface 4 of the first light conductor and the first longitudinal wall 7 of housing 2 arranged adjacent to it, which illuminating element is able to supply illuminating module 1 with light. Two stop elements 15 , for mounting the illuminating element, are formed on the first longitudinal wall 7 of housing 2 . An enlarged representation of stop element 15 is shown in FIG. 1 b. Stop element 15 is resiliently formed on housing 2 and has a stop nose 16 which is designed with an arc-shaped groove 17 . Furthermore, a sprung mounting 18 is formed on the first transverse wall 9 of housing 2 , which mounting can be bent from its position of rest when the illuminating element is assembled. Moreover, housing 2 has on its second transverse wall 10 a recess 19 through which the illuminating element can be threaded when mounted in receiving region 14 . FIG. 1 c shows an enlarged representation of the second transverse wall 10 with recess 19 . On the outside of the second transverse wall 10 are formed, above recess 19 , two retaining elements 20 with which an exact position of the illuminating element can be established in receiving region 14 when assembling the illuminating element in illuminating module 1 .
FIG. 2 a shows illuminating module 1 according to FIG. 1 a, with a second light conductor 21 mounted in receiving region 14 , and FIG. 2 b shows the second light conductor 21 . The second light conductor 21 has a rod-shaped design and has a light coupling surface 22 , an end face 23 opposite light coupling surface 22 and a light uncoupling surface 24 arranged at right angles to light coupling surface 22 or end face 23 . The rear surface 25 of the second light conductor 21 opposite light uncoupling surface 24 has a curved design. Furthermore, the second light conductor 21 is divided into a light supply region 26 and a light discharge region 24 . wherein the second light conductor 21 has a first step 28 between both these regions 26 , 27 , then on light supply region 26 , a first step 28 and perpendicular to this a second step 29 whereby the second light conductor 21 can be retained in receiving region 14 of housing 2 . The second light conductor 21 can be coated with a light reflecting and/or opaque coating, with the exception of light coupling surface 22 and light uncoupling surface 24 , so that light which enters light coupling surface 22 of the second light conductor 21 from a light source (not shown) can only escape again from light uncoupling surface 24 .
When the second light conductor is assembled in receiving region 14 of illuminating module 1 according to FIG. 1 a and FIG. 2 a, the second light conductor 21 , with its light supply region 27 , is threaded through recess 19 of housing 2 so that light supply region 27 projects laterally from housing 2 . Stop elements 15 are bent from the position of rest and the second light conductor 21 is pushed into receiving region 14 so that light uncoupling surface 24 comes into direct contact with light admission surface 4 of the first light conductor 3 . When the second light conductor is assembled stop elements 15 each solidly enclose the curved rear surface 25 of the second light conductor 21 with the arc-shaped groove 17 of their stop noses 16 . The second light conductor 21 rests with its end face 23 and its first step 28 against guiding elements 12 of housing 2 and with its second step 29 on second transverse wall 10 above recess 19 , and is in this manner fixed in receiving region 14 of housing 2 .
The second light conductor 21 may have its own housing and may be manufactured, for example, as a two-component injection moulding. Furthermore, the second light conductor 21 may be composed of a plurality of second individual light conductors which are held together by a common housing, for example, or are inserted individually in receiving region 14 of illuminating module 1 , and there retained. The second individual light conductors may be differently coloured in the case of light sources with the same light colouring. Moreover, the first light conductor 3 in housing 2 may also be composed of a plurality of first individual light conductors which are arranged with their light exit surfaces 5 adjacent to or behind each other, wherein the first individual light conductors may have different symbols and/or letters and/or colours. It is therefore possible to assign to each of the first individual light conductors a second individual light conductor, whereby each of the first individual light conductors can be supplied separately with light.
FIG. 3 a shows illuminating module 1 according to FIG. 1 a with a support plate 30 fitted in receiving region 14 and FIG. 3 b shows support plate 30 . Support plate 30 is designed as a rod-shaped circuit board and is fitted in its light discharge region 31 with four light emitting diodes 32 . Support plate 30 has at one of its end a contact region 33 for electrical connections. Furthermore, support plate 30 is provided at its end opposite contact region 33 with a notch 34 and with a groove 35 between light discharge region 31 and contact region 33 .
When support plate 30 is assembled in receiving region 14 of illuminating module 1 according to FIGS. 1 a and 3 a, support plate 30 is threaded with its contact region 33 through recess 19 of housing 2 , so that contact region 33 projects laterally from housing 2 for simple electrical contacting. Sprung mounting 18 is bent from its position of rest and support 30 is pushed into receiving region 14 so that light emitting diodes 32 are able to come into direct contact with light admission surface 4 of the first light conductor. When support plate 30 is assembled, mounting 18 is engaged in notch 34 of support plate 30 and support plate 30 is engaged with its groove 35 in transverse wall 10 above recess 19 between the two retaining elements 20 , so that support plate 30 is fixed in this manner in receiving region 14 of housing 2 .
Support plate 30 may be designed as a rigid or flexible circuit board. Light emitting diodes 32 are able to radiate light at different times and/or indifferent colours. Furthermore, the first light conductor 3 in housing 2 may be composed of a plurality of first individual light conductors which are arranged with their light exit surfaces 5 adjacent to or behind one another, wherein the first individual light conductors may have different symbols and/or letters and/or colours. It is therefore possible to assign a light emitting diode 32 to each of the first individual light conductors, whereby each of the first individual light conductors can be supplied separately with light. To obtain a light radiation that is distributed uniformly throughout light exit surface 5 , a diffuser foil 36 can be fitted over light exit surface 5 of the first light conductor 3 , which foil is fixed by pins 13 . As an alternative to this, the first light conductor 3 may be manufactured from material which diffusely disperses the admitted light.
FIG. 4 a shows a perspective view of a screen 37 of the domestic appliance, with the assembled illuminating module 1 according to FIG. 3 a, viewed obliquely from the rear of illuminating module 1 . A module receiving device 38 is formed by three stop hooks 39 formed on screen 37 on the rear side of screen 37 . Stop hooks 39 grip by means of stop lugs 40 , which are formed on housing 2 of illuminating module 1 , whereby illuminating module 1 is retained in module receiving device 38 on the one hand, and can easily be released again from module receiving device 38 on the other.
FIG. 4 b shows a front view of screen 37 according to FIG. 4 a. Screen 37 has recesses 38 in the form of an inscription through which the light of illuminating module 1 can be radiated. Recesses 38 can be filled with a transparent material or alternatively the inscription may be designed convexly so that it lies congruently to recesses 38 on light exit surface 5 of the first light conductor 3 , so that when illuminating module 1 is assembled in module receiving device 38 the convexly designed inscription penetrates recesses 38 of screen 37 and forms with screen 37 a flat front face.
FIG. 5 a shows the upper front view of a washing machine 41 , with a grip plate 42 of a detergent dispenser tray 43 behind which illuminating module 1 according to FIG. 2 a is mounted. The position of illuminating module 1 , with the second light conductor 21 , is denoted by a dotted line. The second light conductor 21 is coupled with its light coupling surface 22 , to a light source 44 of washing machine 41 when detergent dispenser tray 43 is closed so that illuminating module 1 is supplied with light and the trademark “SIEMENS” is able to light up on grip plate 42 of detergent dispenser tray 43 .
FIG. 5 b shows diagrammatically the detergent dispenser tray 43 when extended, so that a first chamber 45 for receiving detergent for the pre-wash, a second chamber 45 for receiving detergent for the main wash and a third chamber 45 for receiving fabric softener are visible. A second illuminating module 49 is secured behind rear wall 48 of detergent dispenser tray 43 . The second illuminating module 49 has a first light conductor 3 which consists of a first light radiating element 50 for the first chamber 45 , a second light radiating element 51 for the second chamber 46 , and a third light radiating element 52 for third chamber 47 , which are arranged adjacent to each other in illuminating module 49 . The second illuminating module 49 has a second light conductor 21 , which consists of a first light conducting element 53 for supplying light to the first light radiating element 50 , a second light conducting element 54 for supplying light to the second light radiating element 51 , and a third light conducting element 55 for supplying light to the third light radiating element 52 . The positions of the first, second and third light radiating elements 50 , 51 and 52 , with the first, second and third light conducting elements 53 , 54 and 55 , are denoted in FIG. 5 b by dotted lines.
Rear wall 48 of detergent dispenser tray 43 has a recess in the form of a symbol for pre-wash “I” for the first chamber 45 , a recess in the form of a symbol for main wash “II” for the second chamber 46 , and a recess in the form of a symbol for conditioning “*” for the third chamber 47 , through which recess light from illuminating module 49 can be radiated. When detergent dispenser tray 43 is open, the first light conducting element 53 couples to a first light source 56 , the second light conducting element 54 to a second light source 57 , and the third light conducting element 55 to a third light source 58 , so that the first, second and third light radiating elements 50 , 51 and 52 can be supplied with light independently of each other. The first, second and third light sources 56 , 57 and 58 may, for example, be differently coloured light emitting diodes, bulbs or in turn light conductors which transmit light from a remotely arranged light source. Depending on the set washing programme, the first, second and third light sources can be switched on by a washing machine control system (not shown) before the start of the washing programme when detergent dispenser tray 43 is fully open. The symbol for pre-wash “I” therefore now lights up on rear wall 48 of detergent dispenser tray 43 when a washing programme with pre-wash is selected, so that it is indicated to a user whether the first chamber 45 must be filled with detergent or not. The same applies to the display of the symbol for conditioner.
FIG. 5 c shows an alternative design of detergent dispenser tray 43 . Light coupling surface 22 . Viewed from illuminating module 1 mounted behind grip plate 42 of detergent dispenser tray 43 , light coupling surface 22 is shown to the side of detergent dispenser tray 43 , in which light from the first, second and third light sources 56 , 57 and 58 can couple when detergent dispenser tray 43 is closed. A screen 59 , slightly inclined relative to the front of washing machine 41 , is formed at the rear, upper end of detergent dispenser tray 43 in front of rear wall 48 . This screen, inclined relative to an observer, has for the first chamber 45 the recess in the form of the symbol for pre-wash “I”, for the second chamber 46 the recess in the form of the symbol for main wash “II”, and for the third chamber 47 the recess in the form of the symbol for conditioning “*”, so that the symbols are clearly visible to the user. The second illuminating module 49 is mounted behind this inclined screen 59 , so that when detergent dispenser tray 43 is open the light of the symbols is radiated in the direction of an observer standing in front of washing machine 41 .
LIST OF REFERENCE NUMBERS
1 Illuminating module
2 Housing
3 First light conductor
4 Light admission surface
5 Light exit surface
6 Rear wall of the housing
7 First longitudinal wall of the housing
8 Second longitudinal wall of the housing
9 First transverse wall of the housing
10 Second transverse wall of the housing
11 Stop element
12 Guiding element
13 Pin
14 Receiving region for an illuminating element
15 Stop element
16 Stop nose
17 Arc-shaped groove of the stop nose
18 Sprung mounting
19 Recess
20 Retaining element
21 Second light conductor
22 Light coupling surface
23 End face
24 Light uncoupling surface
25 Rear surface of the second light conductor
26 Light supply region
27 Light discharge region
28 First step
29 Second step
30 Support plate
31 Light discharge region
32 Light emitting diode
33 Contact region
34 Notch
35 Groove
36 Diffuser foil
37 Screen
38 Module receiving device
39 Stop hook
40 Stop lug
41 Washing machine
32 Grip plate
43 Detergent dispenser tray
44 Light source
45 First chamber
46 Second chamber
47 Third chamber
48 Rear wall of the detergent dispenser tray
49 Illuminating module
50 First light radiating element
51 Second light radiating element
52 Third light radiating element
53 First light conducting element
54 Second light conducting element
55 Third light conducting element
56 First light source
57 Second light source
58 Third light source
59 Inclined screen | A luminous module for mounting in a household appliance has a housing that is embodied in such a way as to receive a luminous element. The luminous module further contains a first optical wave guide having a light admission surface via which light emitted by the luminous element enters the first optical wave guide, and a light output surface via which the light emerges from the luminous module. The housing is embodied in such a way as to alternatively receive a first luminous element and a second luminous element that is different from the first. | 3 |
FIELD OF THE INVENTION
[0001] The present invention relates to isoxazoline derivatives and their analogues, which can be used as phosphodiesterase (PDE) type IV selective inhibitors. Compounds disclosed herein can be useful in the treatment of AIDS, asthma, arthritis, bronchitis, chronic obstructive pulmonary disease (COPD), psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome (ARDS), eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis and other inflammatory diseases especially in humans. Processes for the preparation of disclosed compounds, pharmaceutical compositions containing the disclosed compounds, and their use as PDE type IV selective inhibitors, are provided.
BACKGROUND OF THE INVENTION
[0002] It is known that cyclic adenosine-3′,5′-monophosphate (cAMP) exhibits an important role of acting as an intracellular secondary messenger (E. W. Sutherland, and T. W. Roll Pharmacol. Rev, 1960, 12, 265). Its intracellular hydrolysis to adenosine 5′-monophosphate (AMP) causes number of inflammatory conditions which are not limited to psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome (ARDS), eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis. The most important role in the control of cAMP (as well as of cGMP) level is played by cyclic nucleotide phosphodiesterases (PDE) which represents a biochemically and functionally, highly variable superfamily of the enzyme; eight distinct families with more than 15 gene products are currently recognized. Although PDE I, PDE II, PDE III, PDE IV, and PDE VII all use cAMP as a substrate, only PDE IV and PDE VII are highly selective for hydrolysis of cAMP. Inhibitors of PDE, particularly the PDE IV inhibitors, such as rolipram or Ro-1724 are therefore known as cAMP-enhancers. Immune cells contain type IV and type III PDE, the PDE IV type being prevalent in human mononuclear cells. Thus the inhibition of phosphodiesterase type IV has been a target for modulation and, accordingly, for therapeutic intervention in a range of disease processes.
[0003] The initial observation that xanthine derivatives, theophylline and caffeine inhibit the hydrolysis of cAMP led to the discovery of the required hydrolytic activity in the cyclic nucleotide phosphodiesterase (PDE) enzymes. More recently, distinct classes of PDE have been recognized (J. A. Bervo and D. H. Reifsnyder, TIPS, 1990, 11, 150), and their selective inhibition has led to improved drug therapy (C. D. Nicholus, R. A. Challiss and M. Shahid, TIPS, 1991, 12, 19). Thus it was recognized that inhibition of PDE IV could lead to inhibition of inflammatory mediator release (M. W. Verghese et. al, J. Mol. Cell. Cardiol. 1989, 12 (Suppl.II), S 61) and airway smooth muscle relaxation.
[0004] U.S. Pat. No. 5,686,434 (National stage of WO 95/14680) discloses 3-aryl-2-isoxazolines as anti-inflammatory agents. U.S. Pat. Nos. 6,114,367 and 5,869,511 (National stage of WO 95/24398) disclose isoxazoline compounds as inhibitors of TNF release. WO 95/14681 discloses a series of isoxazoline compounds as anti-inflammatory agents. WO 02/100332 discloses isoxazoline compounds having macrophage inhibitory factor (MIF) antagonist activity.
SUMMARY OF THE INVENTION
[0005] The present invention provides isoxazoline derivatives and their analogues, which can be used for the treatment of AIDS, asthma, arthritis, bronchitis, chronic obstructive pulmonary disease (COPD), psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome (ARDS), eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis and other inflammatory diseases, and the processes for the synthesis of these compounds.
[0006] Pharmaceutically acceptable salts, pharmaceutically acceptable solvates, enantiomers, diastereomers or N-oxides of these compounds having the same type of activity are also provided.
[0007] Pharmaceutical compositions containing the compounds, which may also contain pharmaceutically acceptable carriers or diluents, can be used for the treatment of AIDS, asthma, arthritis, bronchitis, chronic obstructive pulmonary disease (COPD), psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome, eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis and other inflammatory diseases.
[0008] Other aspects will be set forth in the accompanying description which follows and in part will be apparent from the description or may be learnt by the practice of the invention.
[0009] In accordance with one aspect, there are provided compounds having the structure of Formula I:
their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, enantiomers, diastereomers or N-oxides.
When X is oxygen in Formula I:
R 1 can represent: hydrogen; alkyl; alkenyl; alkynyl; cycloalkyl; cyano; nitro; amino; substituted amino; hydroxyl; alkoxy; aryloxy; COR′ or COOR′ (wherein R′ can be hydrogen, alkyl, alkenyl, alkynyl, (un)saturated cycloalkyl, aryl, aralkyl, heterocyclyl, (heterocyclyl)alkyl, or (heteroaryl)alkyl); aryl; aralkyl; heteroaryl; heterocyclyl; (heteroaryl) alkyl; (heterocyclyl) alkyl; (CH 2 ) 1-4 OR′ (wherein R′ is as defined above, but also including hydroxy); C(═O)NR x R y (wherein R x and R y can be independently selected from hydrogen, alkyl, C 3-6 alkenyl, C 3-6 alkynyl, (un)saturated cycloalkyl, aryl, aralkyl, heteroaryl, heterocyclyl, heteroarylalkyl, or heterocyclylalkyl); or (CH 2 ) m —C(═O)R 3 [wherein m is an integer in the range of 0-2 and R 3 can be optionally substituted R p or R q (wherein R p can be a 4-12 membered (un)saturated monocyclic or bicyclic ring containing 1-4 heteroatom(s) selected from N, O and S wherein the ring can be attached to (CH 2 ) m C(═O) through N and R q can be a 4-12 membered (un)saturated monocyclic or bicyclic ring containing 0-4 heteroatom(s) selected from the group consisting of N, O and S wherein the ring can be attached to (CH 2 ) m C(═O) through C) and wherein the substituents of R 3 can be one or more of: alkyl, alkenyl, alkynyl, (un)saturated cycloalkyl, halogen, hydroxyl alkoxy, aryloxy, nitro, cyano, amino, substituted amino, hydroxyalkyl, oxo, acyl, optionally substituted amino (wherein the substituents are selected from C 1 -C 6 alkyl, aryl, aralkyl, or cycloalkyl), aryl, carboxyl, alkaryl, carbamoyl, alkyl ether, C(═O)NR 5 R 6 (wherein R 5 and R 6 are independently selected from hydrogen, alkyl, C 3-6 alkenyl, C 3-6 alkynyl, aryl, and aralkyl), optionally substituted monocyclic or bicyclic 4-12 membered carbocyclic ring system (wherein the optional substituent(s) is/are selected from alkyl, alkenyl, alkynyl, halogen, hydroxyl, and alkoxy), heteroaryl, heterocyclyl, heteroarylalkyl, or heterocyclylalkyl].
R 2 can represent: cyano; heteroaryl; heterocyclyl; or (CH 2 ) n NHCOR 7 (wherein n represents an integer 1 to 6 and R 7 can represent hydrogen, alkyl, alkenyl, alkynyl, (un)saturated, cycloalkyl, alkoxy, aryloxy, aryl, aralkyl, heteroaryl, heterocyclyl, (CH 2 ) 1-4 OR′ wherein R′ is the same as defined above, or NR x R y wherein R x and R y are the same as defined above).
R 4 can represent: hydrogen; alkyl; halogen; cyano; carboxy; or C(═O)NR x R y wherein R x and R y are the same as defined above.
X 1 and X 2 can be independently selected from: hydrogen; alkyl; alkenyl; alkynyl; cycloalkyl; acyl; aryl; aralkyl; heteroaryl; heterocyclyl; (heteroaryl)alkyl; or (heterocyclyl)alkyl.
Y can represent: an oxygen atom; a sulphur atom; or NR (wherein R is selected from hydrogen, alkyl, alkenyl, alkynyl, un(saturated) cycloalkyl, acyl, aryl, aralkyl, heteroaryl, heterocyclyl, (heteroaryl)alkyl, or (heterocyclyl)alkyl).
Y 1 and Y 2 can be independently selected from: hydrogen; alkyl; nitro; cyano; halogen; OR wherein R is the same as defined earlier; SR wherein R is the same as defined earlier; NHR wherein R is the same as defined earlier; COOR′; or COR′ wherein R′ is the same as defined above.
Further, Y 1 and X 2 , X 1 and Y 2 , X 1 and X 2 may together form a cyclic ring fused with the ring A containing 3-5 carbon atoms within the ring and having 1-3 heteroatoms selected from N, O or S.
When X is NR 8 or S wherein R is hydrogen, lower alkyl (C 1 -C 6 ) or aryl:
R 1 , R 4 , X 1 , X 2 , Y, Y 1 and Y 2 are the same as defined above.
R 2 can represent: (CH) n NHCOR 7 (wherein n represents an integer 1 to 6 and R 7 is the same as defined above), with the provisio that when R 2 is heterocyclyl, R 1 can not be (CH 2 ) 1-4 OR′, C(═O)NR x R y or (CH 2 ) m —C(═O)R 3 .
[0010] In one particular embodiment, there are provided compounds having the structure of Formula XXXII,
their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, enantiomers, diastereomers or N-oxides.
In such compounds of Formula XXXII,
Y, Y 1 , Y 2 , R 1 and R 4 can be as defined for Formula I;
X 1 can be alkyl;
X 2 can be alkyl, cycloalkyl, or aralkyl;
X 3 , X 4 , X 5 and X 6 can be independently selected from C, CH, CH 2 , CO, CS, NH, N, O and S;
R 15 , R 16 , and R 17 can be independently selected from no atom, alkyl, COCH 3 , COOC 2 H 5 , NH 2 , NH-cyclopropyl, CN and SH; and
------ represents an optional double bond.
[0011] In another embodiment, there are provided compounds having the structure of Formula XXXIII,
their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, enantiomers, diastereomers or N-oxides.
In such compounds of Formula XXXIII,
Y, Y 1 , Y 2 , X 1 , X 2 , R 1 and R 4 can be as defined for Formula I;
X 7 can be O or S; and
R 18 can represent hydrogen, alkyl, aryl, heteroaryl, cycloalkyl, or heterocyclyl.
[0012] In yet another embodiment, there are provided compounds having the structure of Formula XXXIV,
[0013] their pharmaceutically acceptable salts, pharmaceutically acceptable solvates, enantiomers, diastereomers or N-oxides.
[0000] In such compounds of Formula XXXV,
[0000] Y, Y 1 , Y 2 , X 1 , X 2 , R 1 and R 4 can be as defined for Formula I; and
[0000] R 19 can represent cyano, —CONHNH 2 , —C(NH 2 )═N—O—C(O)R′, (CH 2 ) n NHCOR 7 or 6-membered heteroaryl, wherein R 1 , R 7 and n are the same as defined for Formula I.
[0014] The following definitions apply to terms as used herein:
[0015] The term “alkyl,” unless otherwise specified, refers to a monoradical branched or unbranched saturated hydrocarbon chain having from 1 to 20 carbon atoms. This term can be exemplified by groups such as methyl, ethyl, n-propyl, iso-propyl, n-butyl, iso-butyl, sec-butyl, t-butyl, n-pentyl, isopentyl, neopentyl, n-hexyl, n-decyl, tetradecyl, and the like. Alkyl groups may be substituted further with one or more substituents selected from alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, thiocarbonyl, carboxy, carboxyalkyl, aryl, heterocyclyl, heteroaryl, arylthio, thiol, alkylthio, aryloxy, nitro, aminosulfonyl, aminocarbonylamino, —NHC(═O)R f , —NR f R q , —C(═O)NR f R q , —NHC(═O)NR f R q, , —C(═O)heteroaryl, C(═O)heterocyclyl, O—C(═O)NR f R q {wherein R f and R q are independently selected from alkyl, alkenyl, cycloalkyl, cycloalkenyl, aryl, aralkyl, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl}, nitro, or —SO 2 R 6 (wherein R 6 is alkyl, alkenyl, alkynyl, cycloalkyl, aralkyl, aryl, heterocyclyl, heteroaryl, heteroarylalkyl or heterocyclylalkyl). Unless otherwise constrained by the definition, alkyl substituents may be further substituted by 1-3 substituents selected from alkyl, carboxy, —NR f R q , —C(═O)NR f R q , —OC(═O)NR f R q , —NHC(═O)NR f R q (wherein R f and R q are the same as defined earlier), hydroxy, alkoxy, halogen, CF 3 , cyano, and —SO 2 R 6 , (wherein R 6 are the same as defined earlier); or an alkyl group also may be interrupted by 1-5 atoms of groups independently selected from oxygen, sulfur or —NR a — {wherein R a is selected from hydrogen, alkyl, cycloalkyl, alkenyl, cycloalkenyl, alkynyl, aryl, acyl, aralkyl, —C(═O)OR f (wherein R f is the same as defined earlier), SO 2 R 6 (where R 6 is as defined earlier), or —C(═O)NR f R q (wherein R f and R q are as defined earlier)}. Unless otherwise constrained by the definition, all substituents may be substituted further by 1-3 substituents selected from alkyl, carboxy, —NR q , —C(═O)NR f R q , —O—C(═O)NR f R q (wherein R f and R q are the same as defined earlier) hydroxy, alkoxy, halogen, CF 3 , cyano, and —SO 2 R 6 (where R 6 is same as defined earlier); or an alkyl group as defined above that has both substituents as defined above and is also interrupted by 1-5 atoms or groups as defined above.
[0016] The term “alkenyl,” unless otherwise specified, refers to a monoradical of a branched or unbranched unsaturated hydrocarbon group having from 2 to 20 carbon atoms with cis, trans, or geminal geometry. In the event that alkenyl is attached to a heteroatom, the double bond cannot be alpha to the heteroatom. Alkenyl groups may be substituted further with one or more substituents selected from alkyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, —NHC(═O)R f , —NR f R q , —C(═O)NR f R q , —NHC(═O)NR f R q , —O—C(═O)NR f (wherein R f and R q are the same as defined earlier), alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, thiocarbonyl, carboxy, arylthio, thiol, alkylthio, aryl, aralkyl aryloxy, heterocyclyl, heteroaryl, heterocyclyl alkyl, heteroaryl alkyl, aminosulfonyl, aminocarbonylamino, alkoxyamino, nitro, or SO 2 & (wherein R 6 are is same as defined earlier). Unless otherwise constrained by the definition, alkenyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, carboxy, hydroxy, alkoxy, halogen, —CF 3 , cyano, —NR f R q , —C(═O)NR f R q , —O—C(═O)NR f R q (wherein R f and R q are the same as defined earlier) and —SO 2 R 6 (where R 6 is same as defined earlier).
[0017] The term “alkynyl,” unless otherwise specified, refers to a monoradical of an unsaturated hydrocarbon, having from 2 to 20 carbon atoms. In the event that alkynyl is attached to a heteroatom, the triple bond cannot be alpha to the heteroatom. Alkynyl groups may be substituted further with one or more substituents selected from alkyl, alkenyl, alkoxy, cycloalkyl, cycloalkenyl, acyl, acylamino, acyloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, thiocarbonyl, carboxy, arylthio, thiol, alkylthio, aryl, aralkyl, aryloxy, aminosulfonyl, aminocarbonylamino, nitro, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl, —NHC(═O)R f , —NR f R q , —NHC(═O)NR f R q , —C(═O)NR f R q , —O—C(═O)NR f R q (wherein R f and R q are the same as defined earlier), or —SO 2 R 6 (wherein R 6 is as defined earlier). Unless otherwise constrained by the definition, alkynyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, carboxy, carboxyalkyl, hydroxy, alkoxy, halogen, CF 3 , —NR f R q , —C(═O)NR f R q , —NHC(═O)NR f R q , —C(═O)NR f R q (wherein R f and R q are the same as defined earlier), cyano, or —SO 2 R 6 (where R 6 is same as defined earlier).
[0018] The term “cycloalkyl,” unless otherwise specified, refers to cyclic alkyl groups of from 3 to 20 carbon atoms having a single cyclic ring or multiple condensed rings, which may optionally contain one or more olefinic bonds, unless otherwise constrained by the definition. Such cycloalkyl groups can include, for example, single ring structures, including cyclopropyl, cyclobutyl, cyclooctyl, cyclopentenyl, and the like, or multiple ring structures, including adamantanyl and bicyclo[2.2.1]heptane, or cyclic alkyl groups to which is fused an aryl group, for example, indane, and the like. Spiro and fused ring structures can also be included. Cycloalkyl groups may be substituted further with one or more substituents selected from alkyl, alkenyl, alkynyl, alkoxy, cycloalkyl, cycloalkenyl acyl, acylamino, acyloxy, alkoxycarbonylamino, azido, cyano, halogen, hydroxy, oxo, thiocarbonyl, carboxy, carboxyalkyl, arylthio, thiol, alkylthio, aryl, aralkyl, aryloxy, aminosulfonyl, aminocarbonylamino, —NR f R q , —NHC(═O)NR f R q , —NHC(═O)R f , —C(═O)NR f R q , —O—C(═O)NR f R q (wherein R f and R q are the same as defined earlier), nitro, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl, or SO 2 —R 6 (wherein R 6 is same as defined earlier). Unless otherwise constrained by the definition, cycloalkyl substituents optionally may be substituted further by 1-3 substituents selected from alkyl, carboxy, hydroxy, alkoxy, halogen, CF 3 , —NR f R q , —C(═O)NR f R q , —NHC(═O)NR f R q , —O—C(═O)NR f R q (wherein R f and R q are the same as defined earlier), cyano or —SO 2 R 6 (where R 6 is same as defined earlier).
[0019] The term “alkoxy” denotes the group O-alkyl, wherein alkyl is the same as defined above.
[0020] The term “aryl,” unless otherwise specified, refers to carbocyclic aromatic groups, for example, phenyl, biphenyl or napthyl ring and the like, optionally substituted with 1 to 3 substituents selected from halogen (e.g., F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, alkoxy, acyl, aryloxy, CF 3 , cyano, nitro, COOR e (wherein R e is hydrogen, alkyl, alkenyl, cycloalkyl, aralkyl, heterocyclylalkyl, heteroarylalkyl), NHC(═O)R f , —NR f R q , —C(═O)NR f R q , —NHC(═O)NR f R q , —O—C(═O)NR f R q (wherein R f and R q are the same as defined earlier), —SO 2 R 6 (wherein R 6 is same as defined earlier), carboxy, heterocyclyl, heteroaryl, heterocyclylalkyl, heteroarylalkyl or amino carbonyl amino. The aryl group optionally may be fused with a cycloalkyl group, wherein the cycloalkyl group may optionally contain heteroatoms selected from O, N or S.
[0021] The term “aralkyl,” unless otherwise specified, refers to alkyl-aryl linked through an alkyl portion (wherein alkyl is as defined above) and the alkyl portion contains 1-6 carbon atoms and aryl is as defined below. Examples of aralkyl groups include benzyl, ethylphenyl and the like.
[0022] The term “aralkenyl,” unless otherwise specified, refers to alkenyl-aryl linked through alkenyl (wherein alkenyl is as defined above) portion and the alkenyl portion contains 1 to 6 carbon atoms and aryl is as defined below.
[0023] The term “aryloxy” denotes the group O-aryl, wherein aryl is as defined above.
[0024] The term “carboxy,” as defined herein, refers to —C(═O)OH.
[0025] The term “heteroaryl,” unless otherwise specified, refers to an aromatic ring structure containing 5 or 6 ring atoms, or a bicyclic aromatic group having from 8 to 10 ring atoms, with one or more heteroatom(s) independently selected from N, O or S optionally substituted with 1 to 4 substituent(s) selected from halogen (e.g. F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, acyl, carboxy, aryl, alkoxy, aralkyl, cyano, nitro, heterocyclyl, heteroaryl, —NR f R q , CH═NOH, —(CH 2 ) w C(═O)R g {wherein w is an integer from 0-4 and R g is hydrogen, hydroxy, OR f , NR f R q , —NHOR z or —NHOH}, —C(═O)NR f R q , and —NHC(═O)NR f R q , —SO 2 R 6 , —O—C(═O)NR f R q , —O—C(═O)R f , —O—C(═O)OR f (wherein R 6 , R f and R q are as defined earlier, and R g is alkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, heteroarylalkyl or heterocyclylalkyl). Unless otherwise constrained by the definition, the substituents are attached to a ring atom, i.e., carbon or heteroatom in the ring. Examples of heteroaryl groups include oxazolyl, imidazolyl, pyrrolyl, 1,2,3-triazolyl, 1,2,4-triazolyl, tetrazolyl, thiazolyl, oxadiazolyl, benzoimidazolyl, thiadiazolyl, pyridinyl, pyridazinyl, pyrimidinyl, pyrazinyl, thienyl, isoxazolyl, triazinyl, furanyl, benzofuranyl, indolyl, benzothiazolyl, or benzoxazolyl, and the like.
[0026] The term ‘heterocyclyl,” unless otherwise specified, refers to a non-aromatic monocyclic or bicyclic cycloalkyl group having 5 to 10 atoms wherein 1 to 4 carbon atoms in a ring are replaced by heteroatoms selected from O, S or N, and optionally are benzofused or fused heteroaryl having 5-6 ring members and/or optionally are substituted, wherein the substituents are selected from halogen (e.g., F, Cl, Br, I), hydroxy, alkyl, alkenyl, alkynyl, cycloalkyl, acyl, aryl, alkoxy, alkaryl, cyano, nitro, oxo, carboxy, heterocyclyl, heteroaryl, —O—C(O)R f , —O—C(═O)OR f , —C(═O)NR f R q , SO 2 R 6 , —O—C(═O)NR f R q , —NHC(═O)NR f R q , —NR f R q (wherein R 6 , R f and R q are as defined earlier) or guanidine. Heterocyclyl can optionally include rings having one or more double bonds. Unless otherwise constrained by the definition, the substituents are attached to the ring atom, i.e., carbon or heteroatom in the ring. Also, unless otherwise constrained by the definition, the heterocyclyl ring optionally may contain one or more olefinic bond(s). Examples of heterocyclyl groups include oxazolidinyl, tetrahydrofuranyl, dihydrofuranyl, dihydropyridinyl, dihydroisoxazolyl, dihydrobenzofuryl, azabicyclohexyl, dihydroindolyl, pyridinyl, isoindole 1,3-dione, piperidinyl or piperazinyl.
[0027] “Heteroarylalkyl” refers to alkyl-heteroaryl group linked through alkyl portion, wherein the alkyl and heteroaryl are as defined earlier.
[0028] “Heterocyclylalkyl” refers to alkyl-heterocyclyl group linked through alkyl portion, wherein the alkyl and heterocyclyl are as defined earlier.
[0029] “Acyl” refers to —C(═O)R″ wherein R″ is selected from hydrogen, alkyl, cycloalkyl, aryl, aralkyl, heteroaryl, heterocyclyl, heteroarylalkyl or heterocyclylalkyl.
[0030] “Alkylcarbonyl” refers to —C(═O)R″, wherein R″ is selected from alkyl, cycloalkyl, aryl, aralkyl, heteroaryl, heterocyclyl, heteroarylalkyl or heterocyclylalkyl.
[0031] “Alkylcarboxy” refers to C(═O)R″, wherein R″ is selected from alkyl, cycloalkyl, aryl, aralkyl, heteroaryl, heterocyclyl, heteroarylalkyl or heterocyclylalkyl.
[0032] “Amine,” unless otherwise specified, refers to —NH 2 . “Substituted amine,” unless otherwise specified, refers to —N(R k ) 2 , wherein each R k independently is selected from hydrogen {provided that both R k groups are not hydrogen (defined as “amino”)}, alkyl, alkenyl, alkynyl, aralkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, heterocyclylalkyl, heteroarylalkyl, acyl, SO 2 R 6 (wherein R 6 is as defined above), —C(═O)NR f R q , NHC(═O)NR f R q , or —NHC(═O)OR f (wherein R f and R e are as defined earlier).
[0033] “Thiocarbonyl” refers to —C(═S)H. “Substituted thiocarbonyl” refers to —C(═S)R″, wherein R″ is selected from alkyl, cycloalkyl, aryl, aralkyl, heteroaryl, heterocyclyl, heteroarylalkyl or heterocyclylalkyl, amine or substituted amine.
[0034] Unless otherwise constrained by the definition, all substituents optionally may be substituted further by 1-3 substituents selected from alkyl, aralkyl, cycloalkyl, aryl, heteroaryl, heterocyclyl, carboxy, carboxyalkyl, hydroxy, alkoxy, halogen, CF 3 , cyano, —C(=T)NR f R q , —O(C═O)NR f R q (wherein R f , R q and T are the same as defined earlier) and —OC(=T)NR f R q, , —SO 2 R 6 (where R 6 is the same as defined earlier).
[0035] The term “leaving group” refers to groups that exhibit or potentially exhibit the properties of being labile under the synthetic conditions and also, of being readily separated from synthetic products under defined conditions. Examples of leaving groups include, but are not limited to, halogen (e.g., F, Cl, Br, I), triflates, tosylate, mesylates, alkoxy, thioalkoxy, or hydroxy radicals and the like.
[0036] The term “protecting groups” refers to moieties that prevent chemical reaction at a location of a molecule intended to be left unaffected during chemical modification of such molecule. Unless otherwise specified, protecting groups may be used on groups, such as hydroxy, amino, or carboxy. Examples of protecting groups are found in T. W. Greene and P. G. M. Wuts, “Protective Groups in Organic Synthesis”, 2 nd Ed., John Wiley and Sons, New York, N.Y., which is incorporated herein by reference. The species of the carboxylic protecting groups, amino protecting groups or hydroxy protecting groups employed are not critical, as long as the derivatised moieties/moiety is/are stable to conditions of subsequent reactions and can be removed without disrupting the remainder of the molecule.
[0037] The term “pharmaceutically acceptable salts” refers to derivatives of compounds that can be modified by forming their corresponding acid or base salts. Examples of pharmaceutically acceptable salts include, but are not limited to, mineral or organic acids salts of basic residues (such as amines), or alkali or organic salts of acidic residues (such as carboxylic acids), and the like.
[0038] The compounds provided herein can be used for treating AIDS, asthma, arthritis, bronchitis, chronic obstructive pulmonary disease, psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome, eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis and other inflammatory diseases.
[0039] In accordance with yet another aspect, there are provided processes for the preparation of the compounds as described herein.
DETAILED DESCRIPTION OF THE INVENTION
[0040] The compounds described herein may be prepared by techniques well known in the art and familiar to the average synthetic organic chemist. In addition, the compounds of present invention may be prepared by the following reaction sequences as depicted in schemes I, IA, IB, II, III, IV and V.
[0041] The compounds of Formula VII (a) can be prepared according to Scheme I. Thus, reacting a compound of Formula II with compound of Formula X 2 Z (wherein Z is halogen) to give a compound of Formula III [wherein X 1 , X 2 (except hydrogen), Y 1 and Y 2 are the same as defined earlier], which on reaction with hydroxylamine hydrochloride gives a compound of Formula IV, which on treatment with a compound of Formula V gives a compound of Formula VI (wherein R 1 and R 4 are the same as defined earlier and Rr represents [(CH 2 ) n CN, COOH, COOCH 3 , CHO or pyridyl, wherein n is 0 to 2)], which on reaction with hydroxylamine hydrochloride (when Rr is CN) to give a compound of Formula VII, which is finally reacted with a compound of Formula (R′CO) 2 O to give a compound of Formula VII(a) (wherein R′ is the san as defined earlier).
[0042] The reaction of a compound of Formula II with a compound of Formula X 2 Z to give a compound of Formula III can be carried out in a solvent, for example, tetrahydrofuran, dimethylformamide, dimethylsulphoxide or acetonitrile.
[0043] The reaction of a compound of Formula II with compound of Formula X 2 Z can be carried out in the presence of potassium iodide and an inorganic base, for example, sodium carbonate, sodium bicarbonate, potassium carbonate or potassium bicarbonate.
[0044] The reaction of a compound of Formula III with hydroxylamine hydrochloride to give a compound of Formula IV can be carried out in the presence of sodium acetate or potassium acetate in a solvent, for example, methanol, ethanol, propanol or n-butanol.
[0045] The reaction of a compound of Formula IV with a compound of Formula V to give a compound of Formula VI can be carried out in the presence of sodium hypochlorite in a solvent, for example, tetrahydrofuran, dimethylformamide, dimethylsulphoxide or acetonitrile.
[0046] The reaction of a compound of Formula VI with hydroxylamine hydrochloride to give a compound of Formula VII can be carried out in a solvent, for example, tetrahydrofuran, dimethylformamide, dimethylsulphoxide, acetonitrile, acetone, ethanol or mixtures thereof.
[0047] The reaction of a compound of Formula VI with hydroxylamine hydrochloride can be carried out in the presence of an inorganic base, for example, sodium carbonate, sodium bicarbonate, potassium carbonate or potassium bicarbonate.
[0048] The reaction of a compound of Formula VII with a compound of Formula (R′CO) 2 O to give a compound of Formula VII (a) can be carried out in a solvent, for example, tetrahydrofuran, dimethylformamide, dimethylsulphoxide or acetonitrile.
[0049] The reaction of a compound of Formula VII with a compound of Formula (R′CO) 2 O can be carried out in the presence of an organic base, for example, trimethylamine, triethylamine or pyridine.
[0050] The compounds of Formula IX and X can be prepared according to scheme IA. Thus, reacting a compound of
(a) Formula VI (when Rr is COOCH 3 ) with hydrazine hydrate to give a compound of Formula VIII (wherein X 1 , X 2 , Y 1 , Y 2 , R 1 and R 4 are the same as defined earlier), which on reaction with a compound of Formula HC(OR 11 ) 3 gives a compound of Formula IX (wherein R 11 represents alkyl from C 1 to C 3 ); or (b) Formula VI (when Rr is CN) with sodium azide to give a compound of Formula X (wherein X 1 , X 2 , Y 1 , Y 2 , R 1 and R 4 are the same as defined earlier),
[0053] The reaction of a compound of Formula VI with hydrazine hydrate to give a compound of Formula VIII can be carried out at a temperature ranging, for example, from 120 to 140° C.
[0054] The reaction of a compound of Formula Vm with a compound of Formula HC(OR 11 ) 3 to give a compound of Formula IX can be carried out at a temperature ranging, for example, from 120 to 160° C.
[0055] The reaction of a compound of Formula VI with sodium azide to give a compound of Formula X can be carried out in a solvent, for example, benzene, toluene or xylene.
[0056] The reaction of a compound of Formula VI with sodium azide to give a compound of Formula X can be carried out in the presence of hydrochloride salt of an organic base, for example, trimethylamine, triethylamine or pyridine.
[0057] The compounds of Formulae XI-XV can be prepared according to scheme IB. Thus, reacting a compound of Formula VII (wherein X 1 , X 2 , Y 1 , Y 2 , R 1 and R 4 are the same as defined earlier) with
(a) methyl chloroformate to give a compound of Formula XI; (b) thiocarbonyl diimidazole and 1,8-diazabicyclo[5.4.0]undec-7-one to give a compound of Formula XII, which on treatment with a compound of Formula R 11 Z (wherein Z is halogen) gives a compound of Formula XIII (wherein R 11 is alkyl); (c) thiocarbonyl diimidazole and boron trifluoride etherate to give a compound of Formula XIV; (d) a compound of Formula R 12 COOH, (e) a compound of Formula R 12 COCl or (f) a compound of Formula R 12 COOC 2 H 5 to give a compound of Formula XV (wherein R 12 is alkyl, cycloalkyl, aryl, heteroaryl or heterocyclyl).
[0064] The reaction of a compound of Formula VII with methyl chloroformate to give a compound of Formula XI can be carried out in a solvent, for example, xylene, benzene or toluene.
[0065] The reaction of a compound of Formula VII with methyl chloroformate can be carried out in the presence of an organic base, for example, pyridine, trimethylamine or triethylamine.
[0066] The reaction of a compound of Formula VII with thiocarbonyl diimidazole and 1,8-diazabicyclo[5.4.0]undec-7-one to give a compound of Formula XII can be carried out in a solvent, for example, acetonitrile, acetone, dimethylformamide, dimethylsulfoxide or tetrahydrofuran.
[0067] The reaction of a compound of Formula XII with a compound of Formula R 11 Z to give a compound of Formula XIII can be carried out in a solvent, for example, acetone, acetonitrile, tetrahydrofuran or dimethylformamide.
[0068] The reaction of a compound of Formula XII with a compound of Formula R 11 Z can be carried out in the presence of an inorganic base, for example, sodium carbonate, sodium bicarbonate, potassium carbonate or potassium bicarbonate.
[0069] The reaction of a compound of Formula VII with a compound of Formula R 12 COOH to give a compound of Formula XV can be carried out in the presence of isobutylchloroformate and an organic base, for example, triethylamine, dimethylamine or pyridine in a solvent, for example, dimethylformamide, tetrahydrofuran or acetonitrile.
[0070] The reaction of a compound of Formula VII to give a compound of Formula XV can be carried out in the presence of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride, 1-hydroxybenzotriazole and N-methylmorpholine.
[0071] The reaction of a compound of Formula VII with a compound of Formula R 12 COCl to give a compound of Formula XV can be carried out in a solvent, for example, toluene, acetonitrile, acetone, dimethylformamide, dimethylsulphoxide or tetrahydrofuran.
[0072] The reaction of a compound of Formula VII with a compound of Formula R 12 COOC 2 H 5 to give a compound of Formula XV can be carried out in the presence of an inorganic base, for example, sodium carbonate, potassium carbonate or sodium hydride in a solvent, for example, dimethylformamide, tetrahydrofuran or acetonitrile.
[0073] The reaction of a compound of Formula VII with the compounds of Formula R 12 COOH, R 12 COCl and R 12 COOC 2 H 5 can be cared out in the presence of molecular sieves.
[0074] The compounds of Formula XVb can be prepared according to Scheme IC. Thus reacting a compound of Formula XVa with 2-oxo propionic acid ethyl ester gives a compound of Formula XVb (wherein X 1 , X 2 , Y 1 , Y 2 , R 1 , and R 4 are the same as earlier). The reaction can be carried out in a solvent, for example, acetonitrile, acetone, dimethylformamide, dimethylsulphoxide or tetrahydrofuran.
[0075] The compounds of Formula XX can be prepared according to Scheme II. Thus reacting a compound of Formula IV with a compound of Formula XVI to give a compound of Formula XVII (wherein X 1 , X 2 , Y 1 , Y 2 , R 1 , R 4 , Z and n are the same as defined earlier), which on treatment with potassium phthalamide gives a compound of Formula XVIII, which on treatment with a hydrazine hydrate gives a compound of Formula XIX, which is finally treated with a compound of Formula R 12 COCl or R 12 COOH to give a compound of Formula XX (wherein R 12 is the same as defined earlier).
[0076] The reaction of a compound of Formula IV with a compound of Formula XVI to give a compound of Formula XVII can be carried out in a solvent, for example, acetonitrile, acetone, dimethylformamide, dimethylsulphoxide or tetrahydrofuran.
[0077] The reaction of a compound of Formula XVII with potassium phthalamide to give a compound of Formula XVIII can be carried out in a solvent, for example, acetonitrile, acetone, dimethylformamide, dimethylsulphoxide or tetrahydrofuran.
[0078] The reaction of a compound of Formula XVIII with hydrazine hydrate to give a compound of Formula XIX can be carried out in a solvent, for example, methanol, ethanol, propanol, butanol, water or mixture thereof.
[0079] The reaction of a compound of Formula XIX with a compound of Formula R 12 COCl to give a compound of Formula XX can be carried out in a solvent, for example, chloroform, dichloromethane or dichloroethane.
[0080] The reaction of a compound of Formula XIX with a compound of Formula R 12 COCl can be carried out in the presence of an organic base, for example, trimethylamine, triethylamine or pyridine.
[0081] The reaction of a compound of Formula XIX with a compound of Formula R 12 COOH to give a compound of Formula XX can be carried out in the presence of 1-ethyl-3-[3-(dimethylamino)propyl]carbodiimide, 1-hydroxybenzotriazole and N-methyl morpholine in a solvent, for example, dimethylformamide, dimethylsulfoxide or tetrahydrofuran.
[0082] The compounds of Formula XXIII can be prepared according to Scheme III. Thus, reacting a compound of Formula XXI with hydroxylamine hydrochloride to give a compound of Formula XXII (wherein R 13 is alkyl, aryl or heteroaryl), which on reaction with a compound of Formula VI (when Rr is COOH, scheme I) gives a compound of Formula XXIII (wherein X 1 , X 2 , Y 1 , Y 2 , R 1 and R 4 are the same as defined earlier).
[0083] The reaction of a compound of Formula XXI to give a compound of Formula XXII can be carried out in the presence of sodium carbonate or potassium carbonate in a solvent, for example, methanol, ethanol propanol, n-butanol, water or mixture thereof.
[0084] The reaction of a compound of Formula XXII with a compound of Formula VI to give a compound of Formula XXIII can be carried out in a solvent, for example, dimethylformamide or dimethylsulfoxide.
[0085] The reaction of a compound of Formula XXII with a compound of Formula VI can be carried out in the presence of 1-hydroxybenzthiazole, N-methylmorpholine and a coupling agent, for example, 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride or 1,3-dicyclohexyl carbodiimide.
[0086] The reaction of a compound of Formula XXII with a compound of Formula VI to give a compound of Formula XXIII can be carried out in the presence of sodium acetate or potassium acetate solvent, for example, methanol, ethanol, propanol, n-butanol, water or mixture thereof.
[0087] The compounds of Formula XXIV-XXVII can be prepared according to scheme IV. Thus, reacting a compound of
(1) Formula VI (when Rr is CN) with NH 2 CH 2 CH 2 SH. HCl to give a compound of Formula XXIV (wherein X 1 , X 2 , Y 1 , Y 2 , R 1 and R 4 are the same as defined earlier); (2) Formula VI (when Rr is COOH) with NH 2 NHCSNHR 14 to give a compound of Formula XXV (wherein X 1 , X 2 , Y 1 , Y 2 , R 1 , and R 4 are the same as defined earlier, R 14 represents hydrogen, alkyl or cycloalkyl); or (3) Formula VI (when Rr is CHO) with hydroxylamine hydrochloride to give a compound of Formula XXVI which on reaction with methacrylonitrile gives a compound of Formula XXVII (wherein X 1 , X 2 , Y 1 , Y 2 , R 1 and R 4 are the same as defined earlier).
[0091] The reaction of a compound of Formula VI with NH 2 CH 2 CH 2 SH. HCl to give a compound of Formula XXIV can be carried out in the presence of an organic base, for example, triethylamine, trimethylamine or pyridine in a solvent, for example, methanol, ethanol or isopropanol.
[0092] The reaction of a compound of Formula VI with NH 2 NHCSNHR 14 to give a compound of Formula XXV can be carried out in the presence of POCl 3 in a solvent, for example, methanol or dioxane.
[0093] The reaction of a compound of Formula VI with hydroxylamine hydrochloride and sodium acetate to give a compound of Formula XXVI can be carried out in a solvent, for example, methanol, ethanol or isopropanol.
[0094] The reaction of a compound of Formula XXVI with methacrylonitrile to give a compound of Formula XXVII can be carried out in the presence of sodium hypochlorite in a solvent, for example, tetrahydrofuran, dimethylformamide, dimethylsulphoxide or acetonitrile.
[0095] The compounds of Formula XXIX-XXXI can be prepared according to Scheme V. Thus, reacting a compound of Formula VIII
(1) with ethylmethylketone to give a compound of Formula XXVIII, which on treatment with acetic anhydride gives a compound of Formula XXIX (wherein X 1 , X 2 , Y 1 , Y 2 , R 1 and R 4 are the same as defined earlier) (2) with carbon disulphide to give a compound of Formula XXX, which on treatment with hydrazine hydrate gives a compound of Formula XXXI (wherein X 1 , X 2 , Y 1 , Y 2 , R 1 and R 4 are the same as defined earlier).
[0098] The reaction of a compound of Formula VIII with ethylmethylketone to give a compound of Formula XXVIII can be carried out in a solvent, for example, methanol, ethanol or isopropanol.
[0099] The reaction of a compound of Formula XXVIII with acetic acid to give a compound of Formula XXIX can be carried out in the presence of an organic base, for example, pyridine, triethylamine or trimethylamine.
[0100] The reaction of a compound of Formula VIII with carbon disulphide to give a compound of Formula XXX can be carried out in the presence of an inorganic base, for example, sodium hydroxide, potassium hydroxide or calcium hydroxide.
[0101] The reaction of a compound of Formula VIII with carbon disulphide to give a compound of Formula XXX can be carried out in a solvent, for example, methanol, ethanol or isopropanol.
[0102] The reaction of a compound of Formula XXX with hydrazine hydrate to give a compound of Formula XXXI can be carried out in a solvent, for example, methanol, ethanol or isopropanol.
[0103] In the above schemes, where the specific solvents, bases, coupling agents etc., are mentioned, it is to be understood that other solvents, bases coupling agents etc., known to those skilled in the art may be used. Similarly, the reaction temperature and duration may be adjusted according to the desired needs.
[0104] An illustrative list of compounds of the invention are listed below (also shown in Table 1 2, 3, 4, 5, 6 and 7)
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-4H-[1,2,4]oxadiazol-5-one (Compound No. 1), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-4H-[1,2,4]oxadiazole-5-thione (Compound No. 2), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-4H-[1,2,4]thiadiazol-5-one (Compound No. 3), -2-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 4), -2-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-5-methyl-[1,3,4]oxadiazole (Compound No. 5), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-4-methyl-4H-[1,2,4]oxadiazole-5-thione (Compound No. 6), -3-{3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-[1,2,4]oxadiazol-5-yl}pyridine (Compound No. 7), -5-tert-Butyl-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 8), -5-[3-(3-3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4-,5-dihydroisoxazol-5-yl]-1H-tetrazole (Compound No. 9), -3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4-,5-dihydroisoxazole-5-carbonitrile (Compound No. 10), -Morpholine-4-carboxylic acid [3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-ylmethyl]amide (Compound No. 11), —N-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-ylmethyl]-4-fluoro-benzamide (Compound No. 12), -Adamantane-1-carboxylic acid [3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl-methyl]amide (Compound No. 13), -Furan-2-carboxylic acid [3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl-methyl]amide (Compound No. 14), -2-(3-Cyclopentyloxy-4-methoxyphenyl)-N-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-ylmethyl]-acetamide (Compound No. 15), -1-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl-methyl]-3-(2-trifluoromethyl)-phenyl)-urea (Compound No. 16), -1-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl-methyl]-3-(2,4-difluorophenyl)-urea (Compound No. 17), -1-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl-methyl]-3-O-tolyl-urea (Compound No. 18), -Morpholine-4-carboxylic acid [3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl-methyl]-amide (Compound No. 19), -3-(2-Chloro-6-trifluoromethylphenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl-[1,2,4]oxadiazole (Compound No. 20), -3-(2-Chloro-4-fluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 21), -3-(4-Chloro-2-methoxyphenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 22), -3-(3-Chloro-4-fluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 23), -3-(3-Chloro-4-methoxyphenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 24), -3-(3-Fluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 25), -3-(3,4-Difluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 26), -3-(4-Methoxyphenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 27), -3-(3,4-Dimethoxyphenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 28), -3-(2-Chloro-6-fluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 29), -3-(2,5-Difluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 30), -3-(2,6-Dichlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 31), -3-(2,3-Dichlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 32), -3-(2,4-Dichlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 33), -3-(3,5-Dichlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 34), -3-(2,5-Dichlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 35), -3-(3,5-Difluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 36), -3-(3-Chlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 37), -3-(2,4-Difluoro-phenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 38), -3-(3,4-Dichlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 39), -3-(4-Chlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 40), -4-{5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole-3-yl}-phenylamine (Compound No. 41), -3-Phenyl-5-[3-(3-cyclopentyloxy-4-methoxy-phenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 42), -3-(3,4-Dimethyl-phenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 43), -3-(2-Chlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 44), -3-(4-Fluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 45), -3-Methyl-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 46), -3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-5-oxazol-5-yl-4,5-dihydro-isoxazole (Compound No. 47), -5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]thiadiazol-2-yl-amine (Compound No. 48), -{5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]thiadiazol-2-yl}-cyclopropylamine (Compound No. 49), -1-{5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-2-ethyl-2-methyl-[1,3,4]oxadiazol-3-yl}-ethanone (Compound No. 50), -3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-(4,5-dihydro-thiazol-2-yl)-5-methyl-4,5-dihydro-isoxazole (Compound No. 51), -3′-(3-Cyclopentyloxy-4-methoxyphenyl)-5,5′-dimethyl-4,5,4′,5′-tetrahydro-[3,5′]biisoxazolyl-5-carbonitrile (Compound No. 52), -3-{3-[3-(cyclopentyloxy)-4-methoxyphenyl]-5-methyl-4,5-dihydroisoxazol-5-yl}-5-methyl-1,4,2-dioxazole-5-carboxylic acid ethyl ester (Compound No. 53) -4-Amino-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-4H-[1,2,4]triazole-3-thiol (Compound No. 54), -5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-3H-[1,3,4]oxadiazole-2-thione (Compound No. 55), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-methyl-[1,2,4]oxadiazole (Compound No. 56), -4-{3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazol-5-yl}-pyridine (Compound No. 57), -5-tert-Butyl-3-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 58), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(2-ethoxy-phenyl)-[1,2,4]oxadiazole (Compound No. 59), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-cyclopropyl-[1,2,4]oxadiazole (Compound No. 60), -5-(3-Chlorophenyl)-3-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 61), -5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-m-tolyl-[1,2,4]oxadiazole (Compound No. 62), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(3,5-dimethyl-phenyl)-[1,2,4]oxadiazole (Compound No. 63), -2,6-Dichloro-4-{3-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazol-5-yl}-pyridine (Compound No. 64), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-isopropyl-[1,2,4]oxadiazole (Compound No. 65), -5-Cyclohexyl-3-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 66), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-fluoromethyl-[1,2,4]oxadiazole (Compound No. 67), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(tetrahydro-furan-2-yl)-[1,2,4]oxadiazole (Compound No. 68), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(4-fluoro-phenyl)-[1,2,4]oxadiazole (Compound No. 69), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(3-fluorophenyl) [1,2,4]oxadiazol (Compound No. 70), -{3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazol-5-yl}-acetonitrile (Compound No. 71), -4-{3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole-5-yl)-benzonitrile (Compound No. 72), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-trifluoromethyl-[1,2,4]oxadiazole (Compound No. 73), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(3-methoxy-phenyl)-[1,2,4]oxadiazole (Compound No. 74), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(3,4-dimethoxy-phenyl)[1,2,4]oxadiazole (Compound No. 75), -5-(2-Chlorophenyl)-3-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 76), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(2,4-dichloro-phenyl)-[1,2,4]oxadiazole (Compound No. 77), -5-Cyclopentyl-3-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 78), -3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(3,4-dichloro-phenyl)-[1,2,4]oxadiazole (Compound No. 79), -2-[3-(4-Difluoromethoxy-3-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 80), -2-{3-[3-(Bicyclo[2.2.1]hept-2-yloxy)-4-difluoromethoxyphenyl]-5-methyl-4,5-dihydro-isoxazol-5-yl}-[1,3,4]oxadiazole (Compound No. 81), -2-{3-[3-benzyloxy-4-difluoromethoxyphenyl]-5-methyl-4,5-dihydro-isoxazol-5-yl}-[1,3,4]oxadiazole (Compound No. 82), -2-[3-[4-Difluoromethoxy-3-ethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 83), -2-[3-[4-Difluoromethoxy-3-isopropoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-([1,3,4]oxadiazole (Compound No. 84), -2-[3-(3-Cyclohexyloxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 85), -2-[3-(3-Butoxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 86), -2-[3-(3-Cycloheptyloxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 87), -2-[3-(4-Difluoromethoxy-3-propoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 88), -2-[3-(3,4-Bis-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 89), -2-[3-(3-Cyclopentyloxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 90), -2-[3-(3-Cyclopropylmethoxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 91), -2-[3-(3-Cyclopropylmethoxy-4-methoxy-phenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 92), -2-[3-(3-Difluoromethoxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 93), -3-(3-Cyclopropylmethoxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 94), -3-(3-Cyclopentyloxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 95), -3-(3,4-Bis-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 96), -3-(3-Cyclopropylmethoxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 97), -3-(3-Butoxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 98), -3-(4-Difluoromethoxy-3-propoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 99), -3-(4-Difluoromethoxy-3-isopropoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 100), -3-[3-(Bicyclo[2.2.1]hept-2-yloxy)-4-difluoromethoxyphenyl]-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 101), -3-(3-Benzyloxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 102), -2-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-pyridine (Compound No. 103), -3-[3-(Cyclopentyloxy-4-methoxyphenyl]-5-methyl-4,5-dihydroisoxazole-5-carboxylic acid hydrazide (Compound No. 104),
[0209] -Acetic acid (Z)-2-amino-2-{3-[3-(cyclopentyloxy)-4-methoxyphenyl]-5-methyl-4,5-dihydroisoxazol-5-yl}vinyl ester (Compound No. 105).
TABLE 1 Formula I (wherein R 4 = Y 1 = Y 2 = H, R 1 = X 1 = CH 3 , X 2 = cyclopentyl, X = Y = O) Compound No. R 2 1 2 3 4 5 6 7 8 9 10 CN 104 —CONHNH 2 105
[0210]
TABLE 2
Formula I
(Formula I, wherein R 4 = Y 1 = Y 2 = H, R 1 = X 1 = CH 3 , X 2 = cyclopentyl,
X = Y = O, R 2 = (CH 2 ) n —NHCO—R 7 , n = 1)
Compound No.
R 7
11
12
13
14
15
[0211]
TABLE 3
(Formula I, wherein R 4 = Y 1 = Y 2 = H, R 1 = X 1 = CH 3 , X 2 = cyclopentyl,
X = Y = O, R 2 = (CH 2 ) n —NHCONHR 7 , n = 1)
Compound No.
R 7
16
17
18
19
[0212]
TABLE 4
Formula XXXII
Compound No.
R 2
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
[0213]
TABLE 5
Formula XXXIII
Compound No.
R 2
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
[0214]
TABLE 6
Formula XXXII
Compound No.
X 2
X 1
80
—CH 3
—CHF 2
81
—CHF 2
82
—CHF 2
83
—CHF 2
84
—CHF 2
85
—CHF 2
86
CH 3 —(CH 2 ) 3 —
—CHF 2
87
—CHF 2
88
—CHF 2
89
CHF 2
—CHF 2
90
—CHF 2
91
—CHF 2
92
—CHF 2
—CH 3
93
—CH 3
[0215]
TABLE 7
Formula XXXIV
(Formula I, wherein R 4 = Y 1 = Y 2 = H, R 1 = CH 3 , X = Y = O)
Compound No.
X 1
X 2
R 19
94
—CHF 2
CN
95
—CHF 2
CN
96
—CHF 2
—CHF 2
CN
97
—CH 3
CN
98
—CHF 2
CN
99
—CHF 2
CN
100
—CHF 2
CN
101
—CHF 2
CN
102
—CHF 2
CN
103
—CH 3
[0216] Examples set forth below demonstrate the synthetic procedures for the preparation of the representative compounds. The examples are provided to illustrate particular aspect of the disclosure and do not constrain the scope of the present invention as defined by the claims.
EXPERIMENTAL DETAILS
Example 1
Preparation of 3-cyclopentyloxy-4-methoxybenzaldehyde
[0217] The title compound was prepared according to methods described in J. Med. Chem ., (1994), 37, 1696-1703
Example 2
Preparation of 3-cyclopentyloxy-4-methoxybenzaldehyde oxime
[0218] To a stirred solution of 3-cyclopentyloxy-4-methoxybenzaldehyde (0.5 g, 2.2727 mmol, example 1) in ethanol (8 ml) was added hydroxylamine hydrochloride (0.473 g, 6.8181 mmol) and sodium acetate (0.56 g, 6.8181 mmol). The reaction mixture was allowed to stir at room temperature for 50 minutes. Ethanol was removed under reduced pressure and then residue was poured in water (20 ml) and organic compound was extracted with ethyl acetate (2×15 ml). Ethyl acetate layer was dried over anhydrous sodium sulphate, filtered and finally concentrated under reduced pressure to afford compound of Formula III.
[0219] 1 H NMR (CDCl 3 ): 9.84 (s, 1H), 8.07 (s, 1H), 6.84-7.24 (m, 3H), 4.79-4.83 (m, 1H), 3.87 (s, 3H), 1.62-2.18 (m, 8H).
Example 3
Preparation of [3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazole-5-carbonitrile (Compound No. 10)
[0220] 3-cyclopentyloxy-4-methoxybenzaldehyde oxime (500 mg, 0.002 mole, example 2) was taken in 10 mL tetrahydrofuran. Methacrylonitrile (0.285 mL, 0.004 mole) was added and stirred. Sodium hypochlorite solution (10 mL, 20 times) was added dropwise. Reaction mixture was stirred vigorously at an ambient temperature. Tetrahydrofuran was removed under reduced pressure. Water was added and organic layer was extracted with ethyl acetate, dried and concentrated in vacuo. Residue was purified by column chromatography.
[0221] Yield: 63%; m.p.: 105°-106°; 1 H NMR: CDCl 3 δ=7.33-7.34 (d, 1H,), 6.96-6.99 (d, 1H,), 6.84-6.87 (d, 1H), 4.80-4.84 (m, 1H,), 3.86-3.88 (s, 3H), 3.80-3.86 (d, 1H), 3.36-3.41 (d, 1H), 1.80-2.0 (m, 8H), 1.56-1.63 (s, 3H); Mass (m/z) 301.5 (M + +1).
Example 4
Preparation of [3-(3-Cyclopentyloxy-4-methoxyphenyl)-N-hydroxy-5-methyl-4, 5-dihydroisoxazole-5-carboxamidine
[0222] [3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazole-5-carbonitrile (200 mg, 0.0006 mole, example 3) was dissolved in 5 mL ethanol. To it anhydrous potassium carbonate (138 mg, 0.0009 mole) and hydroxylamine hydrochloride (92 mg, 0.0013 mole) was added & refluxed. Ethanol was removed under reduced pressure, water was added. Organic layer was extracted with ethyl acetate, washed with saturated sodium chloride solution, dried and concentrated in vacuo.
[0223] Yield: 95%; Mass (m/z): 334.21 (M + +1).
Example 5
Preparation of 3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazole-5-carboxylic acid hydrazide (Compound No. 104)
[0224] To the ester (300 mg, 0.00086 mole, scheme I, Formula VI), hydrazine-hydrate (0.21 mL, 0.0043 mole) was added. Reaction mixture was heated at 120° C. Reaction mixture was cooled, water was added, solid, which was separated out, was filtered and dried under vacuum.
[0225] Yield: 49%; m.p: 159-160°; 1 H NMR (CDCl 3 ): δ 8.01 (s, 1H), 7.25-7.28 (d, 1H), 6.99-7.02 (d, 1H), 6.81-6.84 (d, 1H), 4.77-4.80 (m, 1H), 3.86 (s, 3H), 3.72-3.80 (d, 1H), 3.20-3.25 (d, 1H), 1.61-2.03 (m, 11H); Mass (m/z): 334.2 (M + +1).
Example 6
Preparation of 5-[3-(3-3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4-,5-dihydroisoxazol-5-yl]-1H-tetrazole (Compound No. 9)
[0226] [3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazole-5-carbonitrile (0.00029 mole, 100 mg, example 3), sodium azide (28 mg, 0.0004 mole) and triethylamine hydrochloride (0.0005 mole, 80 mg) was taken in 20 mL toluene. Reaction mixture was refluxed overnight. Toluene was removed and then added water to it. Extracted with ethyl acetate, washed with brine, dried and concentrated in vacuo.
[0227] Yield: 79%; m.p.: 161° C.; 1 H NMR (MeOD): δ 7.282-7.288 (d, 1H), 7.11-7.15 (d, 1H), 6.93-6.95 (d, 1H), 4.8 (m, 1H), 3.94-4.0 (d, 1H), 3.81 (s, 3H), 3.61-3.675 (d, 1H), 1.59-1.86 (m, 11H); Mass (m/z): 344.22 (M + +1).
Example 7
Preparation of 3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-4H-[1,2,4]oxadiazole-5-thione (Compound No. 2)
[0228] A mixture of [3-(3-Cyclopentyloxy-4-methoxyphenyl)-N-hydroxy-5-methyl-4,5-dihydroisoxazole-5-carboxamidine (0.0006 mole, 200 mg, example 4), thiocarbonyldiimidazole (0.0009 mole, 160 mg) and 1,8-diazabicyclo[5.4.0]undec-7-one (0.002 mol-358 mL) was taken in acetonitrile and stirred at an ambient temperature. Acetonitrile was removed under reduced pressure, water was added, organic layer was extracted with ethyl acetate, washed with saturated sodium chloride solution, dried and concentrated in vacuo. The residue was purified by column chromatography.
[0229] Yield: 50%; m.p: 172° C.; 1 H NMR (CDCl 3 ): δ 7.26 (d, 1H), 6.98-7.01 (d, 1H), 6.83-6.86 (d, 1H), 4.78-4.81 (m, 1H), 3.88-3.92 (d, 1H), 3.86 (s, 3H), 3.40-3.45 (d, 1H), 1.25-2.04 (m, 11H); Mass (m/z): 376.15 (M + +1).
Example 8
Preparation of 2-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 4)
[0230] To 3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazole-5-carboxylic acid hydrazide (250 mg, example 5) was added triethylorthoformate (5 mL). Reaction mixture was heated at 120° C. for 3 hours. Excess triethylorthoformate was evaporated and the residue was heated at 140° C. for 2 hours. Reaction mixture was diluted with water, saturated with potassium carbonate and extracted with ethyl acetate. Organic layer was dried, concentrated and purified by column chromatography.
[0231] Yield: 39%; m.p: 95° C.; 1 H NMR (CDCl 3 ): δ 8.44 (s, 1H), 7.37 (d, 1H), 7.05-7.08 (d, 1H), 6.85-6.88 (d, 1H), 4.82-4.83 (m, 1H), 4.19-4.24 (d, 1H), 3.88 (s, 3H), 3.43-3.49 (d, 1H), 1.62-2.30 (m, 8H), 1.24-1.28 (s, 3H); Mass (m/z): 344.16 (M + +1).
Example 9
Preparation of 2-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-methyl-[1,3,4]oxadiazole (Compound No. 5)
[0232] Prepared as described in example 8 by using triethylortho acetate instead of triethylortho formate.
[0233] Yield: 75%; m.p: oily; 1 H NMR (CDCl 3 ): δ 7.364 (s, 1H), 7.04-7.07 (d, 1H), 6.84-6.87 (d, 1H), 4.816 (s, 1H), 4.16-4.21 (d, 1H), 3.88 (s, 3H), 3.37-3.43 (d, 1H), 2.556 (s, 3H), 1.621-2.15 (m, 8H), 1.25-1.31 (m, 3H); Mass (m/z) 358.23 (M + +1).
Example 10
Preparation of 3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-4H-[1,2,4]thiadiazol-5-one (Compound No. 3)
[0234] Amidoxime (200 mg, 0.0006 mole, scheme L Formula VII) was taken in 3 mL tetrahydrofuran. To it thiocarbonyl diimidazole (160 mg, 0.0007 mole) was added. Reaction mixture was stirred at an ambient temperature. The reaction mixture was diluted with water, extracted with ethyl acetate, washed with water, dried and concentrated in vacuo. The residue was dissolved in tetrahydrofuran. Boron trifluoride etherate was added dropwise. The reaction mixture was stirred at an ambient temperature for 2 hours, diluted with water, extracted with ethyl acetate, dried, concentrated in vacuo and purified by column chromatography.
[0235] Yield: 23%; m.pt: 204° C.; 1 H NMR (CDCl 3 ): δ 7.319 (s, 1H), 7.015-7.042 (d, 1H), 6.83.6.85 (d, 1H), 4.80-4.82 (m, 1H), 3.95-4.00 (d, 1H), 3.87 (s, 3H), 3.33-3.39 (d, 1H), 1.83-2.04 (m, 8H), 1.25-1.62 (m, 3H); Mass (m/z): 376.14 (M + +1).
Example 11
Preparation of 3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-4H-[1,2,4]oxadiazol-5-one (Compound No. 1)
[0236] Amidoxime (100 mg, 0.0003 mole, scheme I, Formula VII) was taken in dimethylformamide (1 mL). At 0° C. pyridine was added then at same temperature methyl chloroformate was added dropwise. The reaction mixture was stirred at 0° C. for about 30 minutes, water was added and organic layer was extracted with ethyl acetate, washed with saturated sodium chloride solution, dried and concentrated in vacuo. To residue xylene (5 ml) was added and refluxed for 18 hours. Xylene was removed under reduced pressure. The crude product was purified by column chromatography.
[0237] Yield: 37%; m.pt.: oily; 1 H NMR (CDCl 3 ): δ 7.29 (s, 1H), 7.01-7.04 (d, 1H), 6.84-6.87 (d, 1H), 4.78-4.81 (m, 2H), 3.91-3.96 (d, 1H), 3.88 (s, 3H), 3.31-3.40 (d, 1H), 1.22-2.00 (m, 11H); Mass (m/z): 360.18 (M + +1).
Example 12
Preparation of 3-{3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-[1,2,4]]oxadiazol-5-yl}-pyridine (Compound No. 7)
[0238] Nicotinic acid (0.0002 mole, 30 mg) was dissolved in dry dimethylformamide (1 mL). To it, molecular sieves (100 mg, 4 A°) and triethylamine (0.0003 mole, 0.05 mL) was added. The reaction mixture was cooled to −20° C. and isobutylchloroformate (0.0004 mole, 0.06 mL) was added. After 10 minutes amidoxime (0.0004 mole, 160 mg, scheme I, Formula VII) in dimethylformamide (2 mL) was added. The reaction mixture was stirred at an ambient temperature overnight. Some fresh molecular sieves were added. The reaction mixture was heated at 120° C. for 12 hours, mixture was filtered. To filtrate water was added, extracted with ethyl acetate, washed, dried and concentrated in vacuo. The residue was purified by column chromatography.
[0239] Yield: 25%; m.p.: oily; 1 H NMR (CDCl 3 ): δ 9.38 (s, 1H), 8.83-8.84 (d, 1H), 8.42-8.44 (d, 1H), 7.47-7.51 (m, 2H), 7.06-7.09 (d, 1H), 6.85-6.87 (d, 1H), 4.81-4.83 (m, 1H), 4.07-4.13 (d, 1H), 3.88 (s, 3H), 3.41-3.46 (d, 1H), 1.62-2.09 (m, 8H), 0.8-0.98 (m, 3H); Mass (m/z): 421.40 (M + +1).
[0240] The following compounds were prepared following the above procedure
-4-{3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazol-5-yl}-pyridine (Compound No. 57),
[0242] Mass (m/z): 421.40 (M + +1)
-5-tert-Butyl-3-[3-(3-cyclopentyloxy-4-methoxyphenyl-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 58),
[0244] Mass (m/z): 400.42 (M + +1)
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(2-ethoxy-phenyl)-[1,2,4]oxadiazole (Compound No. 59),
[0246] Mass (m/z): 464.43 (M + +1)
[0247] m.p.: 138.5-139° C.
-2,6-Dichloro-4-{3-[3-(3-cyclopentyloxy-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazol-5-yl}-pyridine (Compound No. 64),
[0249] Mass (m/z): 489 (M + +1)
[0250] m.p.: 136.5° C.
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-isopropyl-[1,2,4]oxadiazole (Compound No. 65),
[0252] m.p.: 87° C. Mass (m/z): 396.00 (M + +1)
-5-Cyclohexyl-3-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 66),
[0254] Mass (m/z): 426.42 (M + +1)
-5-(2-Chlorophenyl)-3-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 76),
[0256] Mass (m/z): 454.31 (M + +1)
[0257] m.p.: 122° C.
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(2,4-dichloro-phenyl)-[1,2,4]oxadiazole (Compound No. 77),
[0259] Mass (m/z): 488.25 (M + +1)
[0260] m.p.: 129° C.
Example 13
Preparation of 5-tert-Butyl-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-[1.2.4]oxadiazole (Compound No. 8)
[0261] Amidoxime (100 mg, 0.0003 mole, scheme I, Formula VII) was taken in benzene (2 mL). Pivaloyl chloride (0.1 mL, 0.0009 mole) was added. The reaction mixture was refluxed for about 3 hours. Benzene was removed under reduced pressure. The residue was dissolved in ethyl acetate, washed with saturated sodium bicarbonate solution, dried and concentrated in vacuo. The residue was taken is dimethylformamide (5 mL) and refluxed for 3 hours. Dimethylformamide was removed under reduced pressure, water was added, extracted with ethyl acetate, dried and concentrated in vacuo.
[0262] Yield: 25%; m.p.: sticky solid; 1 H NMR (CDCl 3 ): δ 7.39-7.40 (d, 1H), 7.04-7.08 (d, 1H), 6.84-6.87 (d, 1H), 4.80-4.83 (m, 1H), 4.02-4.07 (d, 1H), 3.87 (s, 3H), 3.31-3.36 (d, 1H), 1.74-1.96 (m, 8H), 1.43 (s, 9H), 1.24-1.35 (m, 3H); Mass (m/z): 400.42 (M + +1).
Example 14
Preparation of 3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-4-methyl-4H-[1,2,4]oxadiazole-5-thione (Compound No. 6)
[0263] 3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-4H-[1,2,4]oxadiazole-5-thione (0.0001 mole, 40 mg, example 7), was dissolved in acetone (2 mL). To it potassium carbonate (0.001 mole, 147 mg) and methyliodide (0.0002 mole, 0.016 mL) were added. The reaction mixture was refluxed for overnight. Filtered to remove potassium carbonate, washed with acetone. From filtrate, acetone was removed under reduced pressure to give a low melting solid compound.
[0264] Yield: 72%; 1 H NMR (CDCl 3 ): δ 7.38 (d, 1H), 7.03-7.06 (d, 1H), 6.83-6.86 (d, 1H), 4.80-4.82 (m, 1H), 3.97-4.02 (d, 1H), 3.87 (s, 3H), 3.31-3.37 (d, 1H), 2.72 (s, 3H), 1.80-1.99 (m, 8H), 1.26-1.32 (m, 3M); Mass (m/z): 390.38 (M + +1).
Example 15
General Method of Preparation of Compound of Formula XX (wherein R 1 ═X 1 ═CH 3 , Y 1 ═R 4 ═Y 2 ═H, X 2 =cyclopentyl and n=1)
[0265] Method A: To a stirred solution of 3-(3-Cyclopentyloxy-4-methoxy-phenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-methylamine (0.3569 mmol, 1 equiv, Scheme II, Formula XIX) in 2 mL chloroform was added triethylamine (2.6767 mmol, 7.5 equiv). Compound of Formula R 12 COCl (0.3925 mmol, 1.1 equiv) was added dropwise over a period of 15 minutes with stirring the solution vigorously. The reaction was allowed to stir at an ambient temperature. The reaction mixture was quenched by adding 5 mL water. The resulting mixture was extracted with chloroform. The organic layer was thoroughly washed with water and was dried over anhydrous sodium sulphate, filtered and concentrated over buchi to afford the crude product. The crude product was purified over silica gel column (100-200 mesh) using hexane and ethyl acetate mixture as eluent.
[0000] The following compounds were prepared following the above general procedure
[0000]
-Morpholine-4-carboxylic acid [3-(3-cyclopentyloxy-4-methoxy-phenyl)-5-methyl-4,5-dihydro-isoxazol-5-ylmethyl]-amine (Compound No. 11),
[0267] Mass (m/z): 418.30 (M + +1),
—N-[3-(3-Cyclopentyloxy-4-methoxy-phenyl)-5-methyl-4,5-dihydro-isoxazol-5-ylmethyl]-4-fluoro-benzamide (Compound No. 12),
[0269] Mass (m/z): 427.27 (M + +1),
-Adamantane-1-carboxylic acid [3-(3-cyclopentyloxy-4-methoxy-phenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl-methyl]amide (Compound No. 13),
[0271] Mass (m/z): 467.44 (M + +1),
-Furan-2-carboxylic acid [3-(3-cyclopentyloxy-4-methoxy-phenyl)-5-methyl-4,5-dihydro-isoxazol-5-ylmethyl]-amide (Compound No. 14),
[0273] Mass (m/z): 339.24 (M + +1),
-1-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl-methyl]-3-(2-trifluoromethyl)-phenyl)-urea (Compound No. 16),
[0275] Mass (m/z): 492.40 (M + +1)
-1-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl-methyl]-3-(2,4-difluorophenyl)-urea (Compound No. 17),
[0277] Mass (m/z): 460.31 (M + +1)
-1-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl-methyl]-3-O-tolyl-urea (Compound No. 18),
[0279] Mass (m/z): 438.31 (M + +1)
-Morpholine-4-carboxylic acid [3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl-methyl]-amide (Compound No. 19),
[0281] Mass (m/z): 418.30 (M + +1)
[0282] Method B: To a solution of 3-(3-Cyclopentyloxy-4-methoxy-phenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-methylamine (0.3407 mmol, 1 equiv, scheme II, Formula XX and R 12 COOH (0.3407 mmol, 1 equiv.) in 0.8 mL dry dimethylformamide at 0° C. was added 1-hydroxybenzotriazole (0.3407 mmol, 1 equiv) and N-methylmorpholine (1.3628 mmol, 4 equiv.). The reaction mixture was allowed to stir at 0° C. for 30 minutes. Thereafter, 1-[3-(dimethylamino)propyl-3-ethyl]carbodiimide hydrochloride (0.6814 mmol, 2 equiv.) was added to the reaction mixture and reaction was continued at 0° C. for 1 hour and thereafter at an ambient temperature for 20 hours. The reaction was quenched by adding water. The resulting reaction mixture was extracted with ethyl acetate. The ethyl acetate layer was dried over anhydrous sodium sulphate, concentrated in vacuo to afford the crude product. The crude product was purified over silica gel column (100-200 mesh) using hexane and ethyl acetate mixture as eluent.
[0000] The following compound was prepared following the above procedure (Method B)
[0000]
-2-(3-Cyclopentyloxy-4-methoxy-phenyl)-N-[3-(3-cyclopentyloxy-4-methoxy-phenyl)-5-methyl-4,5-dihydro-isoxazol-5-ylmethyl]-acetamide (Compound No. 15)
[0284] Mass (m/z): 523.37 (M + +1)
Example 16
General Method of Preparation of Compound of Formula IX (wherein R 4 ═Y 1 ═Y 2 ═H, R 1 ═CH 3 , X 1 ═CHF 2 , X═Y═O, R 11 ═H)
[0000] Step 1: Preparation of Compound of Formula VI
[0285] Oxime (Formula IV, scheme I, 1 equiv.) and methyl methacrylate (10 equiv.) were taken in tetrahydrofuran. At ambient temperature sodium hypochlorite solution was added dropwise. The reaction mixture was stirred at room temperature for overnight. Tetrahydrofuran was removed under reduced pressure. Water was added and extracted with ethyl acetate. The mixture washed with saturated sodium chloride solution, dried over anhydrous sodium sulfate and concentrated in vacuo to give pure compound.
[0000] Step 2: Preparation of Compound of Formula VIII
[0286] To the ester compound (Formula VI, step 1) hydrazine hydrate (10 equiv.) was added and allowed to stir at 120° C. for about 3 hours. When the reaction was complete, it was cooled and water was added. Solids which separated out were filtered, dissolved in ethyl acetate, washed with water, dried over anhydrous sodium sulfate and concentrated in vacuo to give pure compound.
[0000] Step 3: Preparation of Compound of Formula IX
[0287] Hydrazide (Formula VIII, step 2) and triethylorthoformate (5 ml per mmole) were heated at 120° C. for about 3 hours. Excess triethylorthoformate was evaporated and the residue heated for further about 2 hours at 140° C. When the reaction was complete, the reaction mixture was diluted with water, saturated with potassium carbonate and extracted with ethyl acetate. Organic layer was dried and concentrated in vacuo. Purification was done by column chromatography to give pure compound.
[0000] The following compounds were prepared following the above general procedure
[0000]
-2-[3-(4-Difluoromethoxy-3-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 80)
[0289] Mass (m/z): 326.12 (M + +1),
-2-{3-[3-(Bicyclo[2.2.1]hept-2-yloxy)-4-difluoromethoxyphenyl]-5-methyl-4,5-dihydro-isoxazol-5-yl}-[1,3,4]oxadiazole (Compound No. 81),
[0291] Mass (m/z): (M + +1)
-2-{3-[3-(benzyloxy)-4-difluoromethoxyphenyl]-5-methyl-4,5-dihydro-isoxazol-5-yl}-[1,3,4]oxadiazole (Compound No. 82)
[0293] Mass (m/z): 402.11 (M + +1),
-2-[3-[4-Difluoromethoxy-3-ethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 83)
[0295] Mass (m/z): 340.12 (M + +1),
-2-[3-[4-Difluoromethoxy-3-isopropoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 84)
[0297] Mass (m/z): 354.0 (M + +1),
-2-[3-(3-Cyclohexyloxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 85)
[0299] Mass (m/z): 394.16 (M + +1),
-2-[3-(3-Butoxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 86)
[0301] Mass (m/z): 368.09 (M + +1),
-2-[3-(3-Cycloheptyloxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 87)
[0303] Mass (m/z): 408.17 (M + +1),
-2-[3-(4-Difluoromethoxy-3-propoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 88)
[0305] Mass (m/z): 354.14 (M + +1),
-2-[3-(3,4-Bis-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 89)
[0307] Mass (m/z): 362.21 (M + +1),
-2-[3-(3-Cyclopentyloxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 90)
[0309] Mass (m/z): 380.19 (M + +1),
-2-[3-(3-Cyclopropylmethoxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 91)
[0311] Mass (m/z): 366.18 (M + +1),
-2-[3-(3-Cyclopropylmethoxy-4-methoxy-phenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 92),
[0313] Mass (m/z): 330.18 (M + +1)
-2-[3-(3-Difluoromethoxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]oxadiazole (Compound No. 93)
[0315] Mass (m/z): 326.11 (M + +1),
Example 17
General Method of Preparation of Compound of Formula XXIV (wherein R 4 ═Y 1 ═Y 2 ═H, R 1 ═X 1 ═CH 3 , X 2 =cyclopentyl, X═Y═O)
[0000] Step 1: Preparation of Compound of Formula XXIII
[0316] Nitriles (Formula XXII, Scheme III, 1 equiv.) was taken in solution of ethanol/water (1:4) and stirred for about 5 minutes. To this hydroxylamine hydrochloride (3.7 equiv.) and sodium carbonate (1.8 equiv.) were added and stirred for about 10 minutes at ambient temperature. The reaction mixture was stirred at reflux for about 18 hours. Ethanol was removed under reduced pressure. Water was added and triturated. Solid which precipitates out was filtered and dried under vacuo to give the desired amidoxime.
[0000] Step 2: Preparation of Compound of Formula XXIV
[0317] Acid (Formula VI, Scheme I, 1 equiv.) and amidoxime (Formula XXII, step 1, 1.1 equiv.) was taken in dry dimethylformamide. At 0° C. hydroxybenzotriazole (1 equiv.) and N-methyl morpholine (4 equiv.) were added and stirred at 0° C. for about one hour. At the same temperature 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride (2 equiv.) was added. The reaction mixture was stirred at room temperature for about 24 hours. Water was added, extracted with ethyl acetate, dried and concentrated in vacuo. Solid, which formed, was taken in ethanol:water (7:1) and sodium acetate (1.5 equiv.) was added. Reaction mixture was refluxed at 80-90° C. for about 3 hours. Cooled, solid, which separated out, was filtered and recrystallized with ethanol.
[0000] The following compounds were prepared following the above general procedure
[0000]
-3-(2-Chloro-6-trifluoromethylphenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl-[1,2,4]oxadiazole (Compound No. 20)
[0319] Mass (m/z): 522.22 (M + +1),
-3-(2-Chloro-4-fluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 21)
[0321] Mass (m/z): 472.22 (M + +1),
-3-(4-Chloro-2-methoxyphenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 22)
[0323] Mass (m/z): 484.25 (M + +1),
-3-(3-Chloro-4-fluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 23)
[0325] Mass (m/z): 472.22 (M + 1),
-3-(3-Chloro-4-methoxyphenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 24)
[0327] Mass (m/z): 484.25 (M + +1),
-3-(3-Fluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 25)
[0329] Mass (m/z): 438.21 (M + +1),
-3-(3,4-Difluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 26)
[0331] Mass (m/z): 456.2 (M + +1),
-3-(4-Methoxyphenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 27)
[0333] Mass (m/z): 450.27 (M + +1),
-3-(3,4-Dimethoxyphenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 28)
[0335] Mass (m/z): 480.27 (M + +1),
-3-(2-Chloro-6-fluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 29)
[0337] Mass (m/z): 472.22 (M + +1),
-3-(2,5-Difluoro-phenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 30)
[0339] Mass (m/z): 456.22 (M + +1),
-3-(2,6-Dichlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 31)
[0341] Mass (m/z): 488.18 (M + +1),
-3-(2,3-Dichloro-phenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 32)
[0343] Mass (m/z): 488.18 (M + +1),
-3-(2,4-Dichlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 33)
[0345] Mass (m/z): 488.18 (M + +1),
-3-(3,5-Dichlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 34)
[0347] Mass (m/z): 488.18 (M + +1),
-3-(2,5-Dichlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 35)
[0349] Mass (m/z): 488.18 (M + +1),
-3-(3,5-Difluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 36)
[0351] Mass (m/z): 456.28 (M + +1),
-3-(3-Chlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 37)
[0353] Mass (m/z): 454.20 (M + +1),
-3-(2,4-Difluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 38)
[0355] Mass (m/z): 456.27 (M + +1),
-3-(3,4-Dichlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 39)
[0357] Mass (m/z): 488.21 (M + +1),
-3-(4-Chlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 40)
[0359] Mass (m/z): 434.24 (M + +1),
-4-{5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole-3-yl}-phenylamine (Compound No. 41)
[0361] Mass (m/z): 435.27 (M + +1),
-3-Phenyl-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 42)
[0363] Mass (m/z): 420.30 (M + +1),
-3-(3,4-Dimethylphenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 43)
[0365] Mass (m/z): 448.32 (M + +1),
-3-(2-Chlorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 44),
[0367] Mass (m/z): 453.5 (M + +1),
-3-(4-Fluorophenyl)-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 45),
[0369] Mass (m/z): 438.29 (M + +1),
-3-Methyl-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 46).
[0371] Mass (m/z): 358.0 (M + +1),
Example 18
General Method of Preparation of Compound of Formula VI (wherein Y 1 ═Y 2 ═R 4 ═H, R 1 ═CH 3 , Rr=CN, (CH 2 ) 2 CN)
[0372] Oxime (Formula IV, scheme 1, 1 equiv.) and compound of Formula V (2 equiv.) were taken in tetrahydrofuran. At ambient temperature, sodium hypochloride solution was added dropwise. The reaction mixture was stirred at room temperature overnight. Tetrahydrofuran was removed under reduced pressure. Water was added, extracted with ethyl acetate, washed with saturated sodium chloride solution, dried and concentrated in vacuo. Purification was done by column chromatography using silica gel (100-200).
[0000] The following compounds were prepared following the above procedure
[0000]
-3-(3-Cyclopropylmethoxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 94),
[0374] Mass (m/z): 323.25 (M + +1)
-3-(3-Cyclopentyloxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 95),
[0376] Mass (m/z): 337.14 (M + +1)
-3-(3,4-Bis-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 96),
[0378] Mass (m/z): 319.15 (M + +1)
-3-(3-Cyclopropylmethoxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 97),
[0380] Mass (m/z): 287.24 (M + +1)
-3-(3-Butoxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 98),
[0382] Mass (m/z): 325.13 (M + +1)
-3-(4-Difluoromethoxy-3-propoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 99),
[0384] Mass (m/z): 311.07 (M + +1)
-3-(4-Difluoromethoxy-3-isopropoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 100),
[0386] Mass (m/z): 311.15 (M + +1)
-3-[3-(Bicyclo[2.2.1]hept-2-yloxy)-4-difluoromethoxyphenyl]-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 101),
[0388] Mass (m/z): 363.14 (M + +1)
-3-(3-Benzyloxy-4-difluoromethoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbonitrile (Compound No. 102),
[0390] Mass (m/z): 360.18 (M + +1)
Example 19
Preparation of 3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-methyl-[1,2,4]oxadiazole (Compound No. 56)
[0391] To a mixture of amidoxime (100 mg, 0.00030 mole, Scheme I, Formula VII) and powdered molecular sieves (4 A°, 500 mg), dry tetrahydrofuran (3 ml) was added. The reaction mixture was stirred for about 30 minutes. Sodium hydride (11 mg, 0.0003 mole) was added and heated at about 60° C. for about 45 minutes. Methyl acetate (0.047 ml, 0.0006 mole) was added to reaction mixture and refluxed at about 65-70° C. for one hour. The reaction mixture was filtered, and washed with ethyl acetate. The organic layer was concentrated under reduced pressure to give crude product, which was purified by column chromatography using silica gel (100-200). Yield: 50 mg.
[0000] The following compounds were prepared following the above procedure
[0000]
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-fluoromethyl-[1,2,4]oxadiazole (Compound No. 67),
[0393] Mass (m/z): 376.22 (M + +1)
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(3-fluorophenyl)-[1,2,4]oxadiazol (Compound No. 70),
[0395] Mass (m/z): 438.24 (M + +1)
-{3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazol-5-yl}-acetonitrile (Compound No. 71),
[0397] Mass (m/z): 383.24 (M + +1)
Example 20
Preparation of 3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(tetrahydro-furan-2-yl)-[1,2,4]oxadiazole (Compound No. 68)
[0398] Amidoxime (100 mg, 0.0003 mole, Scheme I, Formula VI) and tetrahydro-2-furoic acid (0.03 ml, 0.0003 mole) was taken in dimethylformamide (1 ml). At about 0° C., 1-hydroxybenzotriazole (40 mg, 0.0003 mole) and N-methylmorpholine (0.168 ml, 0.0012 mole) were added and stirred for about 1 hour. Thereafter, at about 0° C. 1-(3-dimethylaminopropyl)-3-ethyl carbodiimide hydrochloride (115 mg, 0.0006 mole) was added and stirred at room temperature for about 24 hours. Water (5 ml) was added, extracted with ethyl acetate. The ethyl acetate layer was dried over anhydrous sodium sulphate, and concentrated in vacuo. Dimethylformamide (2 ml) was added to the reaction residue. 50 mg powdered molecular sieves was added and refluxed at about 110-120° C. for about 4 hours. The resultant was filtered and washed with ethyl acetate. The organic layer was concentrated and purified by column chromatography using silica gel (100-200).
[0399] Yield: 40 mg
[0000] The following compounds were prepared similarly
[0000]
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-cyclopropyl-[1,2,4]oxadiazole (Compound No. 60),
[0401] Mass (m/z): 384.31 (M + +1); m.p.: 105-106° C.
-5-(3-Chlorophenyl)-3-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 61),
[0403] Mass (m/z): 454.31 (M + +1); m.p.: 103-104° C.
-5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-m-tolyl-[1,2,4]oxadiazole (Compound No. 62),
[0405] Mass (m/z): 434.42 (M + +1); m.p.: 131-132° C.
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(3,5-dimethyl-phenyl)-[1,2,4]oxadiazole (Compound No. 63),
[0407] Mass (m/z): 448.00 (M + +1); m.p.: 131° C.
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(4-fluoro-phenyl)-[1,2,4]oxadiazole (Compound No. 69),
[0409] Mass (m/z): 438.26 (M + +1); m.p.: 146.1-146.3° C.
-4-{3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole-5-yl)-benzonitrile (Compound No. 72),
[0411] Mass (m/z): 445.32 (M + +1)
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-trifluoromethyl-[1,2,4]oxadiazole (Compound No. 73),
[0413] Mass (m/z): 412.25 (M + +1)
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(3-methoxy-phenyl)-[1,2,4]oxadiazole (Compound No. 74),
[0415] Mass (m/z): 450.26 (M + +1); m.p.: 121-122° C.
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(3,4-dimethoxy-phenyl)[1,2,4]oxadiazole (Compound No. 75),
[0417] Mass (m/z): 480.32 (M + +1); m.p.: 119-120° C.
-5-Cyclopentyl-3-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,2,4]oxadiazole (Compound No. 78),
[0419] Mass (m/z): 412.33 (M + +1)
-3-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-5-(3,4-dichloro-phenyl)-[1,2,4]oxadiazole (Compound No. 79),
[0421] Mass (m/z): 488.17 (M + +1); m.p.: 113.5-114.9° C.
Example 21
Preparation of 2-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-pyridine (Compound No. 103)
[0422] 3-cyclopentyloxy-4-methoxybenzaldehyde oxime (250 mg, 1.063 mmol) and 2-vinyl-pyridine (167 mg, 1.595 mmol) were taken in tetrahydrofuran (3 ml). The reaction mixture was stirred for about 10 minutes. Sodium hypochloride solution (1 ml, 10.63 mmol) was added gradually over 15 minutes and stirred for 2 hours. THF was evaporated off and the residue was extracted with ethylacetate. The organic layer washed with water, dried over anhydrous sodium sulphate and concentrated. The product was purified using column chromatography. Mass (m/z): 339.21 (M + +1).
Example 22
Preparation of {5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]thiadiazol-2-yl}-cyclopropylamine (Compound No. 49)
[0423] 3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carboxylic acid (250 mg, 0.00078 mole) and cyclopropylthiosemicarbazide (102 mg, 0.00078 mole) were taken in dioxane (10 ml). At about 65° C., POCl 3 (0.07 ml, 0.00078) was added to the reaction mixture. The reaction mixture was refluxed at about 65° C. for about 5 hours and then at room temperature overnight. Dioxane was removed under reduced pressure. Saturated sodium bicarbonate solution was added. Extraction was done by ethyl acetate, and the extract washed with saturated sodium chloride solution. The product was dried over anhydrous sodium sulphate and concentrated in vacuo to give solid compound, which was further crystallized by ethanol to give white solid compound having m.pt—188-189° C. Yield=44 mg; Mass (M + +1)=415.
[0000] The following compound was prepared similarly
[0000]
-5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-[1,3,4]thiadiazol-2-yl-amine (Compound No. 48)
[0425] Mass (m/z): 375.37 (M + +1)
Example 23
Preparation of 3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-(4,5-dihydro-thiazol-2-yl)-5-methyl-4,5-dihydro-isoxazole (Compound No. 51)
[0426] 3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydroisoxazole-5-carbonitrile (70 mg, 0.0002 mole) and 2-aminoethanthiol hydrochloride (53 mg, 0.0004 mole) were taken in 5 ml ethanol. Triethylamine (0.04 ml, 0.0003 ml) was added to the reaction mixture and refluxed for about 5 hours. Ethanol was removed under reduced pressure to get crude compound, which was purified by column chromatography using silica gel (100-200). Yield: 50 mg; m.pt.: sticky solid.
Example 24
Preparation of 1-{5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-2-ethyl-2-methyl-[1,3,4]oxadiazol-3-yl}-ethanone (Compound No. 50)
[0427] Step a: Hydrazide (100 mg, 0.0003 mole, Scheme IA, Formula VI) was taken in ethanol (5 ml). Ethylmethyl ketone (0.03 ml, 0.0004 mole) was added. The reaction mixture was stirred at refluxing temperature for about 10 hours. Ethane was removed under reduced pressure to give oily compound.
[0428] Step b: The compound from step a was taken in pyridine (3 ml). One ml acetic anhydride was added and stirred at about 100° C. for about 8 hours. A mixture of acetic anhydride and pyridine was removed under reduced pressure. 5 ml cold water was added and extraction was done by ethyl acetate. The resultant washed with saturated sodium chloride solution, dried over anhydrous sodium sulphate and concentrated in vacuo to give crude compound, which was purified by column chromatography using silica gel (100-200).
Example 25
Preparation of 3′-(3-Cyclopentyloxy-4-methoxyphenyl)-5,5′-dimethyl-4,5,4′,5′-tetrahydro-[3,5′]biisoxazolyl-5-carbonitrile (Compound No. 52)
[0429] Step a: Oxime (350 mg, 0.00148 mole, Scheme I, Formula IV) and methacrolein (0.73 ml, 0.0089 mole) was taken in tetrahydrofuran (10 ml). Sodium hypochlorite solution (10 ml) was added dropwise to residue mixture. The reaction mixture was stirred at room temperature for about 14-16 hours. Tetrahydrofuran was removed under reduced pressure. Water (10 ml) was added, extracted with ethyl acetate, washed with saturated sodium chloride solution, dried over anhydrous sodium sulphate and concentrated in vacuo to give oily compound.
[0430] Step b: The compound from step a was taken in ethanol (10 ml) and to it hydroxylamine hydrochloride (160 mg, 0.0023 mole) and anhydrous sodium acetate (189 mg, 0.0028 mole) were added. The reaction mixture was stirred at room temperature for about one and half an hours. Ethanol was removed under reduced pressure, water was added, extracted with ethyl acetate. Dried over anhydrous sodium sulphate and concentrated in vacuo to give oily compound.
[0431] Step c:—The compound from step b was taken in tetrahydrofuran (5 ml) and to it methacrylonitrile (0.246 ml, 0.0036 mole) was added. Sodium hypochloride solution (3 ml) was added to reaction mixture dropwise within a 15 minute interval. The reaction mixture was stirred for about 15-16 hours. Tetrahydrofuran was removed under reduced pressure. Water (30 ml) was added, extracted with ethyl acetate. Dried over anhydrous sodium sulphate and concentrated in vacuo to give oily compound, which was purified by column chromatography using silica gel (100-200). Yield: 50 mg; m.pt: oily.
Example 26
Preparation of 5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-3H-[1,3,4]oxadiazole-2-thione (Compound No. 55)
[0432] Hydrazide (70 mg, 0.0002 mole, Scheme IA, Formula VIII) was taken in ethanol (5 ml). To it potassium hydroxide solution (0.11 g, 0.0002 mole) in 1 ml ethanol were added followed by carbon disulfide (1 ml). The reaction mixture was refluxed for about 8 hours. Ethanol was removed under reduced pressure. The reaction mixture was neutralized by dilute hydrochloride (2N), and extracted with ethyl acetate. The resultant washed with saturated sodium chloride solution, dried over anhydrous sodium sulphate and concentrated in vacuo to give crude product, which was purified by column chromatography using silica gel 100-200. Yield: 70 mg; m.pt: 195.5-200° C.
Example 27
Preparation of 4-Amino-5-[3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-4H-[1,2,4]triazole-3-thiol (Compound No. 54)
[0433] A mixture of 5-[3-(3-Cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazol-5-yl]-3H-[1,3,4]oxadiazole-2-thione (50 mg, 0.00013 mole, Example 26) and hydrazine hydrate (0.02 ml, 0.0003 mole) in ethanol (2 ml) were refluxed for about 6 hours. The solvent and excess hydrazine hydrate were removed under reduced pressure. Water was added, and the aqueous phase was extracted with ethyl acetate. The extract washed with brine, dried over anhydrous sodium sulphate and concentrated in vacuo to give crude product, which was recrystallized using ethyl acetate hexane (20:80). Yield: 15 mg; m.pt.: 228-229° C.
Example 28
Preparation of Acetic acid (Z)-2-amino-2-{3-[3-(cyclopentyloxy)-4-methoxyphenyl]-5-methyl-4,5-dihydroisoxazol-5-yl }vinyl ester (Compound No. 105)
[0434] [3-(3-Cyclopentyloxy-4-methoxyphenyl)-N-hydroxy-5-methyl-4,5-dihydroisoxazole-5-carboxamidine (Example 4, 0.0007 mole, 250 mg) was dissolved in dichloromethane. To it acetic anhydride (0.0007 mole, 0.07 ml) and triethyl amine (0.0007 mole, 0.105 ml) were added. The reaction mixture was stirred at an ambient temperature for about 2 hours. The mixture washed with water. The organic layer was dried over anhydrous sodium sulphate, concentrated in vacuo and the residue was purified over column chromatography. Yield: 46%; m.pt.: 130.9° C.; 1 H NMR (CDCl 3 ): δ 7.29-7.30 (d, 1H), 7.036-7.06 (d, 1H), 6.83-6.86 (d, 1H), 5.259 (s, 2H), 4.78-4.81 (m, 1H), 3.98 (d, 1H), 3.87 (s, 3H), 3.276-3.33 (d, 1H), 2.16 (s, 3H), 1.79-2.09 (m, 8H), 1.25-1.29 (m, 3H); Mass (m/z): 376.24 (M + +1).
Example 29
Preparation of 3-{3-[3-(cyclopentyloxy)-4-methoxyphenyl]-5-methyl-4,5-dihydroisoxazol-5-yl}-5-methyl-1,4,2-dioxazole-5-carboxylic acid ethyl ester (Compound No. 53)
[0435] To a solution of 3-(3-cyclopentyloxy-4-methoxyphenyl)-5-methyl-4,5-dihydro-isoxazole-5-carbaldehyde oxine (0.480 g, 1.5116 mmole) and 2-oxo propionic acid ethyl ester (1.052 g, 9.0698 mmole) in tetrahydrofuran was added bleach over a period of about 40 minutes. The reaction mixture was allowed to stir at room temperature for about one and half hours. Thereafter, tetrahydrofuran was removed over buchi. To the residue was added water (20 mL) and the resulting solution was extracted with ethyl acetate. Ethyl acetate layer was dried over anhydrous sodium sulphate and finally concentrated to afford an oily residue, which was purified by column chromatography. Yield: 0.200 g; m.p: 139-140° C.; Mass (m/z): 376.24 (M + +1).
Example 30
Efficacy of Compounds as PDE IV Inhibitors PDE-IV Enzyme Assay
[0436] The efficacy of compounds of PDE-4 inhibitors was determined by an enzyme assay using U937 cell cytosolic fraction ( BBRC, 197: 1126-1131, 1993). Hydrolysis of cAMP to AMP was monitored using HPLC and [ 3 H]cAMP in the sample was detected using FLO-ONE Detector.
[0437] The enzyme preparation was incubated in the presence and absence of the test compound for 30 min and amount, [ 3 H]cAMP measured in the sample. The IC 50 values were found to be in the range of double-digit nM to >10 μM concentration. | The present invention relates to isoxazoline derivatives and their analogues, which can be used as phosphodiesterase (PDE) type IV selective inhibitors. Compounds disclosed herein can be useful in the treatment of AIDS, asthma, arthritis, bronchitis, chronic obstructive pulmonary disease (COPD), psoriasis, allergic rhinitis, shock, atopic dermatitis, Crohn's disease, adult respiratory distress syndrome (ARDS), eosinophilic granuloma, allergic conjunctivitis, osteoarthritis, ulcerative colitis and other inflammatory diseases, especially in humans. Processes for the preparation of disclosed compounds, pharmaceutical compositions containing the disclosed compounds, and their use as PDE type IV selective inhibitors, are provided. | 2 |
BACKGROUND OF THE INVENTION
The present invention relates to containers, in particular, to containers featuring multiple product storage enclosures from which an individual product is selectively dispensable.
Containers possessing two or more enclosures, or compartments, for storing and selectively dispensing one of several products are known.
However, there still exists a need for a device possessing individual product dispensers that are releasably locked to each other.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a device for storing and selectively dispensing different products which comprises:
a) a first product dispenser for storing and dispensing a first product, the first product dispenser having a first end portion, a second end portion, a wall extending therebetween defining a fixed or detachable first enclosure and at least one outlet through which first product stored within the first enclosure is dispensable; and,
b) a second product dispenser for storing and dispensing a second product, the second product dispenser having a first end portion, a second end portion and a wall extending therebetween defining a fixed or detachable second enclosure and at least one outlet through which second product stored within the second enclosure is dispensable, the first end portion of the second product dispenser being configured for releasable locking engagement with the second end portion of the first product dispenser and having a cavity therein configured to receive the second end portion of the first product dispenser when the second end portion of the first product dispenser is in locked engagement with the first end portion of the second product dispenser.
The foregoing device can be provided in a large variety of dimensions, e.g., ranging from palm-sized to those approximating or even exceeding the dimensions of a ladies handbag or small item of hand-carried luggage.
Moreover, the device of this invention can be made to assume any of a large variety of configurations, particularly those providing an aesthetic visual appearance such as the embodiments described in the drawings, infra, while retaining the mechanical features that give it its distinctive utility as a dispensing container for a variety of different products.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
In the accompanying drawings, like reference numerals designate like structural elements throughout the figures thereof and wherein:
FIGS. 1A and 1B are isometric views of embodiments in accordance with the invention illustrating individual product dispensers in locked engagement with each other;
FIGS. 2A and 2B are isometric views of the device of FIG. 1A illustrating individual product dispensers disengaged from each other and each product enclosure separated from its recess within its respective product dispenser,
FIGS. 3A and 3B are isometric views of product dispensers respectively illustrating sponge-type and roller-type product applicators;
FIG. 4A is a sectional plan view in cross section of a device of the invention in the locked configuration and illustrating a first product dispenser with a detachable first enclosure and brush-type product applicator and a second product dispenser having a fixed second enclosure;
FIG. 4B is a plan view of the device of FIG. 4A taken through cross-sectional lines 4 B thereof and illustrating the arrangement of powder-dispensing outlets and associated brush applicator elements;
FIG. 5A is a cutaway plan view in cross section of another embodiment of device in accordance with the invention illustrating threads on the mutually engageable ends of the first and second product dispensers;
FIG. 5B is an exploded isometric view of a device of the invention illustrating the snap-fit engagement of the mutually engageable ends of the first and second product dispensers;
FIG. 5C is an isometric view of a second product dispenser having a hinged closure for its single product dispensing outlet;
FIGS. 6A and 6B are cutaway sectional views of a pull tab for facilitating the separation of a detachable enclosure from its recess within the product dispenser;
FIGS. 7A and 7B are plan views of three-product dispenser embodiments of the device herein; and,
FIGS. 8A and 8B are isometric views of the detachable first enclosure and detachable second enclosure, respectively, of FIG. 1A illustrating the hand-exerted bellows-like or compressive action which results in discharge of product therefrom.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIG. 1A , elongated container device 10 of generally oval cross section as viewed from its arbitrarily designated right side includes a first product dispenser 11 possessing first and second end portions 12 and 13 , respectively, a wall 14 extending therebetween and a detachable first enclosure, or replaceable first cartridge, 15 occupying enclosure-accommodating recess 16 defined within the first dispenser such that wall 17 of the enclosure together with wall 14 of the dispenser forms a substantially continuous smooth-walled exterior. First product dispenser 11 also features a thumb-actuated release 18 for facilitating the removal of enclosure 15 from its recess 16 within product dispenser 11 .
Container device 10 further includes a second product dispenser 19 possessing first and second end portions 20 and 21 , respectively, a wall 22 extending therebetween and a detachable second enclosure, or replaceable second cartridge, 23 occupying recess 24 defined within the second dispenser such that wall 25 of the enclosure together with wall 22 of dispenser 19 forms a substantially continuous smooth-walled exterior.
In the configuration of the device shown in FIG. 1A , second end portion 13 of first product dispenser 11 is shown in releasably locked engagement with first end portion 20 of second product dispenser 19 . Second end portion 21 of product dispenser 19 possesses a hinged closure member 26 for sealing the outlet of the second enclosure. An optional gripping or attachment component, e.g., carabiner 27 , is connected to first end portion 12 of first product dispenser 11 .
Shown in phantom in FIG. 1A is an arcuate arrangement of optional bristle elements 28 associated with one or more restricted outlets at second end portion 13 of first product dispenser 11 . As illustrated in greater detail in FIGS. 4A and 4B , infra, bristle elements 28 occupy a complementary arcuate cavity defined within first end portion 20 of second product dispenser 19 .
The embodiment of elongated container device 30 shown in FIG. 1B is similar to that shown in FIG. 1A except that the device is viewed from its left side and first and second product dispensers 31 and 32 possess fixed enclosures 33 and 34 , respectively.
Each product dispenser is adapted for the storage and dispensing of a single product from either 9 fixed or detachable closure. In the embodiment of the device of FIG. 1A , detachable first enclosure 15 can contain a powdery product, e.g., talcum powder, which upon being dispensed therefrom is to a large extent deposited upon its associated product applicator, i.e., bristle elements 28 , from which the powder may then be applied to the skin. Once emptied of powder, the enclosure 15 can be removed from its recess within first product dispenser 11 and a full replacement enclosure, or cartridge, inserted in its place. Similarly, detachable second enclosure 23 once emptied of its contents, e.g., an antimicrobial liquid, cosmetic lotion, cream, sunscreen, medicated ointment, etc., can be removed from its recess 24 within second product dispenser 19 and replaced with a fresh cartridge.
FIG. 2A illustrates first product dispenser 11 of FIG. 1A with its detachable enclosure 15 shown separated from its recess 16 . First enclosure 15 can be inserted into recess 16 from either the left or the right side of product dispenser 11 or from one side only where the opposite side of the dispenser is defined by a continuous wall. Peelable tape 35 provides a temporary closure for outlets 36 of enclosure 15 and may be removed at the time when enclosure 15 is inserted into its recess.
FIG. 2B illustrates second product dispenser 19 with its detachable second enclosure 23 separated from recess 24 . Detachable second enclosure 23 can be inserted into its recess 24 from either the left or the right side of second product dispenser 19 or from one side only where the opposite side of the dispenser is defined by a continuous wall. Peelable tape 37 provides a temporary closure for outlet 38 of enclosure 23 and may be removed at the time the enclosure 23 is inserted into its recess. Hinged closure member 26 at second end 21 of the second product dispenser 19 is shown in its open position to reveal outlet 39 which is aligned with outlet 38 of enclosure 23 to provide a substantially continuous conduit for dispensed product.
FIGS. 3A and 3B illustrate first product dispensers 40 and 50 having, respectively, sponge applicator 41 and roller applicator 51 for receiving product, e.g., liquid, gel, etc., dispensed from detachable first enclosure 15 , and applying the dispensed product to a surface, e.g., skin.
FIG. 4A illustrates in cross section plan view modification 60 of the embodiment of FIG. 1A wherein in place of detachable second enclosure 23 of the latter, the former possesses a fixed second enclosure 23 a as the product-storing portion of second product dispenser 61 .
In the plan view of the device of FIG. 4A taken through cross sectional lines 4 B thereof, there is illustrated in FIG. 4B an arrangement of bristle elements 28 and associated powder-discharging outlets, or orifices, 29 positioned at second end portion 13 of first product dispenser 11 .
FIG. 5A illustrates a cutaway plan view in cross section of an embodiment 70 of the invention wherein detached second end portion 13 of first product dispenser 11 and first end portion 20 of detached second product dispenser 19 are both of circular cross section. External threading 71 on first end portion 13 and internal threading 72 on first end portion 20 provide for locking engagement of product dispensers 11 and 19 .
FIG. 5B is an exploded isometric view of an embodiment 80 of the device of the invention in which first end portion 13 of first product dispenser 11 and second end portion 20 of second product dispensing 19 are generally ovoid in cross section allowing for friction fit-locking engagement, e.g., as shown in the embodiment of FIG. 4A .
FIG. 5C illustrates another embodiment 85 of second product dispenser 19 wherein offset hinged closure member 26 positioned at second end portion 21 of second product dispenser 19 , shown in the open position, provides sealing of outlet 39 .
FIGS. 6A and 6B illustrate cutaway views 90 and 90 a of pull tab 18 shown in the embodiments illustrated in FIGS. 3B , 5 B, 7 A, 7 B and 8 A. Downward (outward) biased movement of pull tab 18 a facilitates detachment of detachable first enclosure 15 from its recess in the first product dispenser. In place of pull tab 18 , there may be provided a thumb actuated snap lock/release mechanism of known or conventional construction for facilitating alternate locking engagement and release of detachable first enclosure 15 from within its recess in the product dispenser.
FIGS. 7A and 7B illustrating 3-product embodiments of the device of the invention and possess a third product dispenser 100 a and 200 a , respectively, positioned between the other two. Numerous other arrangements, including the positioning of product dispenser outlets, may be provided as desired.
FIGS. 8A and 8B illustrate the discharge of product from detachable first and second enclosures 15 and 23 shown in FIGS. 2A and 2B , respectively. In the case of detachable first enclosure 15 in FIG. 8A , a cosmetic powder, e.g., talcum powder, is dispensed therefrom by a bellows-like, or compressing, action exerted against a lateral wall or walls 17 of the enclosure. Similarly, in the case of detachable second enclosure 23 in FIG. 8B a bellows-like or compressing, action exerted against one or both walls 22 cause a fluid product, e.g., an antimicrobial liquid, to be dispensed therefrom.
Other embodiments of the invention will be apparent to those skilled in the art from a consideration of this specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the true scope and spirit of the invention being defined by the following claims. | A device for storing and dispensing different product possesses at least two interlocking product dispenser units each possessing a product dispensing outlet through which stored product may be selectively dispensed. | 0 |
This invention relates to a rear fairing to reduce the drag incident to relatively high speed movement of box-like bodies, such as trucks, trailers and cargo containers to save fuel and thereby reduce the cost of operation during transport of the box-like body.
BACKGROUND OF THE INVENTION
It is well-known in the prior art that there is a considerable drag induced by the flat rear box-like ends of trucks and trailers, particularly when operated at relatively high speeds, such as 55 miles per hour and higher. When such vehicles are operated on a long haul over considerable distances, the excess fuel consumed due to the drag created by the structure of the vehicle becomes a major item of expense, especially when one considers the cost of fuel at the present time.
This problem, however, is not limited to the trucking industry. The railroads, in an effort to compete with the trucking industry, have resorted to use of piggyback railroad cars to transport trailers and cargo containers, also at relatively high speeds. The trailers and cargo containers so transported on specially designed articulated railroad cars for the trailer or flat bed cars for the cargo containers present the same problem faced by the trucking industry with respect to drag during relatively high speed movement and subsequent fuel consumption.
While various means have been proposed in the prior art to attack this problem, none have so far gained universal acceptance, if any. Flat-backed trucks, trailers and cargo containers continue to cruise the roads without regard to the drag they create.
It is an object accomplished by this invention to provide improved means to reduce the drag incident to relatively high speed movement of box-like bodies, such as trucks, trailers, cargo containers, and the like.
A further object is to reduce the drag incident to such movement by providing a rear fairing for such uses and shaped according to aerodynamic principles, yet practically adapted to the desired use.
SUMMARY OF THE INVENTION
The foregoing and other objects of the invention are accomplished by providing a fairing for the rear end of a truck, trailer or cargo container which has two or more outer surfaces shaped to approximate the upper surface of an airfoil and facilitate smooth, two and three dimensional air flow, depending upon the design of the fairing and its environment of use, without flow separation, thereby reducing the drag to a minimum.
More specifically, the fairing of the present invention preferably is detachably affixed to the rear end of a truck, trailer body or cargo container by means hereinafter described.
The reduced wind drag created by the fairing results in a corresponding decrease in the horse power required by the truck, trailer tractor, or railroad car, and therefore an increase in the miles traveled per gallon of fuel used. While the fuel consumption will obviously vary with the design of the fairing, the intended use and the conditions of use, it is nevertheless to be noted that a considerable savings in fuel consumption of the propelling engine can be achieved by use of the fairing of the present invention.
Considering the substantial number of trailers and trucks used in the industry, and the miles traveled by each, it is clear that a savings of even 10% represents a most significant energy and cost saving.
To accomplish the foregoing objectives, the present invention utilizes aerodynamic principles in the formation of the outer surfaces of the fairing.
Essentially, two embodiments of the fairing are contemplated:
The first comprises a rear fairing in which two upright side walls are aerodynamically contoured and terminate in a vertical apex, the top and bottom walls thereof being substantially flat. This embodiment is particularly adapted for use on the rear ends of piggyback containers and truck trailers transported on flat bed railroad cars, especially between cars, but of course, can be used as well on other vehicles, such as self-propelled trailors and trucks.
The second embodiment comprises a rear fairing in which two upright side, top and bottom walls are all aerodynamically contoured and terminate in a vertical apex. This embodiment is particularly adapted for use on the rear ends of self-propelled trucks and trailer bodies transported over the road by trailer trucks, and also on the most rear end of a succession of trailer bodies transported on piggyback railroad cars. This is the most preferred embodiment of the invention.
The fairing of this invention is particularly designed for detachable mounting on the rear end of trucks, trailers and cargo containers, thereby providing more flexability in adaptation of the structure for various uses and conditions of use. For this purpose, a number of means for attachment of the fairing to such box-like bodies are hereinafter described.
DETAILED DESCRIPTION OF THE INVENTION
The invention will be more fully understood by the following detailed description and the appended drawings in which:
FIG. 1 is a schematic view in perspective from the rear end of a fairing illustrating the first embodiment described above;
FIG. 2 is a similar view of the second and preferred embodiment;
FIG. 3 is a schematic view of a representative airfoil illustrating the basic terminology in describing airfoils;
FIG. 4 is a schematic plan view of one half of a fairing and rear of a trailer illustrating the manner in which the sidewalls of the fairing may be designed;
FIG. 5 is a view similar to FIG. 4;
FIG. 6 is a schematic top plan view of a truck trailer provided with a fairing according to FIG. 1;
FIG. 7 is a side elevational view thereof;
FIG. 8 is a rear end elevational view thereof;
FIG. 9 is a front elevational view showing the interior of the fairing of FIGS. 6-8;
FIG. 10 is a schematic side elevational view of a truck trailer provided with a fairing according to FIG. 2;
FIG. 11 is a rear end elevational view thereof;
FIG. 12 is a top plan view of one means for mounting the fairing 1 to a trailer 14;
FIG. 13 is a side elevational view thereof, partly in section;
FIG. 14 is a top plan view of another means for mounting the fairing 1 to a trailer 14;
FIG. 15 is a side elevational view thereof, partly in section;
FIG. 16 is a top plan view of yet another means for mounting the fairing 1 to a trailer 14;
FIG. 17 is a side elevational view partly in section of a top bracket of FIG. 16;
FIG. 18 is a side elevational view partly in section of a bottom bracket of FIG. 16;
FIG. 19 is a side elevational of attachment means for use with the brackets of FIGS. 16-18; and
FIG. 20 is a bottom plan view of the attachment means of FIG. 19.
As indicated above, FIG. 1 is a schematic view of a first embodiment of the fairing 1 of this invention, in which the upright side walls 2 and 4 are aerodynamically contoured and the top 6 and bottom 8 are substantially flat surfaces, all surfaces terminating rearwardly of the fairing in a vertical apex 10. The forward portion 12 adjacent the box-like body is preferably open to reduce the weight of the fairing, but could be sealed by a substantially flat vertical wall to reinforce the structure and prevent passage of air thereinto during transportation. This applies to the forward portion 12 of FIG. 2 which also may be enclosed by a wall, not shown.
While the fairing of embodiment of FIG. 1 may advantageously be affixed to the rear end of a truck or trailer to reduce drag, because of its flat top and bottom surfaces and the height of truck and trailer bodies, it is more functionally adapted for use on the rear ends of containers transported on flat bed piggyback railroad cars, especially between cars with the flat bottom surface at about the same level as the upper surface of the flat bed car and the flat upper surface being in substantially the same plane as the top of the container on the next succeeding rear car.
The embodiment of FIG. 2, which is the most preferred and most universally adaptable fairing of the invention, is provided with aerodynamically contoured surfaces on top 6a, bottom 8a, and sides 2, 4 also terminating in a rear vertical apex 10. This design facilitates three dimentional air flow without flow separation and thereby reduces air drag to a most significant extent.
As pointed out, it is the essence of the invention that various surfaces of the fairing are aerodynamically contoured. By this is meant, that unlike many prior art proposals to "streamline" the rear of trailer bodies and the like, the present invention makes use of aerodynamic principles for contouring the surfaces of the rear fairing 1. This is accomplished by shaping the surfaces, at least in part, in the form of the top surface of an airfoil which is highly cambered and exhibits a high thickness ratio.
A typical airfoil is illustrated in FIG. 3. The chamber is the upward bending of the mean line of the airfoil and is expressed in percent of the chord length C of the airfoil as shown in FIG. 3. The thickness ratio is the maximum distance T between the upper and lower surfaces of the airfoil divided by the chord length. The upper and lower surfaces of the airfoil are equidistant from the mean line.
In selecting the proper airfoil dimensions and contours for the purposes of this invention resort may be had to families of airfoils established by NASA; or NACA (The National Advisory Committee for Aeronatics, the forerunner of NASA ) in Technical Report No. 610 entitled "Tests of Related Forward-Camber Airfoils in the Variable Density Tunnel" published 1937. In this report the coordinates of the upper and lower surfaces and the aerodynamic characteristics of 51 airfoils are given in terms of the angle of attack. (The angle of attack is the angle between the undisturbed wind direction and the chord of the airfoil).
While the parameters of the airfoils which are most suitable for the purposes of this invention vary considerably due to the different factors involved, such as the height and width of the box-like body and the intended use of the fairing, in general the airfoil should be highly cambered, that is about 6 percent, with a thickness ratio from about 15 to 21 percent.
Airfoil surfaces extending from between about 2% to 7% chord station at the front to between 60% to 100% chord station at the rear are used to shape the surfaces of the fairing. In those cases where the airfoil surface is not extended to the 100% chord point, planar surfaces are substituted at the rear of the fairing, so as to achieve the purposes of this invention.
The fairing of this invention is mounted on and effectively forms a part of the box-like bodies, such that the leading outer contoured surfaces thereof are substantially tangent to at least the side walls of the box-like container. The trailing surfaces of the fairing side walls are then inwardly directed to terminate in a vertical apex 10 at the most rearward end thereof.
It is an important feature of this invention to achieve the desired airflow produced by the fairing while at the same time keeping the length L of the fairing to a minimum in terms of the width W of the box-like body. The length L of the fairing from the rear of the box-like body to the rear apex of the fairing should be no more than the width of said body and preferably about one half the width thereof; that is, the length of the fairing is from about one-half to equal the width of the box-like body or even less. This presents problems when adapting an established airfoil surface to these dimensions. Some established airfoil surfaces, when mounted tangent to the end surfaces of the box-like body may have trailing ends which converge too soon to produce the desired airflow, or too far removed from the rear of the body to be practical. Obviously a rear fairing which protrudes too far behind a trailer is unacceptable.
It is therefore necessary to select an airfoil surface which, when used in the design of the fairing, will converge at a rear apex and in a position which is both practical and yet effective in producing two and preferably three dimensional airflow without air flow separation.
Illustrative airfoil ordinates which may be employed in the design of the fairing of this invention are NACA 23021 and NACA 64021. The first digits 2 and 6, respectively, represent the camber in percent of the airfoil chord i.e. 0.02 C and 0.06 C. The next two digits divided by 2 give the location of the point of maximum camber in percent of the chord as measured from the leading edge of the airfoil. Thus the maximum camber of the two foils selected for illustrative purposes occurs at 0.15 C and 0.20 C respectively. The last two digits 21 in both cases represent the thickness ratio in terms of the chord length.
Referring to the NACA 23021 airfoil and to FIG. 4 which shows schematically a top plan view of one half of the rear of a trailer 14 and attached fairing, one side 4 of the fairing being formed by said airfoil surface, the forward end 12 of the fairing is adjacent the rear end 16 of the trailer and the leading edge of the airfoil surface 4 is tangent to the side wall 18 of the trailer 14.
In this illustration it is assumed that the widths W of the trailer body and fairing are 8 feet and the desired length L of the fairing is 4 feet. When the airfoil surface 4 is then positioned at a line coincidental with the side wall 18 of the trailer and tangent to the foil at the 2.25 percent chord position, the foil will assume the position as in FIG. 4. A line perpendicular to the tangent line represents the rear 16 of the trailer and forward end 12 of the fairing. As can be seen the center line of the fairing intersects the chord line after the nominal trailing edge. In other words, the full airfoil surface in the position shown was not sufficiently long to intersect the center line and form an apex closing both side walls. To effect such closure there are essentially three alternatives;
(1) More the point of tangency on the contour as drawn to a more forward position on the airfoil, e.g. about the 1.75 percent chord station;
(2) Recalculate and redesign the entire contour using a larger chord;
(3) Draw a straight line tangent to the contour at about the 70 percent chord station and extending to the center line of the fairing, as shown in FIG. 4.
In the case of the NACA 64021 airfoil used in FIG. 5 the trailer side is shown tangent to the airfoil contour at approximately the 4 percent chord station and the trailing edge of the airfoil intersects the center line of the fairing as preferred. To illustrate the importance of the relationship between the airfoil and its point of tangency with the trailer, FIG. 5 also shows an airfoil wherein the point of tangency is at about the 7 percent chord station. The trailer side, rear end and fairing center line (all shown in broken lines) are thereby effectively rotated clockwise. The result is that the chord line and the fairing center line intersect far aft of the desired apex. Then if a straight line were then drawn tangent to the airfoil at about the 60 percent chord station, the length of the fairing would be in excess of that desired for practical use of the fairing.
It will then be appreciated that the designing of a truly aerodynamic fairing which is practical for use on trailers and the like involves a careful selection of sensitive design parameters. Clearly, it is desirable to construct a fairing having a length as short as possible, to avoid any traffic hazzard and facilitate ease of handling, especially when the fairing is designed for detachable use. On the other hand, the fairing should be long enough to permit use of airfoil contours to the maximum possible extent if the desired airflow and drag reduction are to be achieved. Thus, it may be necessary to compromise one of these factors in favor of the other. For example, in order to obtain the smallest length to width ratio in the fairing, it may not be possible to utilize the entire airfoil contour but only a substantial portion thereof. Thus, as shown in FIGS. 4 and 5, the portions of the airfoils utilized at the point of tangency with the trailer sidewalls starts at the 2.25 percent and 4 percent chord stations, respectively; and in one case (FIG. 4) it is possible to utilize the balance of the airfoil only up to the 70 percent chord station, at which the surface may become planar and continue to the apex of the fairing. In the other illustrative case of FIG. 5 the entire remainder of the airfoil from the 4 percent chord station to the 100 percent trailing edge is utilized for the contoured surfaces of the fairing, which is to be preferred.
The foregoing also applies for the most part to the embodiment of FIG. 2 which shows in addition contoured top and bottom surfaces of the fairing. In this embodiment it is intended that the top and bottom contoured surfaces sufficiently converge on one another only to create three dimensional airflow without flow separation and terminate at the apex formed by the side walls while retaining a substantial portion of the vertical apex 10, in terms of say from about 1/2 to 3/4 the height of the box-like container.
For this purpose the top and bottom contours may be designed by reference to the same or similar airfoils utilized for the design of the side contours of the fairing. The leading portions of the airfoils utilized for the top and bottom surfaces are tangent to the top and bottom flat surfaces of the box-like bodies, but less of the leading surfaces of the airfoul are utilized in order to ensure less convergence of the trailing surfaces than in the case of the side walls which terminate in an apex. Accordingly, the top and bottom surfaces of the airfoils utilized may be tangent to the top and bottom faces of the box-like bodies at from about the 10 percent to 12 percent chord stations of the foils used in the design of the fairing.
It should be noted that, while reference is made herein to the side walls of the fairing terminating in an apex, it is not necessarily intended that this be a sharp apex, but rather that the apex as well as the various intersections of the side, top and bottom walls of the fairing be rounded with generous radii on the outer portions thereof.
Referring now to FIGS. 6-9, FIG. 6 shows a top plan view of a fairing 1 detachably mounted on the rear body 14 of a truck trailer by attachment means 20. As can be seen from FIG. 6, the sides 2 and 4 of the fairing 1 are aerodynamically contoured and terminate rewardly in a vertical apex 10, as shown also in FIG. 1, the top and bottom surfaces of the fairing 1 being flat as shown in FIGS. 7 and 8, FIG. 7 being a side elevational view and FIG. 8 being an end elevational view of FIG. 6. As seen in FIG. 8, the fairing may be provided with lights 22 as required by Federal and State agencies and one or more indents 24 for license plates and suitable wiring for same (not shown).
The interior of fairing 1 as seen from the front thereof is shown in FIG. 9. Thus the fairing, which is constructed of a substantially rigid light weight plastics or metal skin may be internally reinforced by upright numbers 26 and horizontal frames 28 to lend further rigidity to the skin if necessary.
The fairing 1 is detachably mounted on trailer 14 with sufficient clearance, say about 1/2 inch, to facilitate ease of attachment and detachment of the fairing to the trailer, although a soft foam elastomeric strip may be used to minimize air flow through the gap thus formed between the two members.
The top plan view of the embodiment of FIG. 2 is substantially as shown in FIG. 6, which shows a corresponding view of the FIG. 1 embodiment.
The side and rear elevational views of the embodiment of FIG. 2 are shown in FIGS. 10 and 11 respectively.
Referring now to FIGS. 10 and 11, it will be seen that the essential differences between these figures and FIGS. 7 and 8 is the provision of top 6a and bottom 8a contoured surfaces, the leading edges of which are tangent to the top and bottom walls 19 of the trailer with the trailing edges of such surfaces terminating at the vertical apex 10 formed by the two sides 2 and 4 of fairing 1. This structure induces three dimensional airflow when mounted on the trailer, even when operated at relatively high speeds.
Various means 20 may be utilized for detachably mounting the fairing 1 to a trailer body 14 or similar box-like body.
In FIGS. 12 and 13 there is shown a strap-like bracket 30 riveted to the outer side walls 2 and 4 of fairing 1 by counter-sunk rivets 32 and ending adjacent the side walls 18 of the trailer body in a depending pin 34 adapted to be received freely within an eyelet 36 mounted externally of the side wall 18 of trailer 14. The lower portion of pin 34 is tapered at 38 to facilitate assembly and provided with a hole 40 for locking the pin in place by means not shown.
The embodiment of FIGS. 14 and 15 shows a similar strap 42 affixed to the fairing by rivets 32 and terminating in a flange 44 adjacent the side wall 18 of the trailer which is likewise provided with an eyelet 36. Flange 44 is further threaded at 46 to receive a hexagonal bolt 48 partially threaded as indicated to cooperate with the threaded flange and with the aid of a lock washer 50 to lock the bolt to the flange 44. The lower portion of the bolt is tapered at 52 to facilitate assembly and provided with a hole 54 to accommodate locking means not shown. The foregoing structure is particularly useful when it is desired to use one pair of fittings as a hinge to rotate the fairing about same after removing the pins of the other side of the fairing.
The attachment means of FIGS. 16 to 20 utilizes a similar strap 56 terminating in a flange 58 provided with a downwardly tapered hole 60 for alignment with the hole in eyelet 36. Flange 58 is provided with a depending skirt 62 which is arcuately shaped to conform to the outer diameter of eyelet 36 with sufficient clear therebetween to freely fit over the same and extend up to about one fourth of the outer circumference thereof to facilitate assembly.
The depth of skirt 62 on upper flange 58 extends well beyond the vertical diameter of the torus forming the eyelet, at least twice its diameter, to facilitate alignment of the upper flanges 58 with the upper eyelets 36, as shown in FIG. 17. The depth of skirt 62' on the lower flanges 58' is much less, and indeed just sufficient to embrace the vertical diameter of the torus forming the eyelet, thereby to permit a pin and locking means to be attached beneath the eyelet, as shown in FIGS. 18 and 19.
FIGS. 19 and 20 (elevational and bottom plan views, respectively) show an attachment structure for use in cooperation with the structure of FIGS. 16-18, the purpose of which is to provide convenient means for attaching and detaching the fairing to and from the trailer and rotating the same about the trailer by a worker at ground level. For this purpose the lowermost brackets on both sides of the trailer and fairing should preferably be located no more than about 6 feet above ground level.
The attachment structure of FIG. 19 comprises a vertical pipe or tube 64, streamlined in cross section, supporting at top and bottom two horizontal members 66 and 66' which in turn support two depending pins 68 and 68', respectively. Each pin is tapered initially at 70 and 70' to cooperate with tapered holes 60 in flanges 58; and further tapered therebeneath at 72 and 72' to facilitate guiding the same into holes 60. The shank of the lower pin 68' is shorter than that of the upper pin 68 for the same reason. The vertical distances between the lower faces of the upper and lower pin-supporting members should exceed the vertical distance between the upper surfaces of the fairing flanges by an amount to provide sufficient clearance to facilitate assembly. The lower pin 72' is preferably provided with a hole 74 beneath the position of the lower eyelet to permit the introduction of locking means not shown.
Reference has been made to the use of the fairing of this invention on the rear of box-like bodies transported by rail in piggyback manner. It is further contemplated that in accordance with this invention a front fairing, not shown, may be mounted on said bodies to reduce wind resistance, such a fairing taking the form of a hemi-cylindrical body having a convex forward portion and flat top and bottom portions, and further provided with detachable mounting means as described herein.
Resort may be had to such modifications and equivalents as fall within the spirit of the invention and the scope of the claims hereinafter made. | A compact rear fairing to reduce the drag incident to relatively high speed movement of box-like bodies, such as trucks, trailers and cargo containers, is provided. The structure of the fairing is substantially rigid and, depending on the use thereof, is formed with two or more outer surfaces shaped in the contour of the upper surfaces of an air foil, the leading surfaces of which are mountable adjacent the rear of the box-like body and the trailing surfaces thereof being joined together to form an apex at its rear.
The fairing is readily mounted on and detached from the box-like bodies and interchangeable between trucks, trailers, and containers of the same size. | 1 |
FIELD OF THE INVENTION
This invention relates to torch combinations for supporting attachments for cutting, heating and the like. More particularly, this invention relates to the combination torch and check valve assembly in which the check valves are integrally formed into the torch, the torch carrying the attachments for cutting, heating and the like or being a straight cutting torch.
DESCRIPTION OF THE PRIOR ART
In the prior art, there are a wide variety of check valves employing poppets, balls, flappers and the like that support tips for cutting metals, heating metals and for other purposes. Typical of the patents that were turned up by a search on the combination of torch and check valves are the U.S. Pat. Nos. 640,638; 1,726,804; 2,981,322; 3,503,418; 3,791,406; 3,873,028; 4,143,853. These references disclose a variety of check valves which are mounted at the inlet of connector elements but are not specifically associated with torches for cutting, heating and the like. A conventional check valve assembly is frequently too heavyand bulky for use in combination with a welding torch. Specifically, the check valve assembly must be exceptionally light in weight in order not to unbalance the torch when being used by a welder or the like. Moreover, the check valve must operate exceptionally rapidly and with low inertia so as to effect closure to shut off reverse flows and the like and prevent the danger of either burning in the hose of the fuel or oxygen or traveling back up to the regulator, with danger of an explosion. Such explosions are of course hazardous to personnel.
In particular, the prior art has failed to provide a check valve that was lightweight so as not to unbalance a torch and that could be combined with the torch; for example, be incorporated in a hose connection at a torch and provide adequate flow. The prior art check valves did not minimize external dimensions and maximize the internal flow path and satisfy the requirement for low spring loading and low inertia.
In addition, the regulations from the governmental regulation agencies have sought to provide safety but the combinations that have been tried heretofore have been readily circumvented by the workers simply failing to connect the check valves into hoses, regulators and the like.
SUMMARY OF THE INVENTION
Accordingly, it is an object of this invention to provide a torch combination that obviates the disadvantages of the prior art approaches and yet provides ecnomical, balanced torch combination.
It is a specific object of this invention to provide an integral cutting torch or torch handle and check valve combination; to which could be affixed hoses and attachments for welding, cutting, heating and the like; that obviated the disadvantages of the prior art and provided the safety without expense and imbalancing of the torch.
These and other objects will become apparent with the descriptive matter hereinafter, particularly when taken in conjunction with the appended drawings.
In accordance with this invention there is provided an improvement in a torch combination for cutting, heating and the like including at least a body and head that includes at least fuel and oxygen passageways and at least fuel and oxygen valves. The improvement comprises two respective check valve bodies disposed in fluid commmunication with the respective fuel and oxygen passageways connected with the torch handle; each of the check valve bodies having a chamber for receiving a check valve subassembly; and two respective check valve subassemblies inserted within the respective chambers. Each chamber has its first end with a passageway and its second end open for receiving the check valve subassembly. Each check valve subassembly includes a guide having a passageway penetrating longitudinally therethrough and having a first diameter at a first end and a second diameter greater than the first diameter for receiving a retainer; a retainer disposed with its first end in the second diameter passageway; a seal disposed on the first end of the retainer; a movable seat disposed in the guide adjacent the seal; biasing means biasing the movable seat toward the seal for blocking reverse flow, first means holding the guide and retainer together; second means holding the check valve subassemblies within their respective chambers; and respective hose connectors connected with the respective check valve bodies adjacent the second ends for connecting respectively with the fuel and oxygen hoses; such that reverse flow is arrested before it enters a respective hose and regulator. This reduces the danger of explosion.
Specific preferred structural embodiments are described. In these structural embodiments, the chambers are placed in either the body of the torch handle or in the valves, per se. Moreover it is immaterial in this invention whether the combination of torch and check valves be in a cutting torch, per se, or in a handle for supporting heating and cutting attachments.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a partial cross sectional view of a front valve torch incorporating the integral check valve subassemblies in accordance with one embodiment of this invention.
FIG. 2 is an end view of the torch of FIG. 1 showing the valves inserted.
FIG. 3 is a cross sectional view of the check valve subassembly for each of the chambers.
FIG. 3a is an end view thereof.
FIG. 3b is a side elevational view thereof.
FIG. 4 is a cross sectional view of a valve having the chamber for receiving the check valve subassembly in the end having the hose connector.
FIG. 5 is an isometric view of another embodiment of this invention in which the valves have the chamber for receiving the check valve subassemblies and are screwed into the body of the torch.
FIG. 6 is a plan view, partly in section, of a torch in accordance with another embodiment in which the valves are inserted in the body adjacent the chambers for receiving the check valve subassemblies.
FIG. 7 is a partial cross sectional view of another embodiment of the check valve subassembly employing an interference fit between chamber walls and compressible collet fingers of the check valve.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the torch combination 11 includes a torch handle 13 having a body 15, a barrel 17 and a head 19. The handle 13 includes at least two passageways 21, 23 for, respectively, fuel and oxygen. As can be seen in FIG. 2, respective oxygen valve 25 and fuel valve 27 are interposed in their respective chambers 29, 31, in the head 19. As is conventional, the respective valves are held in place by threaded nut conformingly engaging threaded male connection on the head 19. As illustrated in FIG. 1, a cover plate 33 covers a threaded neck for having a torch tip emplaced onto the torch handle. The torch tip may comprise any of the usual attachments, including heating tips, or welding tips, and the like depending upon the type of torch handle employed. As illustrated, the torch handle 13 is a front valve torch in which the valves are located in the head the check valves are in the body adjacent the hose connections 35, 37. As will be appreciated by those skilled in this art, the illustrated torch handle 13 is for conventional heating and welding tips; and a different type of torch handle is employed if a cutting torch tip is the attachment to be used. The cutting torch tip requires a separate cutting oxygen flow passageway and cutting oxygen valve.
In the improved torch combination of this invention, there are also provided two check valve bodies 39, 41 disposed in fluid communication with the respective oxygen and fuel passageways and connected with the torch handle. As illustrated, the respective check valve bodies 39, 41 are integrally formed with the torch handle body 15.
Each check valve body has a chamber 43 for receiving a check valve subassembly 45. Each chamber 43 has a first end 47 having a passageway and a second end 49 open for receiving the check valve subassembly when inserted thereinto.
Each of the check valve subassemblies 45 can be seen more clearly by referring to FIG. 3. Each check valve subassembly includes a guide 51, a retainer 53, a seal 55, a seat 57, a biasing means 59 and a first means 61 holding the guide and retainer together. The guide 51, FIGS. 3 and 7, has a bore 63 penetrating longitudinally therethrough. It has a first diameter at a first end 65 and a second diameter at a second end 67 that is larger than the first end for receiving a retainer. As illustrated, the central passageway has a third diameter 69 for receiving the biasing means 59. The guide 51 also has a fourth diameter 71 for receiving the seat 57. The guide may be formed of any of the conventional materials such as brass or other copper alloy, plastic such as the thermoplastic materials like polybutylene, polyethylene, polyacrylonitrilebutadinestyrene (ABS), polypropylene; and stainless steel or the like. The guide has flow passages defined by lateral apertures 70 and exterior slots 72, FIGS. 2-3b, and 7.
The retainer 53 is disposed with its first end 73 in the second diameter passageway. The retainer has a shoulder 75 for seating in a mating recess 77, FIG. 1 and FIG. 7 in the second end 49. The retainer 53 has a frusto conical inlet throat 79 for providing conventional metal-to-metal seating with mating hose fitting. Disposed in the central longitudinal passageway is a threaded section 81 to facilitate insertion of a threaded tool for disassembly. The retainer 53 may be made of the same material as the guide 51. The retainer must be able to support on its first end 73, the seal 55. The seal 55 comprises an annular ring of resilient material; such as, Neoprene (trademark for synthetic rubber), or other suitable firm but resilient sealing material. As illustrated, it is an annular ring that is disposed about the first end 73. As illustrated in FIG. 3, the first end 73 has a groove 83 disposed around its throat 85 and the seal 55 has a support ring 87 that slips over the throat and into the groove 83 for retaining the seal in place. As illustrated in FIG. 7, the seal is adhered onto the first end 73 by an adhesive. A suitable adhesive comprises the polyacrylate, polymethacrylate, polyepoxy type resins. They are "set" with their respective catalysts, or initiators; such as N,N-dimethyl-p-toluidine; or N,N dimethyl aniline. With the polyepoxy resins, cobalt naphthenate may be employed. Similarly, the catalysts methyl ethyl ketone peroxide may be employed. Other adhesives such as the urethanes, cyano-acrylate resins may be employed. In any event, the seal 55 must be held in place so as to form a seal and block reverse flow of gases when engaged by the seat 57.
The seat 57 is illustrated as a circular stainless steel plate with an exceptionally smooth finish that seals against the seal 55 to block back flow and prevent cutting of the seal or seat. Of course, other forms of seat may be employed but the small, lightweight plate has low inertia and can readily open and close for the respective directions of flow as indicated by the pressure gradient of low magnitude.
To assist in reseating the plate 57, there is provided a biasing means 59. As illustrated, the biasing means 59 comprises a coil spring. The coil spring has a very low strength so to allow opening of the check valve against very low pressures. For example, the spring will open with as little as four ounces per square inch pressure in the illustrated embodiment. The spring may be formed of brass, stainless steel, or other materials compatible with the gas to be flowed through the check valve; similarly as was the case with the seat 57.
The first means 61 holding the guide and the retainer together may take any one of several forms. For example, there may be collet fingers engaging a groove, with or without an interference fit; or there may be a crimp to engage machine cut parts that overlap. As illustrated, the first means 61 comprise collet fingers 89 that conformingly engage a recess, or annular groove, 91. In the embodiment of FIG. 3, the collet fingers do not protrude beyond the dimensions of the retainer such that the entire check valve assembly can be held in place by one type of second means. On the other hand, in FIG. 7 the collet fingers 89 extend beyond the lateral dimensions of the retainer so as to form an interference fit and a second kind of second holding means.
As implied from the foregoing, the torch combination 11 includes a second means 93, FIGS. 1 and 7, holding the check valve subassembly within its chamber 43. As implied from the foregoing the second means may comprise a plurality of different approaches. In the embodiment of FIG. 1, the check valve subassembly is adhered in place by adhesive applied either to the exterior walls of the check valve subassembly or to the interior walls of the chamber 43, or both. Typically, catalysts may be applied to one and adhesive to the other such that completion of the setting of the adhesive is done after the check valve subassembly is in place. As can be seen in FIG. 1, the check valve subassembly is emplaced with the O-ring 95 preventing leakage between the exterior walls of the check valve subassembly and interior walls of the chamber 43.
In the embodiment of FIG. 7, the second means 93 comprises the collet fingers that extend beyond the dimensions of the guide and retainer so as to be compressibly forced inside the wall of the chamber 43 for a friction interference fit to retain check valve subassembly in place. If desired, adhesive or the like may be employed adjacent the shoulder 75 to insure sealing.
The ordinary materials of construction will be employed in constructing the torch handle 13 and the valves 25 and 27.
In operation, the torch handle is constructed and assembled as shown hereinbefore and in accordance with this invention. Specifically, the body 15 has an elongate chamber 43 formed therein for sealingly receiving the check valve subassemblies 45 in the respective chambers 43. The hose connections 35, 37 are prepared for connection respectively with the fuel and oxygen hoses extending from a regulator and a high pressure container or the like. The check valve subassemblies are inserted and the hose connections connected. Thereafter, the torch has its tip assembly emplaced after removal of the protective cover 33. The valves 25 and 27 are, of course, inserted. The torch is then ready for use.
Other embodiments illustrate different ways in which the check valve subassembly can be made an integral part of the torch handle. Referring to FIG. 4, the chamber 43 is placed adjacent the hose connections 99 formed onto the body of the valve 101. The threaded section 103 of the valve 101 is then screwed into the conventional threaded receptacle of the body, shown as receptacle 105, FIG. 5. Similarly as described hereinbefore, the chamber has its first end 47 and its second end 49 of a larger diameter for receiving the check valve subassembly as described with respect to FIGS. 1 and 3. The valve 101 may be formed of any of the conventional materials, such as brass, the copper alloy, stainless steel or the like.
As illustrated in FIG. 6, the torch may be formed in three separate pieces in which the torch handle 13 has the barrel 17 formed separately from the head 19 and the body 15. In the body 15, the chambers 43 are formed internally of the hose connectors 109. The valves 25, 27 are inserted in their separately formed valve chambers 31. Protective cover 33 is removable for affixing suitable attachment, such as a heating tip assembly. The check valve subassemblies insert in each of the chambers in the embodiment of FIG. 6, similarly as described with respect to the embodiment of FIG. 1.
The operation of the respective embodiments are the same in that a flow loss in one of the hoses causes seating of the seat against the seal to block reverse flow of the remaining flowing gas and prevents mixing in the hose for either the oxygen or fuel or in the regulator for either oxygen or fuel. In particular, it is useful in preventing an explosive mixture from traveling completely to a regulator or the like whose frangible parts might be blown up in the resulting explosion when the flow loss was corrected and the torch relighted.
From the foregoing it can be seen that this invention accomplishes the objects delineated hereinbefore. In particular, this invention provides an integral torch and check valve combination that does not imbalance the torch for the user; that maintains a combination that is not easily circumvented to avoid the safety regulations of governmental agencies; that is economical and readily affordable; and, yet, provides a safe combination that alleviates the problems of the prior art.
Although the invention has been described with a certain degree of particularity, it is understood that the present disclosure is made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and the scope of the invention, reference for the latter being had to the appended claims. | A torch combination characterized by a torch handle having a body, barrel and head with at least fuel and oxygen passageways and at least fuel and oxygen valves and an improvement comprising respective check valve bodies disposed in fluid communication with respective fuel and oxygen passageways and connected with a torch handle and having check valve subassemblies received in chambers in each. The two respective check valves subassemblies include a guide having a retainer disposed in one end thereof. The retainer has a seal adjacent its interior end with a moveable seat biased thereagainst inside the guide. Respective first and second means hold guide and retainer together and hold the check valve subassembly within the chambers. Hose connectors are connected with respective fuel and oxygen passageways such that the check valve subassembly block any reverse flow into the hoses and regulators and prevent danger of explosion. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a system for controlling retransmission of data when, in a digital signal transmitting system in which communication is carried out in a packet mode using a communication cable such as a coaxial cable, data sent to the communication cable collide with each other.
As electronic computers have come into wide use and digital signal processing techniques have been developed, data communication is spotlighted in which the communication system and the data processing system are combined, to process data on line. Especially in small scale communication systems such as those in government and public offices or companies, the packet type communication system using a communication cable such as a coaxial cable is watched with keen interest because it is economical, high in reliability and transmission efficiency.
In the packet type communication system, for two-way transmission, a communication cable is installed at a laboratory or the like, and a number of stations (personal stations) are connected to the cable. Each station transmits a message which is divided into data blocks of 1,000 to 2,000 bits for instance. The message is provided with a header including a destination, message number, etc. In the communication system, the network itself is a passive transmission medium having no control function, and therefore the control is distributed to the stations. Accordingly, to access a channel, each station confirms that the transmission path is not being used before it starts transmitting signals. When the packet signal of one station collides with that of another station, these two stations stop transmitting the signals, and try to transmit the signals again after random periods of time. A system for controlling retransmission of messages as described above is called "a retransmission control system."
A variety of retransmission control systems have been proposed in the art. FIG. 1 is a diagram of one of the most famous of these systems, namely, a binary exponential back-off protocol (hereinafter referred to as "a BEB protocol"). It is assumed that stations A, B and C are arranged on a communication cable at predetermined intervals in the stated order. Each station detects the presence or absence of a carrier, to determine whether or not a packet having a message is being transmitted on the communication cable. It is assumed that stations A and B internally provide requests for transmitting messages (hereinafter referred to as "transmission request") SR-A1 and SR-B1 at substantially the same time. If, at that time instant, none of the stations transmit packets, then stations A and B immediately start packets A1 and B1 (as indicated at S-A1 and S-B1), respectively. The packet A1 of station A is delayed when propagated over the coaxial cable. Therefore, the packet A1 is received by the station B after a first time interval and is received by the station C after a second time interval longer than the first. Similarly, the packet B1 of station B is received by stations A and C after ceratin time delays.
Each station has a collision detecting circuit for detecting when packets collide with each other. When the collision occurs, the stations A and B immediately stop transmitting their packets and then try to retransmit their packets after predetermined waiting periods of time.
In the BEB protocol, a station with which the collision has taken place is allowed to look for an empty block in which to transmit its packet after a predetermined retransmission interval t 1 . The retransmission interval t 1 is represented by the following expression (1):
t.sub.1 =τ·n (1)
where τ is the time unit for the retransmission interval, being called "slot time," and n is an interger in the range which is defined by the following expression:
0≦n≦2.sup.l ( 2)
The integer n is generated by a random number generator. In expression (2), l is the number of collisions. The value l is stored in a counter or memory in a station which transmits a packet, and it is increased by one whenever the collision occurs and is cleared to zero when the transmission has been achieved. Thus, in the retransmission control system according to the BEB protocol, as the number of collisions increases, the retransmission interval is increased according to the average thereof.
In the case of FIG. 1, the first collision takes place between stations A and B, and therefore the integer n is 0 or 1. It is assumed that the stations A and B produce the second retransmission requests SR-Aw and SR-B2, for instance, in 1τ, and immediately start transmitting packets A2 and B2. In this case, the second collision takes place similarly, as in the above-described case. It is assumed that, as a result of this, the station A produces the third transmission request SR-A3 in 1τ and the station B produces the third transmission request SR-B3 in 2τ. Furthermore, it is assumed that, before these transmission requests, SR-A3 and SR-B3, are made the station C has made a transmission request SR-C1 and has started transmitting a packet C1 as indicated at S-C1. If, as shown in FIG. 1, the transmission request SR-A3 is made after the station A has received the packet C1, the other stations cannot transmit their packets until transmission of the packet C1 has been accomplished. That is, the stations A and B wait until reception of packet C1 has been completed, and then start transmitting the packets A3 and B3 as indicated at S-A3 and S-B3, respectively. As a result, a collision of packets occurs with the stations A and B. When the collision of packets is detected, the stations A and B try to make their fourth try at packet transmissions. The above-described operation is repeatedly carried out. Thus, when a signal, transmitted by one station, is received by the other stations, no signal transmissions are carried out by the latter, as in the case of the packet C1 transmitted by the station C. The transmission of the latter station's packet can be achieved only after the signal transmission by the one station is completed.
As is apparent from the above description, in the conventional retransmission control system according to the BEB protocol, as the number of packet collisions increase, the retransmission intervals are gradually increased. Accordingly, if a plurality of stations make new transmission requests one after another under the condition that the channels are busy, then the stations are liable to initially, repeatedly transmit their packets at short retransmission intervals. This is, in the system, even if empty channels are available then and there, the collision of packets occurs sucessively with these channels, which lowers the channel utilization percentage.
SUMMARY OF THE INVENTION
In view of the foregoing, an object of this invention is to provide a retransmission control system in which the number of packet collisions is reduced, so that the percentage of channel utilization is increased.
In the invention, when a collision detecting circuit detects the collision of packets, the station which has transmitted the packet produces a random number. When a waiting period of time predetermined according to the random number has passed, a signal retransmission request is made. When the communication cable is being used, then the waiting period is increased as required. As a result, the retransmission interval can be made suitable according to the degree of channel congestion, to thereby increase the percentage of channel utilization.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a time chart illustrating timing information for a conventional retransmission control system employing a BEB protocol.
FIG. 2 is a time chart illustrating timing information for a retransmission control system according to a first embodiment of this invention.
FIG. 3 is a block diagram showing the essential components for a retransmission control circuit according to a first embodiment of the invention.
FIG. 4 is a time chart illustrating timing information for a retransmission control system according to a second embodiment of the invention.
FIG. 5 is a block diagram showing the essential parts of a retransmission control circuit according to a second embodiment.
FIG. 6 is a block diagram showing the essential components of a circuit located at each station, forming a third embodiment of the invention.
FIG. 7 is an explanatory diagram of the frame contents in a communication system called "Modified Ethernet."
FIG. 8 is a block diagram showing the circuit at each station, forming a fourth embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
This invention will be described with reference to its preferred embodiments.
FIG. 2 is a timing diagram for describing one embodiment of a retransmission control system according to the teachings of the invention. As in the conventional system described with reference to FIG. 1, stations A, B and C are connected to a communication cable. It is assumed that stations A and B have made transmission requests SR-A1 and SR-B1 to start transmitting packets A1 and B1 as indicated at S-A1 and S-B1, respectively.
FIG. 3 shows the essential components of one embodiment of retransmission control circuit according to the teaching of this invention. Each station is provided with such a retransmission control circuit. In each of the stations A and B, a collision detecting circuit 1 receives its own packet from a signal transmitting logical circuit 2 and the packet of the other station through a signal receiving buffer amplifier 4 which is transmitted through the coaxial cable 3, so that the first collision of packets is detected, and immediately the collision detecting circuit 1 applies a collision detection signal 6 to a random number generator 5. As a result, the random number generator 5 generates a random number k (k being a positive integer) in a predetermined range. The random number k is set in a counter 7.
The collision detection signal 6 is further applied to a timer circuit 8. The timer circuit 8 starts measuring time from the time instant when the collision detection signal 6 is applied, thereto, to output a carrier detecting signal 9. A signal receiving logical circuit 11 receives a reception signal 12 from the signal receiving buffer amplifier 4, and detects the presence or absence of a carrier when the carrier detecting signal 9 is applied thereto. When the packet of the other station is not received and the carrier is not detected, the signal receiving logical circuit 11 outputs a counting signal 13. In the counter 7, the count value is decreased by one whenever the signal 13 is applied thereto. When the carrier is detected, the signal is not outputted. When the count value of the counter reaches zero (0), a transmission request 14 is produced, whereby the signal transmitting logical circuit 2 starts an operation for retransmission.
It is assumed that, when the first collision of packets occurs, the random number generator 5 in the station A generates one (1), and the random number generator 5 in the station B generates two (2). These numberical values are set in the counters 7 of the stations A and B, respectively. It is assumed that, under the condition that the stations A and B are preparing for retransmission as described above, the station C produces a transmission request-C1 to start transmitting a packet C1 as indicated at S-C1. In this case, as long as the packet from station C is received by the station A, the signal receiving logical circuit 11 in the station A outputs no counting signal 13. That is, the count value in the counter 7 is maintained at one (1). The same thing can be said about the signal receiving logical circuit in the station B, and the count value in the counter 7 remains two (2).
When transmission of the packet C1 from station C has been accomplished, then in station A the signal receiving logical circuit 11 outputs the counting signal 13, so that the content of the counter 7 becomes zero and a transmission request SR-A2 is produced. In this operation, the station B does not yet start transmitting a packet B-2. If no carrier exists on the coaxial cable 3, the station A immediately starts transmitting a packet A2 as indicated at S-A2, thus establishing the calling.
On the other hand, in station B, the count value in counter 7 is reduced to one (1) from two (2) when the content of the counter 7 becomes zero in the station A. If no carrier exists on the coaxial cable 3 after the transmission of the packet A2 has been accomplished in the station A, the count value is changed to zero (0) and a transmission request SR-B2 is outputted with the timing that the counting signal 13 is outputted. Simultaneously, a packet B2 is transmitted as indicated at S-B2.
In the above-described embodiment, after the first collision of packets occurs, the stations A and B use the coaxial cable 3 efficiently in a time division manner, and therefore the channel utilization precentage is high.
FIG. 4 is a timing diagram for explaining the operation of a second embodiment of a retransmission control system according to the teaching of the present invention. As in the first embodiment shown in FIG. 2, stations A, B and C are connected to a communication cable. It is assumed that the stations A and B produce transmission requests SR-A1 and SR-B1 substantially at the same time, thus starting transmission of packets A1 and B1 as indicated as S-A1 and S-B1, respectively.
FIG. 5 shows the essential components of a second embodiment of a retransmission control circuit according to the teachings of the invention. Each station again being provided with such a retransmission control circuit. In FIG. 5, those components which have been described with reference to FIG. 3 are accordingly designated by the same reference numerals, and their detailed descriptions are omitted. When the collision detecting circuit 1 detects the collision of packets, the random number generator 5 receives the collision detection signal 6, to produce a random number k. The random number k is set in the counter 7.
The collision detection signal 6 is further applied through on OR circuit 15 to the set terminal S of a flip-flop circuit 16, to set the flip-flop. When the circuit 16 is set, a counting signal 17 is provided at the output terminal Q and a timer circuit 18 starts its time-counting operation. When the slot τ has been counted, the timer circuit 18 outputs a time-counting completion signal 19. The signal 19 is applied to the counter 7, so that the count value of the counter 7 is reduced by one (1). The signal 19 is further applied to the reset terminal R of the flip-flop circuit 16, to reset the flip-flop. The signal 19 is further applied to the signal receiving logical circuit 11, whereupon the circuit 11 detects whether or not the carrier is being received. When no carrier is received, the circuit 11 outputs a time-counting restart signal 21. When the carrier is received, the circuit 11 outputs ths signal 21 only after the carrier has been terminated. The time-counting restart signal 21 is applied through the OR circuit 15 to the flip-flop circuit 16, to thereby set the flip-flop. When the flip-flop circuit 16 is set, the above-described operation is carried out, so that the content of the counter 7 is further reduced by one (1). When the count value of the counter 7 reaches zero (0), the transmission request 14 is produced. Thus, the signal transmitting logical circuit 2 starts a retransmission operation.
It is assumed that, as in the first embodiment, in response to the first collision of packets the random number generator 5 in the station A generates one (1) and the random number generator 5 in the station B generates two (2). These numerical values are set in the counters 7 in these stations. At the same time, the timer circuits 18 in the stations A and B start the time-counting operations. The contents of the counters 7 in stations A and B are reduced by one (1) after the slot time τ has been counted. As a result, the count value of the counter 7 in station A becomes zero (0), and the transmission request SR-A2 is provided. It is assumed that transmission of packet C1 has been started before the transmission request is provided. In this case, the station A starts transmitting the packet A2 as indicated at S-A2 when the transmission of the packet C1 has been accomplished.
On the other hand, in the station B, the count value becomes one (1) when the count value of the counter 7 in the station A becomes zero (0). In this operation, the signal receiving logical circuit 11 in station B detects the carrier of the packet C1 of station C. Accordingly, the station B outputs the time-counting restart signal 21 after the carrier is terminated, whereby the flip-flop circuit 16 is set again in the station B and the timer circuit 18 starts its operation. When the slot time τ has been counted, the count value of the counter 7 in the station B becomes zero (0) and the transmission request SR-B2 is produced. At this time instant, the packet A2 of the station A is being transmitted. Therefore, transmission of the packet B2 of the station B is started (as indicated at S-B2) when the transmission of the packet A2 is accomplished.
FIG. 6 is a diagram of a retransmission control circuit according to a third embodiment of the invention. In the case where a number of stations are connected to one communication cable, packet collisions may be frequent during time of frequent communications between stations. In the case when the collision of packet occurs repeatedly, the probability that packets collide with one another during an empty period of time can be reduced by increasing the maximum value of the retransmission interval of each station according to the repetitivity of packet collision. Accordingly, in the case where the degree of channel congestion is high, it is effective to use a retransmission control system based on the BEB protocol.
FIG. 6 shows the essential components, at each station, of such a retransmission control system. In FIG. 6, a collision detecting circuit 1 detects the collision of packets from the time relation between the packet which is sent from the signal transmitting logical circuit 2 of its own station and the packet of another station which is received through a coaxial cable 3. Upon detection of the collision, the collision detecting circuit 1 applies a collision detection signal 6 to a collision counter 231 in a BEB retransmission control section 23. The content of the collision counter 231 is cleared when the packet is firstly transmitted, and thereafter the collision counter 231 counts the number of packet collisions with the aid of the collision detection signal 6. When the first collision of packets occurs, the collision counter 231 counts one (1) which is the number of packet collisions. A count value signal 25, which represents the count in the counter 231, is applied to a weighting circuit 232. The weighting circuit 232, receiving a random number 26 from a random number generator 233, obtains an integer n which satisfies the above-described expression (2). The integer n is set, as a weighted numberical value, in a counter 7. Thereafter, the circuit operates as in the first embodiment.
The third embodiment described herein may be modified in various manners. One of the modifications is a retransmission control system which is provided by combining the second embodiment with the BEB protocol. This system can be obtained by modifying the system shown in FIG. 5 in such a manner that the random number generator 5 is replaced by the BEB restransmission control section 23, and therefore its operation can be readily understood. Another modification is a retransmission control system in which the weighting circuit 232 performs weighting in combination with other parameters. Examples of the parameters are the kind and importance of a message transmitted by a station. In transmitting a long message, it is ofter better to increase the weight to make the retransmission interval longer. The same thing may be said about a message low in importance. On the other hand, for a message the transmission delay time of which may cause trouble, weighting should be so carried out that the retransmission interval is as short as possible.
The case where the retransmission control system of the invention is applied to a communication system called "Modified Ethernet," will be described as a fourth embodiment of the invention. First, the communication system will be generally described.
FIG. 7 shows the contents of signal frames in the modified ethernet. The frame, which occurs periodically in time, consists of N blocks, #1 through #N. Each block consists of various bit trains b 1 through b 9 as listed below:
b 1 : rear guard time
b 2 : preamble
b 3 : address bit
b 4 : distance code bit
b 5 : control bit
b 6 : data bit
b 7 : check bit
b 8 : end flag
b 9 : front guard bit
The bit trains b 2 through b 5 , b 7 and b 8 are necessary for forming a packet, and are generally called "overhead (additional) bits." The bit trains b 1 through b 9 are, in combination, called "guard time." The "guard time" is the empty bit trains for preventing overlap of adjacent packets which may occur because of the delay time which occurs when block packets are transmitted over the coaxial cable. That is, the rear guad time b 1 is to protect a packet which is located after it, and the front guard time b 9 is to protect a packet which is located before it.
FIG. 8 is a block diagram outlining the arrangement of a communication system according to the above-described modified ethernet. The system has a coaxial cable as a transmission path which is connected between impedance matching terminators 31 having a resistance equal to the characteristic impedance. A number of stations are connected through T-connectors (taps) 32 to the coaxial cable 3. These stations are fundamentally the same in construction, and only the essential components of the station A are shown in FIG. 8.
Each station has a subscriber device 33 provided with a computer and a telephone set. The subscriber device 33 comprises: a transmitter (encoder) 331 for transmitting a digital signal as a packet to another station; a receiver (decoder) 332 for receiving a digital signal as a packet from another station; and a terminal controller 333 for controlling a terminal. The output signals of the transmitter 331 are temporarily stored in a signal transmitting buffer memory 34. The output signals thus stored are collectively read at a predetermined time instant with the aid of a clock signal, the period of which is equal to the transmission speed of the signal on a transmission medium, namely, a coaxial cable 3. The signals thus read are converted into a packet by a signal transmitting logical circuit 2. The packet is applied through a signal transmitting buffer amplifier 35 and the T-connector 32 to the coaxial cable 3.
On the other hand, all the packets which are transmitted through the coaxial cable 3 are applied through the T-connector 32 to a signal receiving buffer amplifier 4. A signal receiving logical circuit 11 selects only a packet applied to its own station out of the packets thus received. The packet thus selected is temporarily stored in a signal receiving buffer memory 36. The signal thus stored is continuously read by a receiver 332 with the aid of a predetermined clock signal, as a result of which an output signal is obtained.
The signals are transmitted and received as described above. A transmission clock signal used in this operation is generated by a transmission clock generator 37. A frame counter 38 subjects the transmission clock signal to frequency division, to form a frame timing signal 39 and a block timing signal 41 which specify frame timing and block timing, respectively. A transmission control circuit 43 controls a terminal controller 333 according to a signal applied to its own station, and conrols the signal transmitting logical circuit 2 according to instructions from the terminal controller 333.
In the retransmission control system according to the modified ethernet, a timer circuit 8 preferably counts a period of time corresponding to one block length as a slot time τ. This time-counting operation causes the signal receiving logical circuit 11 to detect the presence or absence of the carrier for every block. Whenever an empty block is detected, a counting signal 13 is supplied to a counter 7. When the counter value of the counter 7 is decreased to zero, a transmission request signal 14 is produced, so that an operation for retransmission is started. This retransmission control system is theoretically the same as the first embodiment.
A restransmission control system similar to the second embodiment may also be applied to the modified ethernet. In the modified ethernet, a particular block in a frame which occurs periodically on the time axis can be continually possessed by one station, and real time transmission of voice signals or the like can be achieved. In the real time transmission of voice data or picture data, it is frequently required to possess one or a plural blocks for a long period of time. Accordningly, it is advantageous for teh effective use of channels that in the case of the other data (code data) the retransmission interval is made short, while in the case of the voice data or picture data the retransmission interval is made long with the period of time required for achieving the calling being sacrificed. In view of this, in the case where the retransmission control system according to the third embodiment is applied to the modified ethernet, it is effective that the weighting operation by the weighting circuit is varried according to the contents of the data.
In the fourth embodiment in FIG. 8, the carrier is detected whenever the slot time (block time) passes; however, a system different from this may be employed. That is, the subscriber device 33 is provided with a memory for indicating the possession of blocks, so that empty blocks occurring after the block where the collision of packets takes place are estimated, to reduce the count value. More specifically, the count value is reduced according to the possession of blocks in the preceding frame, and the number of a block where the count value becomes zero is stored, so that the transmission request is produced with that block number in the following frame.
The modified ethernet is a communication system in which communication is carried out with blocks appointed. Therefore, in the modified ethernet, if a block is empty, then the probability is high that the same block in the next frame is empty. Accordingly, the retransmission control system in which only empty blocks (empty slots) are counted without taking blocks used into account is considerabley effective for the modified ethernet, and can provide the most suitable retransmission intervals according to the degree of channel congestion.
As is apparent from the above description, according to the invention, the time-counting operation for measuring the retransmission interval is limited when the communication cable is being use. Therefore, the retransmission can be carried out with time intervals corresponding with the degree of channel congestion. | A signal retransmission control circuit for stations of a multi-station digital communications network interconnected in a time division manner through a communication cable. The retransmission control circuit detects signal collisions when two or more stations simultaneously transmit their signals and in response to this detection of signal collision initiates a signal retransmission waiting time, during which the signal cannot be transmitted. The control circuit further includes a waiting time adjustment means for increasing the waiting time if another station begins signal transmission during a waiting time period. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates generally to determining airway resistance and lung compliance, and more particularly to using a circuit model approach to find the airway resistance and lung compliance where at least one component is non-linear.
In an anesthesia procedure, it is advantageous to know with some certainty the airway resistance and lung compliance in order to ascertain the suitability of the ventilatory management system. Although many attempts have been made to determine airway resistance, most assume the resistance to be linear, when in fact, it is not. Others do not consider the effects of lung compliance. Therefore, both types of systems fall far short of determining either parameter with any certainty and in some cases, results in gross inaccuracies.
It will be shown herein that those systems that assume a linear resistance relationship between pressure and flow in the patient airway will not function properly on intubulated patients. It is also believed that since an endotracheal tube follows the natural path and shape of a patient's airway, such linear systems will not function properly if applied directly to the patient's airway passage. The error found in the results from such linear techniques for determining resistance and compliance will increase dramatically with varying ventilation flow rates. Changing flow rates is common in anesthesia procedures and can be caused by changes to ventilatory settings of tidal volumes, inspiratory flows, or fresh gas delivery to the breathing circuit. In order to assume such a linear relationship then, one must maintain a constant flow rate. However, such an undesirable dependence on requiring a constant flow rate, can also impose errors to the very parameters being estimated because flow rate changes during each breath cycle as well.
Some prior art systems require the injection of an excitation flow into the breathing circuit or an inspiratory pause in order to calculate the airway resistance and lung compliance. However, such techniques are not practical during an anesthesia procedure. In fact, in any breathing system where fresh gas is supplied constantly from a gas source other than the ventilator, an inspiratory pause cannot be imposed.
Other known systems use a forced high frequency oscillation to determine airway resistance and lung compliance. The problem with this system is that no one good resonant frequency can be determined for all patients. Attempting to find the correct frequency for each patient would be time consuming and not practical.
One early attempt at determining lung airway resistance non-linearly is disclosed in U.S. Pat. No. 3,036,569. However, merely finding a resistance at one flow rate does not provide sufficient data to be useful in anesthesia procedures. It has also been found that pressure is not a function of resistance only, but also of compliance. Further, this reference requires an apparatus that forces air into the lung in order to perform the calculation, which would interfere with normal breathing and with anesthesia flow.
It would therefore be desirable to have a system, including a method and apparatus, that does not interfere with normal breathing, is non-intrusive with the normal flow and pressure during an anesthesia procedure, can measure pressure and flow on expiration, does not interrupt or interfere in any way with the respiratory pattern, and can find both airway resistance and lung compliance, while still reporting the non-linear air resistance at a standardized flow rate.
SUMMARY OF THE INVENTION
The present invention provides a system for determining the non-linear airway resistance and lung compliance using a circuit model approach that overcomes the aforementioned problems.
In accordance with one aspect of the invention, a non-linear method of establishing airway resistance and lung compliance is disclosed using a circuit model. The method includes the steps of sensing a gas flow rate through an airway and sensing a gas pressure in the airway, then calculating a gas volume from the gas flow rate, and determining an invariant exponential based on physical characteristics of the airway. Airway resistance and lung compliance can then be accurately calculated based on the gas flow rate, the gas pressure, the gas volume, and the invariant exponential at any flow rate.
In accordance with another aspect of the invention, an apparatus is disclosed to determine airway resistance and lung compliance. The apparatus includes an airway capable of communicating external gas with a patient's lungs, a gas flow rate sensor attached to the airway to sense a gas flow through the airway and produce a flow signal in response, and a gas pressure sensor located in the airway to sense a gas pressure across the airway and produce a pressure signal in response. A processor, such as a computer, a central processing unit, a microcontroller, or any other type of processing unit, is connected to the gas flow and pressure sensors to receive the flow and pressure signals. The processor is programmed to calculate airway resistance and lung compliance using a non-linear model having at least one non-linear component.
The current system does not require injection of excitation flows into the breathing circuit or an inspiratory pause to calculate the airway resistance and lung compliance, as required in the prior art. The present invention acquires pressure and gas flow rate signals from pressure transducers which measure the relative airway pressure and the pressure across a laminar flow element without interruption or interference with normal gas flow.
The analog signals acquired are digitized and supplied to a processor which is programmed to calculate the non-linear airway resistance and lung compliance according to an electrical circuit model. The total airway pressure is equal to the sum of the pressure due to the flow rate, the pressure due to the volume, a pressure constant, and the pressure due to flow change, which in most cases is minimal and can be ignored. The pressure due to flow rate, or resistance, is empirically determined to be non-linear. Various airways such as endotracheal tubes are analyzed and are fit to a common equation in order to determine an invariant exponential. Data is acquired at three convenient points along the expiration cycle in order to solve the circuit model equation by common linear algebra techniques. The resistance can then be converted to a standardized reporting flow rate. Such conversion however is optional since the resistance calculated is accurate at any flow rate, unlike linear resistance models.
Various other features, objects, and advantages of the present invention will be made apparent from the following detailed description and the drawings.
BRIEF DESCRIPTION OF THE DRAWING
The drawings illustrate the best mode presently contemplated for carrying out the invention.
In the drawings:
FIG. 1 shows a block diagram of a system in accordance with the present invention as applied to a human subject.
FIG. 2 is a circuit schematic of the circuit modeling approach encompassed in the system of FIG. 1.
FIG. 3 is a graph showing flow versus pressure across the resistor for various airway tubes.
FIG. 4 is a flow chart used in implementing the system of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows a system 10 which includes an apparatus to determine airway resistance and lung compliance in a patient 12. In one application of the present invention, an endotracheal tube 14 acts as an airway between an external oxygen source (not shown), which can include an anesthesia component, and the lungs 16 of patient 12. The system 10 includes a gas flow rate sensor 18 attached to the airway 14 to sense a gas flow therethrough and produce a flow signal 20. A gas pressure sensor 22 is also located in airway 14 to sense a gas pressure therein and produce a pressure signal 24 from the sensed gas pressure in airway 14. The flow and pressure signals 20, 24 may be provided by pressure transducers in the flow sensor 18 and the pressure sensor 22 which measure the relative pressure across a laminar flow element and the relative airway pressure, respectfully. The signals 20, 24 are proportional to the pressure and flow and are filtered to remove noise and errant signals by the A/D and signal conditioner 26, which also converts the analog signals to digital form for processing by a CPU 28. The data acquisition occurs on a discrete time basis; that is, the A/D converter 26 establishes a data value for the respective signal over its sampling interval, later referred to as the sampling time.
The CPU 28 is connected to the gas flow sensor 18 and the pressure sensor 22 via the A/D converter 26 to receive digitized flow and pressure signals 30. The CPU 28 is programmed to calculate the airway resistance R p and the lung compliance C L using a non-linear circuit model having at least one non-linear component, as will be further described with reference to FIGS. 2-4. Once the airway resistance R P and the lung compliance C L are known, representative signals 32 can be transmitted to an external monitoring apparatus 34 to monitor the ventilatory management system. Although FIG. 1 shows the system 10 of the present invention applied to an airway in the form of an endotracheal tube 14, the present invention is not so limited. For example, the patient may be fitted with a mask having an external airway 14 attached thereto.
Referring to FIG. 2, a circuit schematic 36 is used to illustrate the circuit model approach used to determine the airway resistance R P and the lung compliance C L according to the present invention. To more accurately find the airway resistance R P and the lung compliance C L , the mechanics of the respiratory system are approximated by a mathematical model that relates airway pressure P aw at the vicinity of the patient's mouth to the bidirectional gas flow in and out of the lungs. This mathematical model is illustrated as the circuit model of FIG. 2. The functional relationship is described as:
P.sub.aw =P0+P1(volume)+P2(flow)+P3(flow changes) (1)
Each of the Px terms on the right side of Equation (1) are various pressure contributions from the pulmonary system to the total airway pressure P aw 38. P0 is a constant related to volume offset, end-expiratory pressure, gravitational effects, etc., and is therefore represented as a constant voltage source 40. P1 is a function of volume and is related to the lung compliance effects, and therefore appropriately represented as capacitor 42. The airway restriction P2 is modeled as a resistor 44, however, as will be described with reference to FIG. 3, is a non-linear function of flow. P3 is the chestwall and gas inertia effects which can be represented by inductor 46. The circuit model 36 of FIG. 2 and Equation 1 are based on the well known Kirchhoff's voltage law which states that the algebraic sum of the voltages around any closed path is zero. This law applies equally to the pressures in the pulmonary system.
While it is arguable whether the inertia component P3 is required in the model at all, it has been found that it is only significant at respiratory rates higher than 66 breaths per minutes (bpm). In anesthesia procedures, respiratory rates are typically 40 bpm or less, and therefore the inertia component relating pressure to changes in respiratory flow rates is insignificant and can be ignored. However, for other purposes, one skilled in the art will readily recognize that the inertia effects P3 can be incorporated into the calculations, if desired, in accordance with the present invention.
In an anesthesia procedure, the functional relationship of the restriction term P2, indicated by resistor 44, is dominated by the flow-through resistance in the endotracheal tube 14, FIG. 1. With the exception of late expiration, it is known that gas flow through an endotracheal tube is turbulent. FIG. 3 shows the relationship between pressure in an endotracheal tube on the y-axis, and gas flow through the tube on the x-axis. The various curves show that the pressure versus gas flow relationship (resistance) is clearly non-linear. Each of the curves depict the results from a different sized endotracheal tube. Curve 48 shows the relationship between pressure and flow for a 2.5 mm. endotracheal tube, curve 50 shows the pressure/flow relationship for a 4.5 mm. tube, curve 52 shows the relationship for a 5.0 mm. tube, curve 54 shows that relationship for a 6.0 mm. tube, and curve 56 shows the non-linear properties for a 8.5 mm. tube. The data presented in FIG. 3 can be used to find a common exponential such that each curve can be approximated by a common equation. Using common techniques, this pressure/flow relationship can be approximated by an exponential function, as shown in Equation 2, or a polynomial series, as shown in Equation 3.
P2(F)=K1*f(t).sup.n (2)
P2(F)=A0=A1*f(t)+A2*f(t).sup.2 +. . . (3)
In a typical ventilatory range during anesthesia, the parameters K1 and the Ax terms remain constant within any single breath. The f(t) term is the instantaneous bidirectional flow rate. From the graph in FIG. 3, the data for the pressure and flow can then be used to find the unknown exponential n. For the various endotracheal tubes shown in FIG. 3, it has been found that an invariant exponential value of 1.7 fits each of these curves.
It has also been found that within any single breath, the pressure contribution of the compliance term P1 is proportional to the volume in the lung. The pressure due to volume extension in the lungs acts like an electrically charged capacitor in that increasing the volume in the lung, increases the pressure. According to the present invention, the following equation is used to model and calculate patient pulmonary mechanics:
P.sub.aw =L+1/C.sub.L *v(t)+K.sub.p *f(t).sup.n (4)
Equation 4 is the particular equation that relates to the general Equation 1 with the insignificant inertia term P3 assumed to be zero. The L term is the P0 constant term. C L is modeled as the compliance of the lung and v(t) is the instantaneous volume in the lung. The lung volume v(t) is found by integrating the bidirectional flow rate, as will be described in more detail with reference to FIG. 4. The product of the inverse lung compliance and the volume is the P1 volume term in Equation 1. The K P term is a constant that relates the exponential flow rate to the pressure difference contributed by the airway restriction, and changes for each airway tube. Again, f(t) is the bidirectional flow, and n is the empirically determined invariant exponential determined a priori. The product of the flow and the K P constant for each tube corresponds to the P2 flow term in Equation 1, and is the pressure due to the flow across the resistor.
The curves of FIG. 3 were plotted by placing a constant gas flow through each tube and measuring the flow rate output as well as the change in pressure across the tube. The invariant exponential is found by fitting each curve to a common function and although the K P term changes for each tube, or resistor, the exponential remains the same. In this case, and it is presumed for all tubular airways, the invariant exponential is 1.7 which represents the curvature in the endotracheal tube. It is understood that different geometries of airway configurations may change the invariant exponential. However, during anesthesia, the endotracheal tube dominates the airway resistance. These tubes are similar to the those used empirically to derive the exponent. In masked cases where patients are not intubated, the trachea is the dominant airway resistance. Consequently, the invariant exponent value of 1.7 applies to most anesthesia cases.
As will now be evident, having a value for the exponent, and measurements for the bidirectional flow rate, f(t), the airway pressure, P aw , and a calculated volume, v(t), the calculation of the airway resistance, R P , and the lung compliance, C L , is reduced to a problem of value identification for C L and K P , and ultimately, the linear airway resistance R P . In the preferred embodiment, the solution presented uses simultaneous equations of three sets of data points to solve for the unknown C L and K P . Specifically, three convenient points are chosen to obtain data. The first is at a time T 1 when the flow rate is equal to zero at the beginning of an expiration. The second is at a time T 2 when the flow rate is at a maximum negative flow rate after time T 1 , and the third is at a time T 3 after T 2 when the flow rate is 50% of the maximum negative flow rate. In other words, the three sets of data points are taken at the end of inspiration, at maximum negative expiratory flow and at 50% expiratory flow.
In this case, expiration, or flow out of the patient, is chosen negative. The equations and the data points may then be represented in matrix notation and may be solved by various known techniques. For example, a basic matrix augmentation and row reduction approach can be used for simplicity. However, one skilled in the art will recognize that various other techniques can be implemented to solve for the unknown lung compliance C L and the non-linear airway resistance K P , such as regression or digital filtering. Such methods are less sensitive to measurement noises but are computationally intensive.
In practice, users are familiar and comfortable with a resistance representation, R P , that linearly relates airway pressure and flow rate. To meet this expectation, all the non-linear airway resistances are mapped to linear resistances referenced at a standardized gas flow rate before it is reported. This linear airway resistance varies with flow rate and should only be compared at the referenced flow rate. The following relationship is used to report the airway resistance at a referenced flow rate:
R.sub.P =K.sub.P * F.sub.ref.sup.n-1 (5)
where R P is the linear airway resistance at a referenced flow rate F ref . In practice, it is convenient to report the airway resistance at a standardized 30 liters per minute flow rate.
Although the preferred embodiment describes the aforementioned relationships for an anesthesia application, the present invention is readily applicable to other ventilatory conditions or environments wherein the terms contributing to airway pressure can be described by different relationships or constants.
Referring to FIG. 4, the software algorithm is described in flow chart form. The flow chart of FIG. 4 includes data acquisition at three points during expiration, volume determination, calculation of the unknowns, and conversion of the airway resistance to a standardized flow rate. Upon start up 58 all values are initialized to "1" 60 and 62. The analog values for the pressure and flow are read 64 from the pressure and flow sensors and the analog signals are then digitized 66. The flow and pressure values at the minimum flow (F -- ZERO) are determined by continuously monitoring the present and previous flow rates to differentiate between inspiration and expiration 68, 70. When the present flow (F -- NEW) is zero or less than zero, and the previous flow (F -- LAST) is above zero, then the minimum flow (F -- MIN) has been found 72, indicating the beginning of an expiration cycle in which the values for flow and pressure can be determined and saved as the minimum flow values (V -- ZERO, P -- ZERO) 74. If the present flow (F -- NEW) is at zero, then the flow, volume, and pressure values are simply saved. However, if the present flow is less than zero, then the values are interpolated for zero flow and the interpolated values are saved for V -- ZERO and P -- ZERO. Once an expiration cycle has commenced and zero flow has not yet been reached, the volume value is updated 76 by adding the previous value for the volume to the product of the latest flow value and its respective sampling time.
Next, a maximum negative flow determination is made. After the zero flow value has been found, the system continuously monitors the flow signal to determine when it has reached a maximum negative value 78. This is accomplished by continuously comparing the present flow value (F -- NEW) with the previously saved value (F -- MIN). When the present value is less than the previous value, then the negative value is set to this present value at 80 and the volume and pressure for this flow rate value are saved as V -- MIN and P -- MIN. Again, in determining these values it has earlier been assumed that the flow rate out of the patient is negative. The flow rate could be assumed positive, with corresponding changes in the previous terminology.
The last data points are determined at a 50% flow rate. To find F -- 50, the system continuously monitors the flow signal to determine when it reaches 50% of the previously found maximum negative flow rate value (F -- MIN). This is accomplished by comparing the present flow value (F -- NEW) with 50% of the maximum negative flow value (F -- MIN) at 82. When the present value is less than half the value 84, the volume and pressure related to this 50% flow rate value are stored as V -- 50 and P -- 50 86.
At the end of an expiration cycle 88, 90, the unknowns K P , C L and L can be found at 92, as previously set forth. The resistance is then standardized 94 and can be reported to an external monitoring apparatus 96 and the system can then reiterate 98.
In practice, gases may be lost from the lung thereby making the lung volume actually smaller than the integrated bidirectional flow. The total volume loss within a breath can be determined by the difference of the inspired tidal volume to the expired tidal volume. The instantaneous volume losses may be estimated by apportioning the ratio of the total volume loss in that breath to the instant of volume measurement. The ratio would be determined empirically. This would then minimize the affect of volume loss in the resistance and compliance calculation of the present invention.
Accordingly, the present invention also includes a non-linear method of establishing airway resistance and lung compliance using a circuit model. The method includes the steps of sensing gas flow rate through an airway and sensing gas pressure in the airway. The method also includes calculating a gas volume from the gas flow rate and determining an invariant exponential based on the physical characteristics of the airway. Airway resistance and lung compliance can then be calculated based on the gas flow rate, the gas pressure, the gas volume, and the invariant exponential, as previously set forth.
As described with reference to FIG. 4, the step of calculating gas volume includes differentiating between expiration and inspiration flow rates and multiplying each sensed expiration gas flow rate by a corresponding sampling time for a current gas volume sample. The results are then integrated as a series of current gas volume samples during the expiration cycle. After at least three sets of data are acquired, the airway resistance and lung compliance can be calculated by either forming a matrix of the acquired data and solving the matrix, or with the use of regressive techniques that are commonly known.
The present invention has been described in terms of the preferred embodiment, and it is recognized that equivalents, alternatives, and modifications, aside from those expressly stated, are possible and within the scope of the appending claims. | A method and apparatus is disclosed for determining airway resistance and lung compliance using an electrical circuit model wherein at least one component parameter is non-linear. The system non-intrusively obtains pressure and flow data signals from a pressure transducer and a laminar flow element without interrupting or interfering with normal breathing and gas supply to a patient. An invariant exponential is determined empirically based on physical characteristics of the airway. The non-linear airway resistance and lung compliance can then be calculated based on the sensed flow rate, gas pressure, a calculated gas volume, and the invariant exponential using linear techniques. The resulting airway resistance can be normalized to a standard reporting flow rate value. The system is particularly useful in anesthesia applications, but is also useful in any breathing system where fresh gas is supplied constantly from a gas source other than a ventilator. | 0 |
[0001] This application claims the filing date of a previously filed provisional application having Ser. No. 09/551,333 and an assigned filing date of Apr. 18, 2000 and which contains subject matter substantially the same as that described and claimed in the present application.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to air dryers, and more particularly to a water vapor extractor using high strength electric fields.
[0004] 2. Description of Related Art
[0005] The prior art teaches the use of cold, adsorptive and absorption surfaces for dehumidification. However, the prior art does not teach that a high voltage may be applied in the manner of the present invention to produce such effective dehumidification. The present invention fulfills these needs and provides further related advantages as described in the following summary.
SUMMARY OF THE INVENTION
[0006] The present invention teaches certain benefits in construction and use which give rise to the objectives described below.
[0007] The present invention provides a water vapor extraction machine which uses high voltage to cause moisture to condense out of an airflow in contact with a series of needles. The needles are placed at a very high direct current voltage and the points of the needles are positioned in proximity to ground planes. An air flow is caused to move over these needles and through the high stress electric field. The effect is to extract moisture from the air flow which condenses on the needles and then drips downwardly so that it is taken out of the air circulation.
[0008] A primary objective of the present invention is to provide an air dryer having advantages not taught by the prior art.
[0009] Another objective is to provide such a device using high voltage electric fields to produce the drying effect.
[0010] Other features and advantages of the present invention will become apparent from the following more detailed description, taken in conjunction with the accompanying drawings, which illustrate, by way of example, the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWING
[0011] The accompanying drawings illustrate the present invention. In such drawings:
[0012] [0012]FIG. 1 is a side elevation section view of a preferred embodiment of the present invention;
[0013] [0013]FIG. 2 is a rear view thereof;
[0014] [0014]FIG. 3 is a front view thereof; and
[0015] [0015]FIG. 4 is a section view taken along line 4 - 4 in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The drawings provide illustration of the present invention, an air drying apparatus comprising an electrical buss made up of a plurality of electrically conducting rods 20 arranged in mutually parallel orientation. This is clearly shown in FIG. 1. Each of the rods 20 is a structural element with rigidity and provides plural spaced apart needles 30 extending outwardly from the rods 20 . The rods are preferably of a non-conducting material such as ceramic or such but the needles are interconnected electrically, possibly coaxially within the rods 20 . The needles 30 each terminate with a point at its end. A means for directing a high voltage direct current 50 to the electrical buss rods 20 and therefrom to the needles 30 is provided as shown. As best seen in FIG. 1, the HVDC directing means 50 is a structural network grid of conductors. This is best seen in FIG. 2. A means for directing a flow of moist air 60 over the rods 20 and past the needles 30 , preferably a fan, is used to assure the collection of moisture at a rate dependent on fan speed. A means for receiving water droplets 70 that are extracted from the moist air and formed at the points of the needles 30 for collection is provided as a basin or any similar container positioned appropriately (below) as shown in FIGS. 1 and 4. Electrically conductive cylinders 80 are positioned as shrouds about the rods 30 which are positioned centrally or axially within the cylinders 80 . The cylinders 80 provide a conductive path to electrical ground and this may be constructed in accordance with the drawings by using rigid metal construction. Insulating supports 55 for the electrical directing means 50 are used to hold it in place.
[0017] In operation, an intense electric field is set up at the needles 30 , and as shown in FIGS. 2 - 4 , the field is concentrated at the points of the needles 30 since these points are closest to the inside surfaces of the cylinders 80 , i.e., there is a concentration of electric field lines at the needle points, as is well known in the field of electrical engineering, at the tips of these needles. This very high electric field causes the extraction of moisture as liquid from the air in contact with the needle points. As moist air moves through the cylinders 60 it is subject to the intense electrical fields and moisture is thus extracted from the air and condenses onto the needles 30 , and more specifically at the points of the needles 30 . This moisture drops by gravity into the interior of the cylinders 80 and then flows in the direction of air flow to the rearward end of the cylinders 80 where it drips into the basin 70 .
[0018] While the invention has been described with reference to at least one preferred embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the invention is to be interpreted only in conjunction with the appended claims. | A air dryer uses high voltage direct current to cause moisture to condense out of an airflow in contact with a network of needles creating a high intensity electric field within grounded shields. The moisture is collected in a basin positioned below the needles. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. application Ser. No. 083,732 filed Aug. 10, 1987 ,now U.S. Pat. No. 4,845,900.
BACKGROUND OF THE INVENTION
This invention relates generally to the grinding or sharpening of cutting tools, particularly of relatively elongate, straight-edged cutting tools such as knives for use on veneer lathes and veneer slicers. More particularly, the invention pertains to a method of, and apparatus for, finish-grinding the edges of such cutting tools to an extent known as superfinishing in the art, after they have been rough-ground by conventional machines.
The superfinishing of the cutting tools of the class under consideration has long relied upon the dexterity of veteran workers using flat abrasive stones. Being based on empirical knowledge, such hand finishing requires utmost skill which is attainable only after years and years of practice. The operation itself, moreover, is very timeconsuming and uneconomical.
Recently, machine finishing has been introduced which employs a mechanical spring for pressing a superfine grinding wheel against the work. Preparatory to grinding, the spring is stressed to an extent necessary to enable the wheel to grind the work to a desired depth. The use of a spring is objectionable, however, because it does not necessarily urge the grinding wheel against the work under constant pressure; rather, the spring tends to impart vibrations to the grinding wheel, resulting in the fine skipping of the wheel over the work as the wheel travels longitudinally of the work. The spring-biased grinding wheel may thus fail to grind the work to a desired degree of superfine finish and, in the worst case, may even destroy its cutting edge.
Finish grinding has long been thought of as an indispensable, but somewhat minor, supplement to rough grinding. It has therefore been practiced to use a rough-grinding machine for finish grinding, merely by changing the grinding wheels to finer ones. This practice is objectionable not only because of the poor finish obtained, but also because the grinding wheel or wheels are set at fixed angles with respect to the work. Such fixed-angle wheels do not lend themselves to use for double-, triple- or other multiple-taper grinding of the work for the provision of more durable cutting edges. For these reasons the advent of exclusive superfinishing machines has long been awaited in the woodworking industry.
SUMMARY OF THE INVENTION
The present invention aims at the provision of a novel method of, and apparatus for, finish-grinding relatively long, straight-edged cutting tools to an unvarying degree of sharpness throughout its longitudinal dimension and without the likelihood of impairing the cutting edge in so doing.
Basically, in accordance with the invention, a fluid-actuated cylinder is employed for urging a grinding wheel endwise against the work. The method of this invention dictates, first of all, to press the grinding wheel against the work via the fluid-actuated cylinder until sufficient fluid pressure builds up in the cylinder to enable the grinding wheel to grind the work to any required depth. Then, with the grinding wheel held in rotation and urged against the work under the fluid energy, the grinding wheel is reciprocated longitudinally of the work until the work is ground to a desired depth. During such reciprocation the grinding wheel is relieved of the fluid energy each time it reaches either end of the work, until it restarts traveling toward the other end of the work. As desired, the opposite sides of the work may be ground simultaneously by a pair of grinding wheels which are urged against the work by respective fluid-actuated cylinders.
No matter how long the work may be, the grinding wheel or wheels under fluid pressure can grind one or both sides of the work to a constant depth or depths throughout its length, even in the presence of possible surface undulations or other imperfections of the work. As an additional advantage, since the grinding wheel or wheels are temporarily relieved of the fluid pressure at both ends of the work, the overgrinding of the work ends is avoided during the periods of standstill for a change in direction.
The invention also provides apparatus for carrying out the above summarized method. Typically, and not necessarily, the apparatus comprises a pair of grinder units of like construction each comprising a grinding wheel, a fluid-actuated cylinder, wheel drive means, etc. Both mounted on a common grinder carriage for reciprocation longitudinally of the work, the pair of grinder units concurrently grind the opposite sides of the work. The grinding wheels of the two grinder units have such an offset therebetween in the longitudinal direction of the work that they do not interfere with each other during grinding.
Preferably, at least one of the grinder units is pivoted on the grinder carriage for angular adjustment about an axis parallel to the longitudinal direction of the work. The pivotal grinder unit makes it possible to grind one side of the cutting edge of the work at any desired angle, or at a series of two, three or more different angles for the double-, triple- or multiple-taper grinding of the work.
An additional grinding mode is possible with the pivotal grinder unit. For superfinishing a rough-ground cutting tool having its edge defined by a sloping side and nonsloping side with an acute angle therebetween, the pivoted grinder unit may first grind the sloping side of the work to a predetermined depth at a greater acute angle with respect to its nonsloping side than the initial acute angle between the sloping and nonsloping sides of the work. The sloping side of the work may then be ground to progressively smaller depths at progressively smaller angles with respect to the nonsloping side. So ground, the sloping side of the cutting tool, which has initially been planar, can be convexed in cross section. The cutting edge of the tool can thus be rendered materially more durable than if its sloping side is ground flat, without the sacrifice of its sharpness.
The operation of the apparatus, inclusive of both single- and multiple-taper grinding, is easy to automate, as also disclosed herein as an additional feature of the invention. The automatic control of the apparatus requires the provision of a grinding depth detector for producing a depth signal indicative, in real time, of the depth to which the work has been ground, as well as an angle detector for producing an angle signal indicative of the angle of the grinding wheel with respect to the work. These depth and angle signals are input to control circuit means. Also input to the control circuit means are data representative of a desired grinding angle or angles and of a desired depth to which the work is to be ground at the desired angle or each desired angle. Such data representative of several different desired grinding angles, or of several different desired series of grinding angles, and of associated desired grinding depths may be previously introduced into the control circuit means. Further, as required, an additional desired grinding angle or series of grinding angles and an additional desired grinding depth or series of grinding depths may be manually input to the control circuit means preparatory to the commencement of each grinding job.
Supplied with all such data, the control circuit means will automatically control the operation of the apparatus for either single- or multiple-taper grinding. The actual grinding depth may be determined either by counting the reciprocations or strokes of the grinder carriage traveling longitudinally of the work, by detecting the axial displacement of the grinding wheel or wheels toward the work, or by shooting the work with a video sensor.
The above and other features and advantages of this invention and the manner of realizing them will become more apparent, and the invention itself will best be understood, from a study of the following description and appended claims, with reference had to the attached drawings showing some preferable embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of the apparatus constructed in accordance with the novel principles of this invention, the apparatus being shown in the act of simultaneously grinding the opposite sides of a straight-edged cutting tool;
FIG. 2 is a rear elevation of the apparatus, seen from the left hand side of FIG. 1;
FIG. 3 is a front elevation of the apparatus, seen from the right hand side of FIG. 1;
FIG. 4 is a somewhat enlarged, diagrammatic illustration of a chain-and-sprocket arrangement for driving the grinder carriage in the longitudinal direction of the work, the chain-and-sprocket arrangement being shown as seen in the direction of the arrows IV-IV in FIG. 1;
FIG. 5 is an enlarged section taken along the line V-V in FIG. 3 and showing how the lower grinding wheel shaft is supported both for rotation and for axial displacement relative to the baseplate;
FIG. 6 is a fragmentary, cross-section through the work which has been rough-ground and which is yet to be finished;
FIG. 7 is a view similar to FIG. 6 except that the work is shown after having been finished by the apparatus of this invention;
FIG. 8 is a block diagram explanatory of how the work is automatically multiple-taper ground by the apparatus of FIG. 1, with the actual grinding depth detected by the counter counting the reciprocations of the grinder carriage;
FIG. 9 is a block diagram explanatory of how the work is semiautomatically multiple-taper ground by the apparatus of FIG. 1, with the actual grinding depth also detected by counting the reciprocations of the grinder carriage;
FIG. 10 is a block diagram explanatory of how the work is automatically multiple-taper ground by the apparatus of FIG. 1, with the actual grinding depth detected from the axial displacement of the grinding wheel toword the work;
FIG. 11 is a block diagram explanatory of how the work is semiautomatically multiple-taper ground by the apparatus of FIG. 1, with the actual grinding depth detected from the axial displacement of the grinding wheel toward the work;
FIG. 12 is a block diagram explanatory of how the work is automatically multiple-taper ground by the apparatus of FIG. 1, with the actual grinding depth detected by shooting the work with the video sensor.
FIG. 13 is a block diagram explanatory of how the work is semiautomatically multiple-taper ground by the apparatus of FIG. 1, with the actual grinding depth detected by shooting the work with the video sensor;
FIG. 14 is a fragmentary illustration of an analog display panel for visually indicating the progress of the automatic or semiautomatic multiple-taper grinding operation of the apparatus;
FIG. 15 is a similar illustration of a digital display panel alternative to the analog display panel of FIG. 14;
FIG. 16 schematically illustrates how the sloping side of the work is ground into a convex form for the provision of a more durable cutting edge in accordance with the invention;
FIG. 17 is a block diagram explanatory of an automatic control system for grinding the sloping side of the work into a convex form as in FIG. 16 by the apparatus of FIG. 1;
FIG. 18 is a block diagram explanatory of a semiautomatic control system for grinding the sloping side of the work into a convex form as in FIG. 16 by the apparatus of FIG. 1;
FIG. 19 is a view similar to FIG. 1 but showing an alternative form of the apparatus in accordance with the invention;
FIG. 20 is a fragmentary top plan of another alternative form of the apparatus in accordance with the invention;
FIG. 21 is a right hand side elevation of the apparatus of FIG. 20;
FIG. 22 is an enlarged top plan of one of the grinder units of the apparatus of FIG. 20; and
FIG. 23 is a right hand side elevation of the grinder unit of FIG. 22.
DETAILED DESCRIPTION
Mechanical Construction
Reference is first directed to FIGS. 1-3 showing the general construction of a preferred form of superfinishing apparatus in accordance with the invention as adapted for simultaneously grinding the opposite sides of a cutting tool. Generally designated 10, the representative apparatus has a framework 12 which is L-shaped as seen in a side view as in FIG. 1. The framework 12 comprises a bed 14 and a wall 16 erected on its back. Also erected on the bed 14 and disposed just forwardly of the wall 16 is a table 18 extending horizontally from side to side of the apparatus 10. The table 18 is shown to have mounted thereon the work W in the form of an elongate, straight-edged cutting knife extending longitudinally of the table. The cutting edge of the work W protrudes forwardly, or to the right as seen in FIG. 1, beyond the front edge of the table. A required number of clamps, one seen at 20 in FIG. 1, are arranged at longitudinal spacings on the table 18 for immovably holding the work W thereon.
It will also be noted from FIG. 1 that the work W has the sloping side 22 of its cutting edge oriented downwardly, and the nonsloping side 24 oriented upwardly. These opposite sides 22 and 24 of the work W are to be finish-ground by a pair of grinder units 26 and 26', respectively, of essentially like design. The lower grinder unit 26 has a superfine grinding wheel 28 movable into and out of endwise grinding contact with the sloping side 22 of the work W. The upper grinder unit 26' likewise has a superfine grinding wheel 28' movable into and out of endwise grinding contact with the nonsloping side 24 of the work W.
As will be better understood from FIGS. 2 and 3, the pair of grinder units 26 and 26' are both mounted on a common grinder carriage 30. On this grinder carriage the two grinder units 26 and 26' are offset from each other in the longitudinal direction of the work W in order that their grinding wheels 28 and 28' may not interfere with each other as they make grinding contact with the opposite sides of the work. The grinder carriage 30 is shown to have three sets of wheels or rollers 32 in rolling engagement with two guide rails 34 which are laid on the framework 12 and which both extend parallel to the longitudinal direction of the work W. Thus the grinder carriage 30 with the two grinder units 26 and 26' thereon is reciprocable longitudinally of the work W.
The grinder carriage 30 is self-propelled for rolling over the guide rails 34, having a carriage drive mechanism 36, FIGS. 1 and 3, mounted thereon adjacent its bottom end. The carriage drive mechanism 36 comprises a reversible electric motor 38 (hereinafter referred to as the carriage drive motor) mounted fast on the grinder carriage 30. The carriage drive motor 38 has a drive pulley 40 rigidly mounted on its armature shaft 42. An endless belt 44 is wrapped around the drive pulley 40 and a driven pulley 46 of greater diameter fixedly mounted on one end of a shaft 48. This shaft 48 has its midportion rotatably journaled in a bearing 50 which is bracketed at 52 to the grinder carriage 30.
Rigidly mounted on the other end of the shaft 48 is a sprocket wheel 54 shown in FIG. 1 and on an enlarged scale in FIG. 4. The sprocket 54 is positively engaged with a length of chain 56 extending parallel to the work W and having its opposite extremities anchored to the bed 14 via tension springs, not shown. Preferably, and as shown in FIG. 4, a pair of guide sprocket wheels 58 of smaller diameter may be disposed on both sides of the first recited sprocket 54 for engagement with the chain 56, in order that the chain may engage the periphery of the sprocket 54 through a greater angle. With the sprocket 54 so engaged with the chain 56, the rotation of the sprocket will be translated into the linear rolling of the grinder carriage 30 over the guide rails 34 more efficiently and with less vibration. It is thus seen that the grinder carriage 30 is movable back and forth along the guide rails 34 with the bidirectional rotation of the carriage drive motor 38.
Although the two grinder units 26 and 26' are of substantially like configuration as aforesaid, the lower grinder unit 26 differs from the upper unit 26' primarily in that its angular position is adjustably variable about an axis parallel to the cutting edge of the work W. Such angular displacement of the lower grinder unit 26 enables the lower grinding wheel 28 to grind the sloping side 22 of the work W at various angles. The following is a description of how the lower grinder unit 26 is supported on the grinder carriage 30 for angular displacement, and of how the angular position of the lower grinder unit is adjustably varied.
With particular reference to FIGS. 1 and 3 the lower grinder unit 26 has its grinding wheel 28 and various other working components, to be set forth subsequently, mounted on a slanting baseplate 60 of generally rectangular shape. The baseplate 60 has a pair of trunnions 62, FIG. 3, protruding from its opposite sides in alignment with each other about an axis parallel to the cutting edge of the work W. The trunnions 62 are rotatably supported by a pair of upstanding support plates 64 fixedly mounted on a ledge 66, FIG. 1, of the grinder carriage 30. Thus the lower grinder unit 26, comprising the baseplate 60 and the various working components mounted thereon, is pivotable on the grinder carriage 30 about the aligned axis of the trunnions 62.
At 68 in FIG. 1 is shown a mechanism for adjustably varying the angular position of the lower grinder unit 26 about the axis of the trunnions 62. The angle adjustment mechanism 68 comprises an arm 70 which is firmly anchored at one end to the lower grinder unit baseplate 60 and which extends with clearance through a slot 72 in one of the support plates 64. The other end of the arm 70 is threadedly engaged with a worm 74 rotatably supported by a pair of bearing lugs 76 on the grinder carriage 30. Also mounted on the grinder carriage 30, a reversible electric motor 78 (hereinafter referred to as the angle adjust motor) is coupled directly to the worm 74. Therefore, with the bidirectional rotation of the angle adjust motor 78 and hence of the worm 74, the lower grinder unit 26 is angularly displaceable back and forth about the axis of the trunnions 62.
FIG. 1 also shows at 80 an angle detector of conventional design acting between one of the trunnions 62 and one of the support plates 64 for detecting the angular position of the lower grinder unit 26 with respect to the work W. The angle detector 80 may take the form of an encoder, linear transducer or like known device capable of putting out an electric signal indicative of the angular position of the lower grinder unit 26.
FIG. 3 best illustrates the working components of the lower grinder unit 26 which are mounted on the pivotal baseplate 60. Such components include an electric motor 82 which serves to impart rotation to the grinding wheel 28 and which therefore will be called the wheel drive motor. The wheel drive motor 82 has a drive pulley 84 mounted fast on its armature shaft 86. A driven pulley 88 of much greater diameter is mounted on one end of a wheel drive shaft 90 for joint rotation therewith, on the other end of which is fixedly mounted the grinding wheel 28. An endless belt 92 extends over the drive pulley 84 and driven pulley 88 for transmitting the rotation of the wheel drive motor 82 to the wheel drive shaft 90. This wheel drive shaft is rotatably supported by a pair of bearings 94, one seen in FIG. 3, with the driven pulley 88 disposed between the bearings.
It is to be noted that the wheel drive shaft 90 is axially displaceable back and forth relative to the driven pulley 88 and bearings 94, even though this wheel drive shaft is nonrotatable relative to the driven pulley 88 and rotatable relative to the bearings 94. Such axial displacement of the wheel drive shaft 90 is necessary for pressing the grinding wheel 28 against the work W during grinding, as explained in detail hereafter.
As illustrated on an enlarged scale in FIG. 5, a guide 96 of U-shaped cross section is immovably mounted on the baseplate 60, providing a linear guideway parallel to the wheel drive shaft 90. A first slide 98, also U-shaped in cross section, is slidably mounted to the guide 96. This first slide 98 is itself provided with a pair of opposed channel-shaped guides 100 extending parallel to the wheel drive shaft 90. Slidably engaged in the guides 100 are a pair of fins 102 formed substantially in one piece with a second slide 104 of tubular shape, so that this second slide is slidable relative to the first slide 98 in a direction parallel to the wheel drive shaft 90. The wheel drive shaft 90 concentrically extends through the tubular second slide 104 for rotation relative to the same but is constrained to joint axial displacement therewith. Therefore, the wheel drive shaft 90 is axially displaceable not only with both first and second slides 98 and 104 relative to the fixed guide 96 on the baseplate 60, but also with the second slide 104 relative to the first slide 98.
With reference back to FIG. 3 the second slide 104 has rigidly mounted to its rear end, away from the grinding wheel 28, an abutment 106 in the form of a rectangular plate extending in opposite lateral directions from the second slide in a plane at right angles with the axis of the wheel drive shaft 90. The abutment 106 is held against the rear end of the first slide 98. A clearance hole 108 in the abutment 106 permits the wheel drive shaft 90 to rotatably extends therethrough.
The first slide 98 has a rearward extension 110 with an arm 112 protruding laterally therefrom. The arm 112 makes threaded engagement with a feed worm 114 which is rotatably mounted on the baseplate 60 by a bearing, not seen in FIG. 3, and which is driven by an electric feed motor 116 mounted on the baseplate 60 in any convenient manner. A reference back to FIG. 1 will reveal that the feed motor 116 is coupled to the feed worm 114 via bevel gearing 118. The arm 112 and feed worm 114 constitute in combination a motion translating mechanism for converting the rotation of the feed motor 116 into the linear travel of the first slide 98 along the guide 96.
FIG. 3 further shows a fluid-actuated, preferably pneumatic, cylinder 120 and a dial indicator 122, both mounted fast on the extension 110 of the first slide 98. The air cylinder 120 has its piston rod 124 fixed endwise with the abutment 106 on the second slide 104, and the dial indicator 122 also has its spindle 126 held endwise against the abutment 106. The air cylinder 120 may be of either the double-acting, or the single-acting, spring-return type. Thus, as indicated by the graphic symbols in FIG. 3, at least the head end chamber of the air cylinder 120 communicates with an air pump 121 via a three-position, three-way, solenoid-actuated, normally closed, directional control valve 123. This valve may be solenoid actuated in either direction for selectively placing the air cylinder 120 in communication with the pump 121 or with a drain.
The dial indicator 122 is capable of visually indicating the relative displacement of the first and second slides 98 and 104. Further, preferably, the dial indicator 122 may be equipped with electrical contacts for presetting the depths of grinding by the grinding wheel 28. An encoder, linear transducer and other detectors may be substituted for the dial indicator 122.
Such being the construction of the lower grinder unit 26, the construction of the upper grinder unit 26' is self-evident from an inspection of FIGS. 1 and 2 taken together with FIG. 3. Therefore, in FIGS. 1 and 2, the various parts and components of the upper grinder unit 26' are identified by priming the reference numerals used to denote the corresponding parts and components of the lower grinder unit 26. As has been stated the upper grinder unit 26' differs from the lower one 26 in that its baseplate 60' is rigidly mounted on the grinder carriage 30. Another difference is that the feed worm 114' of the upper grinder unit 26' is driven directly by the feed motor 116', instead of via the bevel gearing 118 as in the lower grinder unit 26. Any more detailed description of the upper grinder unit 26' would be merely redundant.
As indicated in FIGS. 2 and 3, a pair of end-of-travel sensors 128 are mounted in any convenient locations at both ends of the grinder carriage 30 for detecting the fact that the grinder carriage has reached the predetermined extremities of its travel along the guide rails 34. Such sensors may take the form of limit switches, phototubes, proximity switches, etc.
FIG. 1 shows at 130 a coolant pan for collecting the coolant which is to be flooded over the grinding wheels 28 and 28' and work W during grinding. Mounted on the bed 14 in underlying relation to the work W, the coolant pan 130 extends throughout the complete path of travel of the grinding wheels 28 and 28'.
Operation
In the use of the superfinishing apparatus 10 constructed as in the foregoing, the work W to be ground is mounted on the table 18, with its cutting edge protruding forwardly of the table and with its sloping side 22 oriented downwardly, as shown in FIG. 1. Then the work W is locked against displacement by the clamps 20.
FIG. 6 is a fragmentary illustration of the work W thus mounted on the table 18 for superfinishing. It is understood that this work has already been ground by a conventional knife grinder. Both sloping side 22 and nonsloping side 24 of the work W have still rough surfaces, and its cutting edge 132 has, in all likelihood, burrs 134 which may be bent toward the nonsloping side 24.
FIG. 7 is a similar illustration of the same work W that has been superfinished by the apparatus 10 in a manner hereinafter set forth. Both sloping side 22 and nonsloping side 24 of the superfinished work W are smoothsurfaced, defining a sharp, straight cutting edge 132 free from burrs. As desired or required, the work W may be double-tapered, as indicated by the phantom line designated 136, or even triple- or multiple-tapered, by the superfinishing apparatus 10 for the provision of a more durable cutting edge having its sloping side 22 substantially rounded as seen cross-sectionally. Such multiple-taper grinding of the work is possible by varying the angular position of the lower grinder unit 26 about the axis of the trunnions 62, as will be detailed subsequently.
Following the mounting and clamping of the work W on the table 18, the angular position of the lower grinder unit 26 may be adjusted as required for grinding the sloping side 22 of the work W at an optimum angle. Such adjustment will be accomplished simply as the angle adjust motor 78 is revolved in either direction.
Then the carriage drive motor 38 is set into rotation for moving the grinder carriage 30 over the guide rails 34 to an extent necessary for bringing the pair of grinding wheels 28 and 28' opposite the sloping side 22 and nonsloping side 24, respectively, of the work W. It is understood that the grinding wheels 28 are now held retracted away from the work W by the feed motors 116 and 116'.
Then, possibly with the carriage drive motor 38 set out of rotation, the air cylinders 120 and 120' is placed in communication with the pump 121 for fully extending their piston rods 124 and 124' by the delivery of pressurized air into their head end chambers. Such extension of the air cylinders 120 and 120' will result in the maximum relative displacement of the first slides 98 and 98' and the second slides 104 and 104' in the direction parallel to the wheel drive shafts 90 and 90'. The wheel drive motors 82 and 82' may now be set into motion for imparting rotation to the grinding wheels 28 and 28', which are still out of contact with the work W, via the endless belts 92 and 92' and wheel drive shafts 90 and 90'.
Then the feed motors 116 and 116' may be set into rotation for revolving the feed worms 114 and 114'. Thereupon, being threadedly engaged with the feed worms 114 and 114' via the arms 112 and 112' on their rearward extensions 110 and 110', the first slides 98 and 98' together with the air cylinders 120 and 120' and dial indicators 122 and 122' thereon will travel along the guides 96 and 96' toward the work W. Such motion of the first slides 98 and 98' will be transmitted to the second slides 104 and 104', and thence to the wheel drive shafts 90 and 90' and the grinding wheels 28 and 28' thereon, as the fully extended piston rods 124 and 124' of the air cylinders 120 and 120' butt on the abutments 106 and 106' affixed to the second slides 104 and 104'.
Then, upon abutment of the cutting faces of the revolving grinding wheels 28 and 28' against the opposite sides 22 and 24 of the work W, the travel of the second slides 104 and 104' will be arrested, these being not axially displaceable relative to the wheel drive shafts 90 and 90'. The feed motors 116 and 116' may be maintained in rotation after the abutment of the revolving grinding wheels 28 and 28' with the work W. Such continued rotation of the feed motors 116 and 116' will cause only the first slides 98 and 98' to travel forwardly, with the consequent contraction of the air cylinders 120 and 120' as the air contained in their head end chambers become compressed.
The energy thus stored in the air cylinders 120 and 120' is utilized for forcing the grinding wheels 28 and 28' against the work W during the subsequent process of superfinishing. The feed motors 116 and 116' may be set out of rotation at a preset moment or when the dial indicators 122 and 122' give a predetermined reading. The amount of energy stored in the air cylinders 120 and 120' as above described must be sufficient to enable the grinding wheels 28 and 28' to superfinish the work W even in the face of undulations or other surface imperfections that may be present in the rough-ground work, and of the inevitable wear of the grinding wheels themselves during such superfinishing.
In the method of operation so far described the grinding wheels 28 and 28' have been in rotation throughout the period of their contact with the work W. Therefore, as required or desired, the grinder carriage 30 may be driven at low speed during this period in order to prevent the grinding wheels 28 and 28' from removing too much stock from the same parts of the work W.
Alternatively, the grinding wheels 28 and 28' may be initially be held out of rotation and may be retracted away from the work following the setting of a prescribed amount of grinding energy. Then the grinding wheels 28 and 28' may be set into rotation before being moved into grinding contact with the work.
Now the apparatus 10 is ready for actual superfinishing operation. The carriage drive motor 38 may again be set into rotation for propelling the grinder carriage 30 along the guide rails 34. Driven by the carriage drive motor 38, the sprocket wheel 54 will revolve in positive engagement with the chain 56 which, by virtue of the pair of guide sprockets 58, is wrapped around the sprocket 54 through such a great angle as to preclude any possibility of slippage. The revolving grinding wheels 28 and 28' will concurrently grind the opposite sides 22 and 24 of the work W as they travel with the grinder carriage 30 in the longitudinal direction of the work.
Each time the grinder carriage 30 reaches either end of the work W, the rotational direction of the carriage drive motor 38 is automatically reversed in response to the output from either of the end-of-travel sensors 128. This output from either of the sensors 128 may also be used for temporarily draining the fluid from the head end chambers of the cylinders 120 and 120', thereby relieving the grinding wheels 28 and 28' of the forces that have been urging them against the work W. The head end chambers of the cylinders 120 and 120' may both be repressurized immediately when the grinder carriage 30 restarts traveling in the opposite direction. The overgrinding of the opposite longitudinal end portions of the work W can thus be prevented.
Such reciprocation of the grinder carriage 30 may be repeated a required number of times until the work W is superfinished as illustrated in FIG. 7. Of course, in cases where only the sloping side 22 of the work W is to be superfinished, only the lower grinder unit 26 may be operated as in the foregoing. The upper grinder unit 26' may be held out of operation, or may not be provided at all, for such use of the apparatus in accordance with the invention.
The provision of the upper grinder unit 26' is nevertheless preferable, however, as it can be used for ready removal of the burrs 134, FIG. 6, from the cutting edge 132 of the work W and for making the nonsloping side 24 of the work free of various possible surface imperfections that have been produced by the preceding rough grinding. Usually, the upper grinder unit 26' needs to grind the nonsloping side 24 of the work W to a much less depth than does the lower grinder unit 26 to grind the sloping side 22 of the work. If the lower grinder unit 26 must reciprocate 10 times for superfinishing the sloping side 22 of the work W, the upper grinder unit 26' will have to reciprocate seven times or so for grinding the nonsloping side 24 of the work to a satisfactory degree. In this case the upper grinder unit 26' may be set into operation after the lower grinder unit 26 has made three reciprocations, so that the grinding of both sides of the work will be completed simultaneously. If the work W is to be multiple tapered, the upper grinder unit 26' may be held retracted during the second and subsequent steps of angled grinding of the sloping side of the work by the lower grinder unit 26.
In some cases, the upper grinder unit 26' may also be made pivotable about an axis parallel to the longitudinal direction of the work W. Such pivotable upper grinder unit may be used for grinding off the cutting edge 132 of the work W to an extent necessary for the provision of a very durable cutting tool. In this case, too, the grinding of both sides of the work may be completed simultaneously.
Automatic and Semiautomatic Control Systems
The superfinishing apparatus 10 of the above described construction and operation is well calculated for automation. FIGS. 8-13 are block-diagrammatic illustrations of several possible automatic and semiautomatic control systems to be incorporated with the superfinishing apparatus 10. For the convenience of disclosure, all these illustrations are limited to the control of only the lower grinder unit 26 as used for multiple-taper grinding.
FIGS. 8, 10 and 12 represent automatic control systems comprising electronic control circuitry 140 in which are stored, practically as a plurality of different superfinishing models, data representative of the angle and grinding depth of single-taper grinding, and of the angles and grinding depths of multiple-taper grinding. FIGS. 9, 11 and 13, on the other hand, represent semiautomatic control systems having memory means 142 for the storage of data representative of desired grinding angles and depths as such data are manually input preparatory to the commencement of each job.
All these auotmatic and semiautomatic control systems are classifiable into three groups according to the way in which the grinding depth is detected at each angle. In the FIGS. 8 and 9 systems the grinding depths are ascertained from the number of reciprocations of the grinder unit 26 in the longitudinal direction of the work W. To this end a counter 144 is electrically connected to one of the end-of-travel sensors 128 on the grinder carriage 30. In the FIGS. 10 and 11 systems the dial indicator 122 has electrical contacts in prescribed positions thereon for presetting the grinding depths, with the expected wear of the grinding wheel 28 taken into consideration. Grinding to the preset depths, being manifested by the relative displacement between the first and second slides 98 and 104 in the axial direction of the wheel drive shaft 90, is to be detected by proximity switches or the like. The FIGS 12 and 13 systems employ a video sensor 146 for shooting the work W and for producing an image signal 148 indicative of the progress of grinding. Grinding to each preset depth is ascertained from this image signal.
It will also be noted from FIGS. 8-13 that the control circuitry 140 is electrically connected both to the angle adjustment 68 (or to its motor 78) and to the angle detector 80. Each time the angular position of the lower grinder unit 26 is varied with respect to the work W by the angle adjustment 68, this new angle is fed back to the control circuitry 140 from the angle detector 80. Then the grinder unit 26 starts grinding the work W through the above described procedure, traveling back and forth along the work.
The control circuitry 140 will temporarily set the grinder unit 26 out of operation when the work is ground to a desired depth. The fact that the work has been ground to the desired depth is determined in the FIGS. 8 and 9 systems when the counter 144 counts a prescribed number of input pulses representative of the reciprocations of the grinder unit 26, in the FIGS. 10 and 11 systems when the dial indicator 122 produces an electric signal indicative of the prescribed relative displacement between the first and second slides 98 and 104, and in the FIGS. 12 and 13 systems when the image signal 148 from the video sensor 146 represents a prescribed level. Then the control circuitry 140 will proceed to re-actuate the angle adjustment 68 for setting the grinding wheel 28 at the next angle required. Thereafter the same procedure will be repeated until the desired multiple-taper superfinishing is accomplished.
It is recommended that the control circuitry 140 be associated with a display system having either a set of analog display windows 150 of FIG. 14 or a set of digital display windows 150' of FIG. 15. Data to be displayed on these windows 150 or 150' are the angles of the grinding wheel 28, and the desired (preset) grinding depth, present depth that has been ground, and remaining depth to be ground, at each angle.
More specifically, in the case of the FIGS. 8 and 9 control systems, the display windows 150 or 150' may display the preset numbers of grinder unit reciprocations, the numbers of reciprocations practiced, and the remaining numbers of reciprocations, at the various angles of the grinding wheel 28, as illustrated in FIGS. 14 and 15. In the case of the FIGS. 10 and 11 control systems, the display windows 150 or 150' may display the preset, current, and remaining relative displacements between the first and second slides 98 and 104 at various grinding wheel angles. In the case of the FIGS. 12 and 13 control systems, the display windows 150 or 150' may display the preset, current, and remaining grinding depths at various grinding wheel angles.
The particular showings of FIGS. 14 and 15 indicate that the grinding wheel 28 is to be first set at an angle of 28 degrees and then at 25 degrees with respect to the plane of the horizon. The desired number of grinder unit reciprocations is 10 at the first angle and four at the second angle. Currently, the grinder unit has completed four reciprocations at the first angle, the remaining number of reciprocations being six.
Generally, in veneer- or plywood-manifacturing or other woodworking plants, cutting tools are resharpened at regular intervals, and their grinding angles and depths are customarily determined. Therefore, in most cases, the cutting tools can be automatically resharpened by the apparatus 10 by selecting one of the customary sets of grinding angles and depths that are built into the control circuitry 140. In some special instances, however, manual inputting of different grinding angles and depths may become necessary. The grinding depths at various angles of multiple-taper grinding normally differ. A typical grinding depth at the first step of multiple-taper grinding is normally from 5/100 to 8/100 millimeters. This range of grinding depths is equivalent to counts of seven to ten by the counter 144 in the FIG. 9 control system. In the FIG. 11 control system the desired grinding depth must be preset on the dial indicator 122 in consideration of the expected wear, empirically known to the specialists, of the grinding wheel 28. In the FIG. 13 system the desired grinding depths may be input to the control circuitry 140 for storage in a form capable of comparison with the image signal 148 to be produced by the video sensor 146.
All such data representative of the desired grinding angles and depths will be visually displayed on the windows 150 or 150', FIGS. 14 and 15, in approprite analog or digital form depending upon the way in which grinding depths are preset and detected.
Regardless of whether the required set of superfinishing data is input manually or selected from among the exemplary sets build into the control circuitry 140, the apparatus 10 will operate substantially as previously described for superfinishing the work W. Each time the grinding of the work W at one angle is completed, as indicated by the count of the counter 144 (FIGS. 8 and 9), by the output from the dial indicator 122 (FIGS. 10 and 11), or by the image signal 148 from the video sensor 146 (FIGS. 12 and 13), the grinding operation will be automatically suspended. Then the angle adjust motor 78 will be re-energized, either in accordance with the program of the control circuitry 140 or with the data manually input to its memory means 142, for setting the lower grinder unit 26 at the next grinding angle with respect to the work W.
The same procedure will be repeated thereafter until the desired multiple-taper grinding is completed. As has been set forth in connection with FIGS. 14 or 15, the operator or supervisor of the apparatus 10 will be visually informed of the progress of such multiple-taper grinding on the display windows 150 or 150'.
It will now be apparent that the automatic control systems of FIGS. 8, 10 and 12 and the semiautomatic control systems of FIGS. 9, 11 and 13 lend themselves to use, as an extreme case of multiple-taper grinding taught in the foregoing, for convexing or rounding the sloping side 22 of the work W as drawn by the solid line in FIG. 16, thereby providing a cutting edge of more extended service life. The following is a discussion of how to multiple-taper grind the work W so as to provide the rounded sloping side 22 of FIG. 16.
Let us suppose that, as indicated by the phantom outline in FIG. 16, the cutting edge 132 of the work W as rough-ground by a separate grinder and mounted on the superfinishing apparatus 10 has an angle of, say, 21 degrees. The sloping side 22 of this work W may first be ground at a greater angle of, for example, 30 degrees, then at progressively smaller angles of, say, 28 degrees, 26 degrees, etc. The grinding depth at the first angle of 30 degrees should be the greatest, for example, from 8/100 to 10/100 millimters, and the grinding depths at the subsequent smaller angles should become progressively smaller. For example, the grinding depth at the second angle of 28 degrees may be from 5/100 to 6/100 millimeters, and that at the third angle of 26 degrees from 2/100 to 3/100 millimeters.
FIGS. 17 and 18 are explanatory of typical automatic and semiautomatic control systems, respectively, for use in carrying out the multiple-taper grinding of FIG. 16 in practice. These automatic and semiautomatic control systems are equivalent to those of FIGS. 8 and 9, respectively, in that the grinding depths are determined by the counter 144, except, however, that in the FIGS. 17 and 18 systems the counter is activated by the pair of end-of-travel sensors 128 at both ends of the grinder carriage 30 of FIGS. 1-3. Thus, in the FIGS. 17 and 18 systems, the counter 144 counts the strokes of the grinder carriage 30 in either direction along the guide rails 34, instead of counting the reciprocations of the grinder carriage as in the FIGS. 8 and 9 systems.
The above specified desired grinding depths at the various angles are equivalent in this particular embodiment, to seven to 10 strokes at 30 degrees, four to five strokes at 28 degrees, and two to three strokes at 26 degrees. It must be heeded, however, that the work is not necessarily ground to the same depth with each stroke of the grinding wheel 28. For example, for grinding at the first angle of 30 degrees, the grinding wheel 28 is initially in contact only with the cutting edge 132 of the work W. Since the work W tapers to this cutting edge 132, the area of contact between the work and the grinding wheel 28 will gradually increase with the progress of grinding operation, so that the grinding wheel will grind the work W to a progressively less depth during each of the subsequent seven to 10 strokes.
All such data representative of the desired grinding angles and depths may either be previously introduced into the control circuitry 140 in the automatic control system of FIG. 17 or manually input in the memory means 142 preparatory to each job in the semiautomatic control system of FIG. 18.
The multiple-taper grinding operation itself for the provision of the rounded sloping side 22 of FIG. 16 can be performed just as previously described with reference to FIGS. 8-13. So ground, the initially planar sloping side 22, indicated by the phantom line in FIG. 16, of the work W will become convexed as shown by the solid line in the same figure. Of course, the greater the number of different grinding angles, the smoother curve will the sloping side 22 of the work W represent as seen cross-sectionally or in an end view as in FIG. 16.
FIG. 16 further shows that the nonsloping side 24 of the work W is ground off at 152 at an angle to its plane for the provision of a still more durable cutting edge. This angled grinding of the nonsloping side 24 necessitates the pivotal mounting of the upper grinder unit 26' in addition to that of the lower grinder unit 26. It is evident that the upper grinder unit 26' can be pivoted, and its angular position adjusted, by the same means as the lower grinder unit 26 is pivoted and has its angle adjusted with respect to the work.
Alternative Mechanical Constructions
The automatic or semiautomatic control of the superfinishing apparatus is not an essential feature of this invention. Thus, in an alternative superfinishing apparatus 10a shown in FIG. 19, handwheels 116a and 116'a are employed in substitution for the electric feed motors 116 and 116' of the first disclosed apparatus 10. These handwheels may be turned manually for the storage of the required fluid energy for forcing the grinding wheels 28 and 28' against the work W.
The angle adjust motor 78 and angle detector 80 of the FIGS. 1-3 apparatus 10 are also absent from the alternative apparatus 10a. In the modified angle adjustment 68a of the apparatus 10a, the worm 74 is to be turned manually for varying the angular position of the lower grinder unit 26 with respect to the work W. The angle detector 80 of the apparatus 10 is replaced in this alternative apparatus 10a by an angle indicator 80a comprising a pointer 154 and a dial 156. Mounted on one of the trunnions 62, FIG. 3, of the lower grinder unit 26, the pointer 154 is pivotable therewith to visually indicate the angular position of the lower grinder unit on the dial 156 on one of the support plates 64.
In another alternative superfinishing apparatus 10b shown in FIGS. 20 and 21, the work W is mounted on a table 18b with its cutting edge oriented upwardly, instead of forwardly as in the apparatus 10 and 10a. The sloping side of the work W is oriented forwardly, that is, downwardly as seen in FIG. 20 and to the left as seen in FIG. 21. A series of fluid actuated cylinders 20b are arranged on a framework 12b at spacings in its longitudinal direction for immovably holding the work W against the table 10b.
Mounted on the framework 12b for rolling motion along a pair of guide rails 34b, a grinder carriage 30b is substantially in the shape of an inverted U as seen in a side view as in FIG. 21. The grinder carriage 30b has mounted thereon a front grinder unit 26b for grinding the sloping side of the work W and a rear grinder unit 26'b for grinding the nonsloping side of the work. Although FIG. 20 shows only the grinding wheels 28b and 28'b and baseplates 60b and 60'b of the front and rear grinder units for illustrative convenience, it will nevertheless be seen that the two grinding wheels are displaced from each other in the longitudinal direction of the work W in order to avoid mutual interference during grinding. The grinder carriage 30b has a carriage drive motor 38b mounted thereon and is thereby self-propelled for reciprocation in the longitudinal direction of the work.
The front grinder unit 26b is provided with an angle adjustment 68b for adjustably varying the angle of the front grinding wheel 28b with respect to the work W. The angle adjustment 68b of this alternative apparatus 10b comprises a sector gear 160 rigidly mounted to the baseplate 60b, and a pinion 162 rotatably mounted on the grinder carriage 30b for driving engagement with the sector gear 160. It will be apparent from the foregoing disclosure that the rear grinder unit 26'b could likewise be made pivotable about an axis parallel to the longitudinal direction of the work W.
Seen at 164 in FIGS. 20 and 21 is a control console in which are housed the various electrical and electronic controls, including the control circuitry 140 of FIGS. 8-13, 17 and 18, of the superfinishing apparatus. The control console 164 has a control panel 166 on which can be arranged the display windows 150 of FIG. 14 or the display windows 150' of FIG. 15.
FIGS. 22 and 23 are enlarged elevations of the front grinder unit 26b, it being understood that the rear grinder unit 26'b can be of like construction. The front grinder unit 26b has its baseplate 60b pivotally mounted between a pair of support plates 64b on the grinder carriage 30b. Mounted on this pivotal baseplate 60b, a feed motor 116b is operatively coupled to a rack 168, extending parallel to a wheel drive shaft 90b, via a pinion assembly 170. This pinion assembly includes rack guide means, not shown, such that the rack 168 reciprocates longitudinally in response to the bidirectional rotation of the feed motor 116b. The rack 168 has a carrier arm 172 rigidly mounted thereto and extending right-angularly therefrom. A fluid actuated cylinder 120b, normally an air cylinder, has its head end mounted fast to the distal end of the carrier arm 172 and has its piston rod 124b oriented parallel to the ' wheel drive shaft 90b. The piston rod 124b is coupled to the wheel drive shaft 90b via another arm 106b.
As in the lower grinder unit 26 of the FIGS. 1-3 apparatus 10' the wheel drive shaft 90b is rotatably supported by the pair of bearings 94 on the baseplate 60b and is driven from the wheel drive motor 82 via the pulleys 84 and 88 and endless belt 92. The wheel drive shaft 90b is axially displaceable relative to the pulley 88 and bearings 94.
In the operation of the front grinder unit 26b of FIGS. 22 and 23, the rotation of the feed motor 116b in a preassigned direction results in the linear travel of the rack 168, and therefore of the grinding wheel 28b, toward the work W. The continued rotation of the feed motor 116b after the grinding wheel 28b has moved into abutment against the work W results in the contraction of the air cylinder 120b. The energy thus stored in the air cylinder 120b can be used for forcing the grinding wheel 28b against the work W during the subsequent process of superfinishing. The other details of construction and operation of the alternative apparatus 10b are considered self-evident from the foregoing description of FIGS. 1-18. | For superfinishing an elongate cutting tool which has been rough-ground by a separate machine, a pair of grinding wheels are first urged against the opposite sides of the work via respective fluid-actuated cylinders, until sufficient fluid energy builds up in the cylinders to enable the grinding wheels to grind the work to any desired depths. Being mounted on a common carriage, the grinding wheels are then reciprocated longitudinally of the work while being held in constant rotation and being urged against the work under the fluid pressure. On reaching either end of the work during such reciprocation, the grinding wheels are relieved of the fluid pressure until they restart traveling toward the other end, in order to avoid overgrinding the opposite ends of the work. The reciprocation of the grinding wheels is terminated when the opposite sides of the work are ground to required degrees. The complete operation can be automated. Preferably, one of the grinding wheels is angularly displaceable relative to the work about an axis parallel to the longitudinal direction of the work. | 1 |
This is a divisional application of U.S. Patent application Ser. No. 08/313,419 filed Sep. 27, 1994, now abandoned, which is a divisional application of U.S. patent application Ser. No. 08/007,187 filed Jan. 21, 1993, now U.S. Pat. No. 5,375,376 issued Dec. 27, 1994, entitled POLYMERIC SEALING/SPRING STRIP AND EXTRUSION METHOD OF PRODUCING SAME.
TECHNICAL FIELD
The present invention pertains to a polymeric sealing/spring strip and method of producing same. The polymeric sealing/spring strip of the present invention has several various embodiments which are based upon the incorporation of silicone rubber. Some of the embodiments are based on the formation of a resilient silicone rubber surface to provide a sealing/spring contact with an opposing surface period. Other embodiments of the invention incorporate the silicone rubber in such way as to utilize its resilient properties to produce a sealing/spring strip which has improved mechanical resilience properties.
The method of the present invention allows the production of a sealing/spring strip in accordance with the present invention by using extrusion techniques.
BACKGROUND
There are a wide variety of sealing strips known and used in the prior art. Such sealing strips may be used in many applications such as for weather stripping, insulated doors and windows, such as those found in buildings and on appliances, and in various other applications where a seal between two adjacent surfaces (moveable or immoveable) is desired.
In applications were a seal is desired between two surfaces held in place, it is desirable that a sealing strip maintain a good seal which is the uniform throughout the length of the sealing strip. It is also desirable that the strip be resistent to adverse environmental conditions such as heat, water and sun light to which the sealing strip may be exposed, and maintain a seal and notwithstanding such conditions. Known sealing strip materials such as foamed urethane degrade over time when exposed to such environmental conditions.
To do this, it is desirable to provide a flexible and degradation-resistant surface which possess a degree of resilience which is capable of providing a consistent static of force against an opposing surface.
It is also desirable to provide a sealing strip of materials which have heat insulative qualities.
In the instances where a sealing strip is to be applied between two surfaces moveable with respect to one another, it is also important that a sealing strip be adapted to facilitate the movement of such surfaces. It is also desirable that the sealing strip possess overall resilience properties which resist fatigue over several cycles of separating and realigning of the opposing surfaces to which the sealing strip is applied; such as in the case of the opening and closing of a door or a window.
One of the materials often used in insulative sealing is silicone rubber. Silicone rubber has very good resilience and resists the fatigue and environment degradation described above. However, one of the drawbacks to the use of silicone rubber is that it must be applied as a fluid and subsequently cured to form a dimensionally stable material. Because of its flow characteristics in the uncured state, silicone rubber is often difficult to apply in manufacturing processes, particularly in those processes which involve high speed production such as is the case in extrusion machinery set ups. Spillage is also a problem inherent to the use of a liquid material in extrusion production. Accordingly, it is difficult to incorporate a silicone rubber portion into an extrudate at rates at which extrudates are typically formed.
Accordingly, it would be desirable to be able to incorporate dimensionally stable silicone rubber portions into a sealing strip construction, particularly those constructions produced by the polymeric extrusion.
Another disadvantage of the use of silicone rubber is that it is generally a more expensive per unit volume than the industrial polymers typically used in the production of a sealing strip. Accordingly, it would be desirable to be able to incorporate silicone rubber into a sealing/spring strip to gain its advantages while minimizing the amount of silicone used in the sealing strip as a whole.
Another application for the present invention is in the field of spring-like devices, with or without reference to insulative or other environmental sealing. Such devices may find application in a wide variety of settings, such as in cabinetry where a spring-like device is used to urge the opening of doors as they are unlatched. Another potential application is in wall protection systems which are designed to absorb shock, such as those used in hospital interiors to protect walls from the impact of wheeled beds, carts, wheelchairs, etc. Many of the desirable properties discussed above are also important to this general area, such as resilience, fatigue resistance, integrity against environmental degradation. It is also desirable in such applications to minimize the amount of silicone rubber used.
In view of the present disclosure and/or the practice of the present invention and its many embodiments, other advantages or the solutions to other problems may become apparent to one of ordinary skill in the art.
SUMMARY OF THE INVENTION
The present invention generally relates to a polymeric sealing/spring strip incorporating silicone rubber, and a method of producing the same by extrusion or co-extrusion. The profiles of the polymeric extrudates used in the present invention can all be produced with conventional extrusion equipment, and with extrusion dies produced in accordance with methods known in the art.
The sealing/spring strip of the present invention has many different embodiments, each having features which may be preferred in different applications.
The first embodiment of the inventive sealing/spring strip comprises a longitudinally extending polymer and silicone rubber composite strip. The strip, in cross-section, comprises a base portion which has first and second sides. One side (e.g. the "first" side) is provided with a longitudinally extending well formed in the first side. The well is provided with a cured silicone rubber bead which fills the well to an extent that it extends from the well so that it provides a resilient surface of silicone rubber which extends from (or above) the first surface, i.e. in such a way that it will make contact with an opposing surface before the first surface will.
Rather than being formed in the first side itself, an alternative embodiment provides that the base portion of the cross-section may be provided with at least two extension portions which extend so as to form a well between them (i.e. substantially perpendicular to the base portion's first surface).
With respect to either the first embodiment or its alternative, an additional longitudinally sealing/spring number may be placed in the well so as to enclose a space which is rendered unavailable to filling by the silicone rubber. As can be appreciated particularly in light of the figures showing this embodiment, such excluded space allows the resulting silicone rubber surface to have the particular width and height above the base portion surface desired by the user, while minimizing the overall amount of silicone rubber used.
The above-described first embodiment types are exemplified by FIGS. 1, 2 and 6 discussed in more detail below.
In a second embodiment type, a sealing/spring strip in accordance with the present invention may be provided by forming a longitudinally extending polymeric strip whose cross-section comprises a base portion having first and second sides providing respective first and second surfaces. One of the sides (e.g. the "first" side) is provided with at least one "vaned extension portion" which extends from the first side and is adapted to support uncured silicone rubber and resist the spreading of the uncured silicone rubber over the respective first surface.
As used herein the term "vaned polymeric extension" refers to any extension with a series of one or more sides at angles so as to provide physical support for a bead of uncured silicone rubber, as well as to provide increased surface area so that the silicone rubber will resist spreading of virtue of mechanical resistance and increased surface tension.
The vaned extension in accordance with the present invention may take on almost any imaginable geometric shape functional for the intended purpose such as V-shapes, T-shapes and/or cross-shapes.
Examples of the second embodiment type of the present invention are shown in FIG. 3 below.
The advantages of the first two embodiment types of the present invention include the ability to provide additional structural support for a resilient surface of silicone rubber in a sealing/spring strip. These embodiments also allow the silicone rubber surface to extend substantially further from or above the first surface than if the silicone rubber were left unsupported prior to curing. This is especially important where such sealing/spring strips are produced in an extrusion process so that the silicone rubber can be applied and cured onto a freshly produced extrudate without spreading. This allows the desired height and resilience characteristics can be achieved.
A third embodiment type of the present invention is a sealing/spring strip which also comprises a longitudinally extending polymer and silicone rubber composite strip, the strip having a cross-section which comprises a base portion having first and second sides and at least one extension portion extending from one of such sides (e.g. the "first" side), at an acute angle to the surface of the first side. In this way, a longitudinally extending acute corner is formed between the extension(s) and the first surface.
The extension portion(s) is/are flexible with respect to the base portion, and is/are therefore moveable between a rest position relatively further from the base portion and a compressed position relatively closer to the base portion.
Cured silicone rubber is disposed in the acute angle corner, either in a broken or unbroken bead, whereby the cured silicone rubber resists the movement of the extension portion(s) from the rest position to the compressed position.
In this way, much more of the physical structure of the total sealant strip is provided by the polymeric material while a relatively small amount of the silicone rubber is strategically placed to take advantage of its resilience and non-fatigue qualities.
The acute angle corner also serves to hold the cured silicone rubber in place, particularly in an extrusion process where the polymeric strip is held in such a way so that the angle opens upwardly to allow the uncured silicone rubber to be placed in the V-shaped well formed thereby. This also permits the silicone or rubber to be maintained most deeply in the corner to provide the best resilient mechanical properties in the finished product.
It is preferred that the acute angle corner be formed by the coextrusion of polymers of differing physical characteristics to best perform the intended function. In this regard, the polymer used to form the major portion of the extension portion(s) and the base portion is preferably of a higher impact rating (i.e. lower flexibility) than that minor portion of the extension portion(s) used to hold the extension portion(s) at an acute angle to the base member. This allows the major portion of the extension portion(s) not to bend under a load while the minor corner section itself flexes. This construction helps to prevent the polymer in the extension portion(s) from fatiguing over several flexing cycles and from having a shape memory imparted to such portion(s).
Examples of a combination of polymeric materials which may be used for the base and major portion of the extension portion(s), and for the minor portion of the extension portion(s) (i.e. that holding the major portion of the extension portion(s) at an acute angle to the base portion(s)) are, respectively high impact PVC formulation 85857 and flexible PVC formulation 83741, both commercially available from B. F. Goodrich Chemicals of Akron, Ohio. One alternative of this embodiment is to provide two extension portions extending at opposing angles to the first surface. This embodiment may be desirable where more uniform static forces are desired once the opposing surfaces to be sealed by the sealing/spring strip are brought in close to proximity to move the extension portions toward the compressed position.
This embodiment may be produced by maintaining the base portion flat whereby the acute angle corner(s) will help to maintain the uncured silicone rubber bead in the corner. In a preferred embodiment, the extension portion(s) and/or the base portion is provided with small extensions which extended into the interior of the acute angle formed thereby, so as to assist in the retention of the silicone rubber bead in the acute angle corner, without affecting the movement of the extension portion between the rest and compressed positions.
The angle at which the extension portion(s) are held with respect to the base portion may be any acute angle, but will normally be considered in the range of 1 to 60 degrees depending on the desired application.
An example of this embodiment is shown in more detail in FIGS. 4, 8, 9 and 10 below.
A fourth embodiment of a sealing/spring strip in accordance the present invention compresses a longitudinally extending polymer and silicone rubber composite strip, these strips having a cross section which comprises a base portion having first and second sides which provide respective first and second surfaces. The base portion has a longitudinally extending well formed in one of its sides (e-g. the "first" side). The cross section also comprises at least extension portion which is partially disposed inside the well and extends away from the first surface at an angle. The extension portion(s) is held resiliently in place by silicone rubber in the well so that the extension(s) is/are moveable from a rest position relatively further from the first surface, to a compressed position relatively closer to the first surface. The cured silicone rubber thereby resists the movement of the extension from the rest position to the compressed position.
The base portion and extension portion(s) may be extruded as individual portions. Alternatively, the base portion may be integrally incorporated into the balance of the structure to which the sealing/spring strip is to be applied.
In an alternative to the fourth embodiment, the sealing/spring strip may comprise two such extension portions extending at opposing angles from the first surface, such extension portions being held resiliently in place by the silicone rubber disposed in the well, and each moveable between a rest position and a compressed position.
The present invention also includes methods for preparing sealing/spring strips in accordance with any of the aforesaid embodiments.
In order to produce a sealing/spring strip in accordance with the above-described first, second, or third embodiments, a longitudinally extending polymeric strip of the appropriate profile is extruded or pultruded. As used herein, further reference to extrusion or extrudates shall be understood as also encompassing pultrusion and pultrudates, respectively.
The polymeric material(s) which may be used in the present invention include any thermoplastic or thermosetting polymeric material, such as those amenable to extrusion or pultrusion, for example, polyvinylchlorides, chloropolyvinylchlorides, fluoropolymers, and mixtures, composites and alloys thereof. Of these, high impact, weatherable PVC, such as B. F. Goodrich 85857 PVC, is preferred for all such constructions, except in the preferred embodiment of the third embodiment type discussed above where PVC of two different impact ratings (i.e. different flexibilities) are used.
In a preferred embodiment, the polymeric material(s) may be foamed to provide small gas spaces within the polymeric material(s). This not only increases the insulative value of the polymeric material(s), but reduces the volume of polymeric material(s) per linear foot of the coextrudate. The polymeric material(s) may be foamed using either azo-type or bicarbonate foaming agents, azo-type agents being preferred. The foaming agents are admixed with the polymeric material(s) in the extruder in accordance with known practice. Examples of appropriate azo-type agents include Siligen®, Grade AZRV, commercially available from Uniroyal Chemical Company of Middlebury, Conn., and Grade No. HRVP01 from Hughes Industrial Corporation. The azo-type foaming agents are used in a concentration range of from about 0.1 to about 1.0 parts per hundred (pph), preferably in the range of about 0.3 to 0.5 pph, with 0.3 pph being the most preferred value. An example of the bicarbonate type foaming agents include Hydrocerol®, commercially available from Boehringer Ingelheim, which is used in a concentration range on the order of those given above for the azo-type foaming agents.
The thickness of the polymeric material(s) (foamed or non-foamed) is not critical, and typically are in the range of above about 10 mils, depending on the desired application. This can normally be determined by considering the prospective amount of load and/or stress to be imparted to the sealing/spring strip.
As an example, the Hughes Industrial Corporation Grade No. HRVP01 was used with a high impact, weatherable PVC, B. F. Goodrich 85857, at a concentration of about 0.3 pph. A Davis Standard 1.25 inch single screw extruder produced the extrudate at a rate of 6.5 ft/min using a barrel temperature of 345° F.
At a point in the extrusion/pultrusion line where the extrudate becomes sufficiently dimensionally stable to accept it, a bead of silicone rubber is supplied to the strip in the prescribed location.
With respect to the first embodiment, silicone rubber is placed in the well formed in the extruded polymeric strip at a rate sufficient to fill the well to an extent that is sufficient to produce a meniscus extending from the boundaries of the well. This can be readily determined by calculating the necessary volume of silicone rubber per length of the extrudate while also considering the speed at which the extrudate is produced so as to arrive at a flow rate for the silicone rubber. These parameters will of course vary with the well height, well depth and well geometry for each desired application.
As to the second embodiment, a longitudinally extending polymeric strip is extruded so as to have a profile forming at least one vaned polymeric extension adapted to support uncured silicone rubber and resist its spreading over the upper surface of the extrudate.
The uncured silicone rubber may placed on the vaned polymeric extension(s), such as in the form of a bead of silicone rubber which is laid on the vaned polymeric extension(s) as the extrudate emerges from the extruder. The silicone rubber is then cured in the normal manner and accordance with the methods known in the art at a subsequent point in the extruder line. It is preferred that the curing being initiated immediately after the uncured silicone rubber is placed on the extrudate in order that the initial shape of the uncured silicone rubber bead be maintained.
Turning to the third embodiment which involves the placement of uncured silicone rubber in the acute corner formed in extradite profile, this embodiment may be formed by extruding a polymeric strip of an appropriate profile to form such an acute angle corner as described above.
Where only one such extension is to be formed, it is preferred that the extrudate be oriented such that the acute angle corner opens upwardly. This allows the uncured silicone rubber to be placed in,the acute angle corner so that it is maintained in the corner by gravity, much in the same way as is the case with respect to the well of the above-described first embodiment. The uncured silicone rubber may be disposed in the acute angle corner by running a bead of uncured silicone rubber into this portion of the extrudate after the appropriate profile is formed.
Curing of the silicone rubber bead follows downstream in the extruder line.
Where extensions of opposing acute angles are to be produced (as shown in FIG. 4), the base portion of the extrudate may be oriented horizontally and two beads of silicone rubber injected laterally into the opposing acute angle corners. Surface tension will generally hold the silicone rubber in place and it is preferred that the curing of the silicone rubber follow immediately after its injection in order that the silicone rubber be maintained well within the acute angle corners. Most preferred however is to provide that the profile have small extension portions that extend into the acute angle corner to prevent the uncured silicone rubber from flowing from its intended position.
In producing a sealing/spring strip in accordance with the fourth embodiment of the invention, the individual portions of the sealing/spring strip construction may be extruded in such a way as to maintain their orientation to form the polymer and silicone rubber composite. For example, a base portion is extruded which has a well formed into its upper side. Uncured silicone rubber is injected into the well and at least one longitudinally extending polymeric extension member is extruded in such a way that it extends into the uncured silicone rubber in the well and is oriented at an angle to the upper side of the base portion. Once the extension member(s) is/are in place, the silicone rubber is cured so as to maintain the extension member(s) in place so as to complete the formation of the polymer and silicone rubber composite strip.
The polymer and silicone rubber strips prepared in accordance with the present invention may be used in any of a wide variety of applications where the sealing and/or spring-like characteristics of the present invention are desired. The present invention is not limited to any particular use thereof.
The sealing/spring strips may be cut to size to fit any application, and it may be that very short lengths may suffice where only the spring-like properties are desired.
Strips in accordance with the present invention may be applied to, or incorporated into, the closure edges of doors, in window jambs and along the edges of other building members were there is a need to create a seal and/or spring means between two surfaces brought into close proximity.
The present invention may also be applied to surfaces in such a way as to take advantage of its spring-like properties. An example of such an application is along the edges of cabinet doors or the surfaces they abut, particularly in the use of doors which use a pressure-activated latch, so that the cabinet door is urged toward the open position once the latch is opened.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section view of the sealing/spring strip in accordance with the first embodiment type of the present invention.
FIG. 2 is a cross-section view of the sealing/spring strip in accordance with an alternative embodiment of the first embodiment type of the present invention.
FIG. 3 is a cross-section view of a sealing/spring strip showing three alternative embodiments of the third embodiment type of the present invention.
FIG. 4 is a cross-section view of a sealing/spring strip in accordance with a third embodiment type of the present invention.
FIG. 5 is a cross-section view of a sealing/spring strip in accordance with a fourth embodiment type of the present invention.
FIG. 6 is a cross-section view of a sealing/spring strip in accordance with a first embodiment type of the present invention, and featuring a profile adapting the strip for use in a dual pane window assembly.
FIG. 7 is a cross-section view of the sealing/spring strip in accordance with an alternative embodiment of the first embodiment type of the present invention, and featuring a profile adapting the strip for use in a dual pane window assembly.
FIG. 8 is a cross-section view of a sealing/spring strip in accordance with a third embodiment type of the present invention, and featuring a profile adapting the strip for use in a dual pane window assembly.
FIG. 9 is a cross-section view of a sealing/spring strip in accordance with a third embodiment type of the present invention.
FIG. 10 is a cross-section, environmental view of a jamb liner in a window frame, and incorporating a sealing/spring strip in accordance with a third embodiment type of the present invention in said jamb liner.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following is a detailed description of the preferred embodiments of the invention which are presently considered to be the best modes of the invention for a variety of applications.
FIG. 1 shows a cross-section view of a first embodiment type in accordance with the present invention. FIG. 1 shows sealing/spring strip 1 which comprises polymeric extrudate 2. Polymeric extrudate 2 has upper surface 3 from which extend extension portions 4 so as to form well 5. Well 5 is completely filled with silicone rubber 6 so as to expose a meniscus forming resilient surface 7 of silicone rubber. Sealing/spring strip 1 is employed by fixing it to a first surface 8 which, together with second surface 9 represent two surfaces between which a seal is desired. Once fixed to first surface 8, the sealing/spring strip may be urged against second surface 9 so that resilient surface 7 forms a seal against second surface 9.
Sealing/spring strip 1 may be affixed to first surface 8 by any well-known mechanical means such as through the use of nails, screws, bolts, adhesives or any other equivalent mechanical force. Alternatively and preferably, the sealing/spring strip 1 may be integrally incorporated into the balance of the structure represented by first surface 8 (such as in the form of an integral polymeric piece).
FIG. 6 shows a cross-sections of a sealing/spring strip in accordance with a first embodiment type of the present invention, and featuring a profile adapting the strip for use in a dual pane window assembly. This embodiment shows that the base portion of the extrudate may be shaped to adapt to any particular application. In the case of FIG. 6, the profile of the extrudate is adapted to accept and maintain in position two glass panes in a dual pane thermal window assembly, in accordance with known geometries for such assemblies. Such assemblies may be manufactured in accordance with assembly and production practices known in the art. FIG. 6 shows base portion shows jamb liner 60 which incorporates base portions 61, each provided with extension portions 62, forming respective wells 63, and adapted to hold silicone rubber bead 64. The balance of the jamb liner structure 65 is formed so as to be amenable to its use as a jamb liner; that is, to engage a dual pane window assembly in accordance with profiles and arrangements known in the art as exemplified in FIG. 10 herein.
FIG. 7 is a cross-section view of the sealing/spring strip in accordance with an alternative embodiment of the first embodiment type of the present invention, and featuring a profile likewise adapting the strip for use in a dual pane window assembly. FIG. 7 shows base portion shows jamb liner 70 which incorporates base portions 71, each provided with extension portions 72, forming respective wells 73, and adapted to hold silicone rubber bead 74. Wells 73 also contain longitudinally extending spacer member 76 which creates space 77. The balance of the jamb liner structure 75 is formed so as to be amenable to its use as a jamb liner; that is, to engage a dual pane window assembly in accordance with profiles and arrangements known in the art as exemplified in FIG. 10 herein.
FIG. 2 shows an alternative embodiment of the first embodiment type of the present invention. FIG. 2 shows a sealing/spring strip 10 which is formed by a polymeric extrudate 11 having first surface 12. Extending from first surface 12 are extension portions 13 which form well 14. This embodiment also features a sealing portion 15 which serves to seal off excluded space 16. The balance of well 14 is then filled completely with silicone rubber 17 such that resilient surface 18 is exposed. This embodiment allows a reduction in the volume of silicone rubber needed in respective lengths of the sealing/spring strip. Also, this type of arrangement can be used to add additional strength to the overall sealing/spring strip construction.
Sealing/spring strip 10 can be employed in the same way as sealing/spring strip 1 of FIG. 1. The sealing/spring strip can be attached to a first surface 19 while the resilient surface 18 is urged against second surface 20 so as to form a seal between the two surfaces. Alternatively and preferably, the sealing/spring strip 10 may be integrally incorporated into the balance of the structure represented by first surface 19 (such as in the form of an integral polymeric piece).
FIG. 3 shows three ways in which a sealing/spring strip in accordance with a second embodiment type of the present invention might be prepared. FIG. 3 shows a sealing/spring strip 20 which comprises polymeric extrudate 21. Polymeric extrudate 21 is shown as having three different types of vaned extension portions 22, 23, and 24 which are examples of the variety of ways vaned extension portions can be provided in a sealing/spring strip in accordance with this embodiment of the present invention. Vaned extension 22 is an example of a vaned extension comprising one or more V-shapes. Vaned extension 23 is a T-shaped extension, and vaned extension 24 is cross-shaped. It should be understood that a sealing/spring strip in accordance with this embodiment of the present invention may be formed using one or more than one such vaned extensions of the same or differing geometries. Each of the vaned extensions is shown as extending from upper surface 25.
Each vaned extension is provided with a bead of silicone rubber, shown as silicone rubber beads 26, 27 and 28 disposed respectively over vaned extensions 22, 23 and 24. A sealing/spring strip 20 may be used to form a seal between first surface 29 and second surface 30. This may be done by physically affixing polymeric extrudate 21 to first surface 29 so as to present the resilient surfaces of silicone rubber beads 26, 27 and 28 to second surface 30. Alternatively and preferably, the sealing/spring strip 20 may be integrally incorporated into the balance of the structure represented by first surface 29 (such as in the form of an integral polymeric piece). These resilient surfaces are urged against second surface 30 so as to form a seal.
FIG. 4 shows a cross-section view of a sealing/spring strip prepared in accordance with a third embodiment type of the present invention. FIG. 4 shows sealing/spring strip 40 which comprises polymeric extrudate 41 having first surface 42. From first surface 42, extend extension portions 43 which form acute angle corners 44 with the first surface 42. The extension portions of 43 are sufficiently flexible so as to be movable from a rest position (the position shown in FIG. 4) to a compressed position relatively closer to the upper surface 42 of the polymeric extrudate 41 (as indicated by directional movement arrows 45). Acute corners 44 are provided with silicone rubber 46 which once cured, serves to resist the movement of extension portions 43 from the rest position to the compressed position.
In order to produce a sealing/spring strip in accordance with this embodiment of the invention, it is preferred that the extrudate be oriented as is shown in FIG. 4 so that the silicone rubber 46 can be laterally injected into the respective acute angle corners 44. It will also be appreciated that this embodiment type of the present invention can be executed using only one such extension portion 43 as part of a polymeric extrudate such as 41. In such cases it may be desirable to orient the extrudate such that the single acute angle corner 44 so produced is oriented so as to open upwardly to better retain the uncured silicone rubber in the acute angle corner.
Sealing/spring strip 40 may be affixed to a first surface 47 by any mechanical means such as those mentioned above. The affixed sealing/spring strip may then be brought in contact with second surface 48 so that second surface 48 comes in contact with extension portions 43, forcing them towards a compressed position along directional movement arrows 45 as described above. Alternatively and preferably, the sealing/spring strip 40 may be integrally incorporated into the balance of the structure represented by first surface 47 (such as in the form of an integral polymeric piece). The resilience of silicone rubber bead 46 causes a seal to be formed between the second surface 48 and the extension portions 43 of the sealing/spring strip 40.
FIG. 8 is a cross-section view of the sealing/spring strip in accordance with the third embodiment type of the present invention, and featuring a profile adapting the strip for use in a dual pane window assembly as described with respect to FIGS. 6 and 7 above. FIG. 8 shows base portion shows jamb liner 80 which incorporates base portions 81, each provided with extension portions 82, forming acute angles 83, and adapted to hold silicone rubber bead 84. Extension portions 82 may preferably be provided with an inwardly curved edge 85 which allows it to ride more easily against the surface it contacts as may be appreciated from the environmental view of FIG. 10 herein for the embodiment of FIG. 9. The balance of the jamb liner structure 86 is formed so as to be amenable to its use as a jamb liner; that is, to engage a dual pane window assembly in accordance with profiles and arrangements known in the art as exemplified in FIG. 10 herein.
FIG. 9 is a cross-section view of a preferred embodiment of the third embodiment type of the present invention, which is presently considered to be the best mode of practicing the invention when used in a window jamb liner. FIG. 9 is shown as approximately 5 times actual size. FIG. 9 shows base portion shows jamb liner portion 90 which comprises base portions 91, each provided with extension portion 92, forming acute angle 93, and adapted to hold silicone rubber bead 94. Extension member 92 may preferably be provided with an inwardly curved edge 98 which allows it to ride more easily against the surface it contacts as may be appreciated from FIG. 10 herein. Extension member 92 preferably may also be provided with extension member 95 which extends toward the interior of the acute angle so formed (i.e. toward the first surface of the base portion 91) so as to provide additional mechanical support for the uncured silicone rubber bead once placed in the of the acute angle, and to provide physical support and alignment for the cured silicone bead 94. Likewise, base portion 91 preferably may also be provided with extension member 96 which extends toward the interior of the acute angle so formed (i.e. toward the first surface of the base portion 91) so as to provide additional mechanical support for the uncured silicone rubber bead once placed in the of the acute angle, and to provide physical support and alignment for the cured silicone bead 94. As mentioned above, the acute angle preferably may be formed by the coextrusion of two polymer of differing physical characteristics. FIG. 9 shows that extension member 92 and base member 91 is formed from a polymer having a higher impact rating than that used to form the acute corner itself (leg portion 97), so that the extension portion does not bend under a load while the leg portion 97 flexes. This construction helps to prevent the polymer in the extension portion(s) from fatiguing over several flexing cycles and from having a shape memory imparted to them. Examples of a combination of polymeric materials which may be used for the base and extension portion(s), and for the acute angle portion(s) are, respectively high impact PVC formulation 85857 and flexible PVC formulation 83741, both commercially available from B. F. Goodrich Chemicals of Akron, Ohio.
The dimensions of the jamb liner portion, though not a limitation to the invention are, for the embodiment shown in FIG. 9, as follows: the extension portion 92 and base portion 91 have a thickness of about 0.060 inches; the thickness of the leg portion 97 is about 0.030 inches; the diameter of the silicone bead 94 may be in the range of about 0.094 inches to 0.140 inches; and the thickness of the smaller extension members 95 and 96 is about 0.020 inches.
The jamb liner portion may be incorporated into a jamb liner structure as is shown in FIG. 10. Alternatively and preferably, the jamb liner portion may be integrally incorporated into a jamb liner by extruding the structure as a single piece as shown, for instance, in FIG. 8 where the base portion and the balance of the jamb liner are extruded as a single structure.
FIG. 10 shows a cross-section of a window frame construction 100 containing a jamb liner prepared in accordance with the present invention. FIG. 10 shows wooden window frame 101 having groove 102. The jamb liner 103 is formed from a conventional jamb liner which is adapted to grip groove 102 as shown in a window frame. The window frame also has trim facia piece 105. Where normally a urethane foam would be placed in groove 102, jamb liner portion(s) 90 is disposed so as to provide a spring-like member to urge the jamb liner 103 against the abutting tongues 104 of wooden frame 101. The base portion of the jamb liner portion may be adhered or otherwise attached to the inside of the jamb liner 103 as shown, such as with two-sided adhesive tape. The extension portions (item 92 in FIG. 9) face the inside of the groove 102. As jamb liners such as 103 are readily commercially available, the improved jamb liner portion of the present invention may be assembled in this way by adhering the base portion to the inside of the stock jamb liner as shown in FIG. 10. However, because it involves less labor intensive steps (and is therefore relatively more economical) to form the inventive jamb liner as a single piece as described in FIG. 8, this method is preferred over extruding the assembly in individual pieces as shown in FIG. 10. Accordingly, the embodiment of FIG. 10 is presently considered to represent the best mode of the invention for the production of jamb liners with the exception that the improved jamb liner be formed as a single piece as shown in FIG. 8.
Turning to FIG. 5, this figure shows yet another variation of the present invention in accordance with a fourth embodiment type thereof.
FIG. 5 shows a sealing/spring strip 50 which comprises a polymeric extrudate 51 which forms well 52. Polymeric extrudate 51 has first surface 53. Two extension portions 54 are provided which both extend into well 52 and extend above surface 53. Well 52 is filled with silicone rubber 55 such that extension portions 54 extend into the silicone rubber 55, and are held in the positions shown in FIG. 5.
Extension portions 54 may be separately extruded and oriented in position in either before or after the silicone rubber 55 is placed in well 52. Once cured, the silicone rubber not only holds the position of extension portions 54 shown in FIG. 5 (the so-called rest position) but also resists their movement into a compressed position closer to the upper surface 53 along directional movement arrows 56.
sealing/spring strip 50 may be applied to form a seal between first surface 57 and second surface 58. The polymeric extrudate 51 is attached to first surface 57 by any of the mechanical means mentioned above or their equivalent. Here it is noted that first surface 57 may be contoured so as to accommodate the size of well 52. Another embodiment may be to thicken extrudate 51 so that the thickness of the portions not forming well 52 is equal to the thickness dimensions of those portions forming the well. This would allow application of the sealing/spring strip 52 to a flat surface. Once fixed to a surface 57, the sealing/spring strip is brought into contact with surface 58 by urging surface 58 against extension portions 54. Alternatively and preferably, the sealing/spring strip 50 may be integrally incorporated into the balance of the structure represented by first surface 57 (such as in the form of an integral polymeric piece). Movement of surface 58 against extension portions 54 causes these extensions to move along directional movement arrows 56 from the rest position to the compressed position closer to surface 53. The resilience of the silicone rubber 55 resists this movement causing a seal between the two surfaces to be formed.
It will also be appreciated that this embodiment of the present invention may also be executed using only a single extension 54.
In order to produce sealing/spring strips in accordance with the present invention, it will normally be the case that such sealing/spring strips can be most efficiently produced by polymeric extrusion to produce the polymeric extrudate portions of the present invention as outlined above. Such extrudates may be produced using any conventional extruder apparatus. Examples of such apparatus include extruder model CM-80 OR CM-111, commercially available from Cincinnati Milacron Company of Cincinnati, Ohio.
The polymeric materials used to make the polymeric extrudates for the present invention may be of any suitable polymeric material depending on the desired application. Such materials include polyvinylchloride (PVC), chloropolyvinylchloride (CPVC), with or without polyvinylidinefluorides and/or acrylics, or alloys of any of the aforesaid. Of these materials, where a high impact weatherable PVC is to be used in accordance with the present invention, B. F. Goodrich formulation 85857 in cube form is preferred. Where the high impact PVC is to be coextruded with a flexible PVC, a preferred flexible PVC is B. F. Goodrich formulation 83741 in cube form.
The silicone rubber which may be used in accordance with the present invention may be of any commercially available type, again depending on the desired application and the dictates of economics. An example of commercially available silicone rubber is Nuva-Sil 83 commercially available from Loctite Corporation of Newington, Connecticut. Although not a limitation, the silicone rubber may be foamed with nitrogen to an extent such as 40% to 50% of the total volume, with 50% being preferred. Although not limited to any particular dimension of the silicone rubber bead, a typical thickness for the silicone bead is about 0.100 inches in diameter (measured from the upper surface of the base portion of the extrudate) The silicone rubber may be injected onto the extrudate using an injector such as The Foamix System Model, commercially available from Nordson Company of Cleveland, Ohio. This device uses and impeller which creates bubbles in the silicone rubber as it passes into a cavity having a nitrogen atmosphere.
The silicone rubber may be cured in accordance with manufacturer's specifications. For instance, with an extrude speed of about 60 feet per minute (or one foot per second) and assuming a light intensity of 100 mw/cm 2 at a distance of six inches from the light source and requiring a total power output of 1.5 joules, the amount of light necessary can be calculated.
Using the formula: T=Joules/Light Intensity 1.5 W-sec/sm 2 /0.1 W/sm 2 (or 100 mw/sm 2 )=15 seconds. With the exposure time in hand, this is multiplied by the extrudate speed to obtain the light exposure length in inches:
15 seconds×60 ft/min/60 sec/min=15 feet Using six inch UV light bulbs, this would require 30 UV light sources to provide the necessary power output.
An alternative light source such as fusion light could provide more light intensity, thus decreasing the amount of bulb necessary to cure the silicone rubber.
The finished extrudate product may be cut to a desired length such as through the use of Teflon®-coated blades.
The polymeric material(s) and the type of silicone rubber used to execute the present invention are not critical limitations of the present invention.
In view of the foregoing disclosure, it will be within the ability of one or ordinary skill in the relevant art to make variations, alterations, and modifications, including the substitution of equivalent materials, variations in geometry, or the integration or disintegration of parts, to execute the present invention without departing from its spirit as reflected in the appended claims. | The present invention pertains to a polymeric sealing/spring strip and method of producing same. The polymeric sealing/spring strip of the present invention has several various embodiments which are based upon the incorporation of silicone rubber. Some of the embodiments are based on the formation of a resilient silicone rubber surface to provide a sealing/spring contact with an opposing surface period. Other embodiments of the invention incorporate the silicone rubber in such way as to utilize its resilient properties to produce a sealing/spring strip which has improved mechanical resilience properties. The method of the present invention allows the production of a sealing/spring strip in accordance with the present invention by using extrusion techniques. | 4 |
[0001] This application is a continuation of Ser. No. 13/274,706, filed Oct. 17, 2011, now U.S. Pat. No. 8,239,530, which application was a continuation of Serial No. 12/122,796, filed May 19, 2008, now U.S. Pat. No. 8,041,809, which application was a continuation of Ser. No. 11/598,400, filed Nov. 13, 2006, now U.S. Pat. No. 7,376,736, which application was a continuation of Ser. No. 10/272,368, filed Oct. 15, 2002, now U.S. Pat. No. 7,136,922.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates generally to techniques for enabling a Web site origin server to obtain content delivery services from a third party service provider on an as-needed basis.
[0004] 2. Description of the Related Art
[0005] Today's Web sites are a double-edged sword. They present enterprises with the opportunity for both resounding success and costly, dramatic failure. The possibility for either scenario to occur is chiefly due to the Internet's open design. Indeed, the ability to reach a global community of customers and partners via the Web comes with many risks. The open design means that enterprises must expose themselves by opening a public entry-point to get the global reach they need. Couple that with the inherent weaknesses of centralized infrastructure and there is a recipe for failure. Indeed, a growing number of threats can bring a site down daily. These threats include hacker attacks, viruses, Internet worms, content tampering and Denial of Service (DoS) attacks. Moreover, the site's popularity itself can generate “flash crowds” that overload the capabilities of the site's origin server(s). Any one of these events can produce unpredictable site disruptions that impede revenue operations, dilute brand investments, hamper productivity and reduce goodwill and reputation.
[0006] A content provider can ameliorate these problems by outsourcing its content delivery requirements to a content delivery network (a “CDN”). A content delivery network is a collection of content servers and associated control mechanisms that offload work from Web site origin servers by delivering content on their behalf to end users. A well-managed CDN achieves this goal by serving some or all of the contents of a site's Web pages, thereby reducing the customer's infrastructure costs while enhancing an end user's browsing experience from the site. In operation, the CDN uses a request routing mechanism to locate a CDN content server close to the client to serve each request directed to the CDN, where the notion of “close” is based, in part, on evaluating results of network traffic tests.
[0007] While content delivery networks provide significant advantages, some content providers prefer to maintain primary control over their Web site infrastructure or may not wish to pay for the cost of fully-provisioned CDN services. As a result, the site remains exposed to the myriad of potential security and flash crowds that may bring the site down at any time.
[0008] It would be highly desirable to provide a content provider the ability to receive “on demand” use of a CDN to provide an additional layer of protection to ensure business continuity of an enterprise Web site. The present invention addresses this need.
BRIEF SUMMARY OF THE INVENTION
[0009] It is a primary object of the present invention to provide an infrastructure “insurance” mechanism that enables an origin server to selectively use or fail over to a content delivery network (CDN) upon a given occurrence at the site. Upon such occurrence, at least some portion of the site's content is served from the CDN so that end users that desire the content can still get it, even if the content is not then available from the origin site.
[0010] It is another primary object of the invention is to provide origin server “insurance” to render server content accessible even if access to the origin server is inhibited in some way.
[0011] It is another more specific object of the present invention to provide a mechanism that enables a Web site origin server to use a content delivery network for insurance purposes on an as-needed basis. Preferably, this operation occurs in a seamless and automatic manner, and it is maintained for a given time period, e.g., for as long as the need continues.
[0012] According to an illustrative embodiment, the technical advantages of the present invention are achieved by monitoring an origin server for a given occurrence and, upon that occurrence, providing failover of the site to a CDN. Preferably, this is accomplished by re-directing DNS queries (to the origin server) to the CDN service provider's request routing mechanism. In this fashion, DNS queries for content are resolved by the CDN DNS mechanism as opposed to the site's usual DNS. The CDN DNS mechanism then maps each DNS request to an optimal server in the CDN in a known manner to enable the requesting end user to obtain the desired content, even if the origin server is unavailable. As a consequence of this site insurance, given content on the origin server is always available.
[0013] The site insurance may be triggered upon a given occurrence—the scope of which is quite variable. Representative occurrences include, without limitation, a flash crowd at the site, a site failure, excess traffic to the site originating from certain geographies or networks, excess demand for certain content on the site such as high resolution streaming content, excess latency or slowdown at the site as perceived by network downloading agents deployed throughout the CDN or elsewhere, or a site attack such as a Denial of Service (DoS) attack at or adjacent the site. Generally, the present invention selectively moves traffic from the origin to the CDN when there is excessive load on the origin or the origin is unreachable. These examples, however, are merely illustrative.
[0014] The site insurance functionality may operate in a standalone manner or be integrated with other CDN services, such as global traffic management.
[0015] The foregoing has outlined some of the more pertinent features of the present invention. These features should be construed to be merely illustrative. Many other beneficial results can be attained by applying the disclosed invention in a different manner or by modifying the invention as will be described.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a block diagram of a known content delivery network in which the present invention may be implemented;
[0017] FIG. 2 is a simplified block diagram illustrating how site insurance functionality is provided according to the present invention;
[0018] FIG. 3 is a flowchart illustrating how the site insurance is triggered upon determination of a given event at the origin server; and
[0019] FIG. 4 illustrates a global traffic management system in which the site insurance functionality may be integrated according to an embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0020] By way of background, it is known in the prior art to deliver digital content (e.g., HTTP content, streaming media and applications) using an Internet content delivery network (CDN). A CDN is a network of geographically-distributed content delivery nodes that are arranged for efficient delivery of content on behalf of third party content providers. Typically, a CDN is implemented as a combination of a content delivery infrastructure, a request-routing mechanism, and a distribution infrastructure. The content delivery infrastructure usually comprises a set of “surrogate” origin servers that are located at strategic locations (e.g., Internet network access points, Internet Points of Presence, and the like) for delivering content to requesting end users. The request-routing mechanism allocates servers in the content delivery infrastructure to requesting clients in a way that, for web content delivery, minimizes a given client's response time and, for streaming media delivery, provides for the highest quality. The distribution infrastructure consists of on-demand or push-based mechanisms that move content from the origin server to the surrogates. An effective CDN serves frequently-accessed content from a surrogate that is optimal for a given requesting client. In a typical CDN, a single service provider operates the request-routers, the surrogates, and the content distributors. In addition, that service provider establishes business relationships with content publishers and acts on behalf of their origin server sites to provide a distributed delivery system.
[0021] As seen in FIG. 1 , an Internet content delivery infrastructure usually comprises a set of “surrogate” origin servers 102 that are located at strategic locations (e.g., Internet network access points, and the like) for delivering copies of content to requesting end users 119 . A surrogate origin server is defined, for example, in IETF Internet Draft titled “Requirements for Surrogates in the HTTP” dated Aug. 9, 2000, which is incorporated herein by reference. The request-routing mechanism 104 allocates servers 102 in the content delivery infrastructure to requesting clients. The distribution infrastructure consists of on-demand or push-based mechanisms that move content from the origin server to the surrogates. A CDN service provider (CDNSP) may organize sets of surrogate origin servers as a group or so-called “region.” In this type of arrangement, a CDN region 106 typically comprises a set of one or more content servers that share a common back-end network, e.g., a LAN, and that are located at or near an Internet access point. Thus, for example, a typical CDN region may be co-located within an Internet Service Provider (ISP) Point of Presence (PoP) 108 . A representative CDN content server is a Pentium-based caching appliance running an operating system (e.g., Linux, Windows NT, Windows 2000) and having suitable RAM and disk storage for CDN applications and content delivery network content (e.g., HTTP content, streaming media and applications). Such content servers are sometimes referred to as “edge” servers as they are located at or near the so-called outer reach or “edge” of the Internet. The CDN typically also includes network agents 109 that monitor the network as well as the server loads. These network agents are typically co-located at third party data centers or other locations. Mapmaker software 107 receives data generated from the network agents and periodically creates maps that dynamically associate IP addresses (e.g., the IP addresses of client-side local name servers) with the CDN regions.
[0022] Content may be identified for delivery from the CDN using a content migrator or rewrite tool 106 operated, for example, at a participating content provider server. Tool 106 rewrites embedded object URLs to point to the CDNSP domain. A request for such content is resolved through a CDNSP-managed DNS to identify a “best” region, and then to identify an edge server within the region that is not overloaded and that is likely to host the requested content. Instead of using content provider-side migration (e.g., using the tool 106 ), a participating content provider may simply direct the CDNSP to serve an entire domain (or subdomain) by a DNS directive (e.g., a CNAME). In either case, the CDNSP may provide object-specific metadata to the CDN content servers to determine how the CDN content servers will handle a request for an object being served by the CDN. Metadata, as used herein, refers to a set of control options and parameters for the object (e.g., coherence information, origin server identity information, load balancing information, customer code, other control codes, etc.), and such information may be provided to the CDN content servers via a configuration file, in HTTP headers, or in other ways. The Uniform Resource Locator (URL) of an object that is served from the CDN in this manner does not need to be modified by the content provider. When a request for the object is made, for example, by having an end user navigate to a site and select the URL, a customer's DNS system directs the name query (for whatever domain is in the URL) to the CDNSP DNS request routing mechanism. A representative CDN DNS request routing mechanism is described, for example, in U.S. Pat. No. 6,108,703, the disclosure of which is incorporated herein by reference. Once an edge server is identified, the browser passes the object request to the server, which applies the metadata supplied from a configuration file or HTTP response headers to determine how the object will be handled.
[0023] As also seen in FIG. 1 , the CDNSP may operate a metadata transmission system 116 comprising a set of one or more servers to enable metadata to be provided to the CDNSP content servers. The system 116 may comprise at least one control server 118 , and one or more staging servers 120 a - n , each of which is typically an HTTP server (e.g., Apache). Metadata is provided to the control server 118 by the CDNSP or the content provider (e.g., using a secure extranet application) and periodically delivered to the staging servers 120 a - n . The staging servers deliver the metadata to the CDN content servers as necessary.
[0024] The above described content delivery network is merely illustrative. The present invention may leverage any content delivery infrastructure in which a service provider operates any type of DNS-based request routing mechanism.
[0025] According to the present invention, a content provider's origin server(s) provide the Web site's content in the usual manner that would occur in the absence of a content delivery network (CDN). The origin server(s) may be located at a content provider location or a third party hosting site. Thus, conventionally, an end user running a client machine would launch his or her Web browser to a URL identifying the content provider Web site. Through conventional DNS, the end user's browser would be connected to the origin server to fetch the content. That well-known operation is augmented according to the present invention to provide so-called “site insurance,” which is a technique to provide “on-demand” use of the CDN in given circumstances. The CDN service provider preferably makes the site insurance functionality available to one or more content provider customers as a managed service, which is available on an as-needed basis. Thus, according to the invention, Web site traffic is handled by the origin server(s) in the usual manner (i.e., without the CDN) and is triggered upon a given occurrence at the origin server. Representative occurrences include, without limitation, a flash crowd at the site, a site failure, excess traffic to the site originating from certain geographies or networks, excess demand for certain content on the site such as high resolution streaming content, excess latency or slowdown at the site as perceived by network downloading agents deployed throughout the CDN or elsewhere, a Denial of Service (DoS) attack at or adjacent the site, a DoS attack that indirectly impacts the site, or the like. Of course, the above examples are merely illustrative.
[0026] FIG. 2 is a simplified block diagram of how site insurance is provided to a particular origin server 200 by the service provider operating a CDN 202 . Origin server 200 has a name service 204 (e.g., running DNS software such as BIND) associated therewith. According to the invention, the name service 204 is modified to include a control mechanism 206 that monitors the server for one or more given occurrences that trigger the site insurance. Alternatively, control mechanism 206 operates in association with the CDN name service. In an illustrative embodiment, the control mechanism is implemented in software executable on a processor and implements a dynamic modification of a local DNS record (e.g., a DNS A record) upon determining that the given occurrence has taken place. Thus, the local DNS record may be modified so that a given content provider domain is directed to a CDN-specific domain, i.e., a domain that cues the CDN's request routing mechanism 208 to handle the given request. Illustratively, assume that the normal content provider domain is www.cp.com and that this is the domain that is used by a given end user browser to fetch content from the origin server. According to the invention, when the control mechanism 206 identifies the given condition at the site that triggers the site insurance server, that mechanism rewrites the DNS record in the name service 204 so that www.cp.com points to a CDN request routing mechanism. Thus, for example, if the CDN domain is g.cdnsp.net, the domain www.cp.com is pointed to g.cdnsp.net. A convenient way to do this is to insert a DNS CNAME into the A record for www.cp.com. Any other convenient aliasing technique, such as domain delegation, can be used. As a result of this modification, requests for content associated with the www.cp.com domain are selectively handled by the CDN.
[0027] FIG. 3 is a flowchart of the process for a particular event that triggers the site insurance. Step 300 assumes the default operation wherein the origin server is operating without assistance from the CDN. At step 302 , a test is made to determine whether a given event triggering the site “insurance policy” has occurred. If not, the routine cycles. As noted above, there may be many diverse types of events that could trigger the insurance. When the given event occurs, as indicated by a positive outcome of the test at step 302 , the routine continues at step 304 wherein the control mechanism rewrites the local DNS record as described above. This redirects DNS queries, which were originally intended for the content provider domain, to the CDN domain. At step 306 , this rewrite cues the CDNSP's DNS request routing mechanism to resolve the query. As a consequence, the query (and thus the content request) is managed by the CDN, thereby relieving the origin server of having to handle the request. At step 308 , a test is made to determine whether the given event that has triggered the insurance has ended. If not, the routine cycles and the site insurance is maintained. If, however, the outcome of the test at step 308 indicates that the given event that triggered the insurance has ended, the routine continues at step 310 to rewrite the local DNS record (e.g., by removing the CNAME). This returns the site back to its default operation, wherein the content is delivered without reference to the CDN. Steps 308 and 310 are not required, as the given site insurance may simply be removed after a given timeout, at a given time, or upon some other condition.
[0028] The content delivery network service provider may provide the site insurance functionality as a standalone product or managed service (as described above) or integrated with a global traffic management (GTM) product or service. An illustrative GTM system is known commercially as FirstPoint SM and is available from Akamai Technologies of Cambridge, Mass. This technique is described in commonly-owned U.S. Pat. No. 7,111,061, titled Global Load Balancing Across Mirrored Data Centers, which is incorporated herein by reference. Other commercial available products include Cisco Global Director, global load balancers from F5, and the like. Any product/system/managed service that has the ability to direct a client request to one of a set of mirrored sites based on network traffic conditions, server load, and the like, may be used as the GTM system.
[0029] In this embodiment, the content provider purchases the GTM and the site insurance services from the CDN service provider. The content provider's origin server may or may not be mirrored, but typically it will be. Accordingly, the GTM directs end user requests to the origin server, or to one of the mirrored origin servers, in the usual manner. Upon occurrence of a given event triggering the insurance policy, however, the GTM, as modified to include the site insurance mechanism, automatically and seamlessly moves traffic away from the origin servers and onto the CDN.
[0030] Integrating GTM and site insurance functionality in this manner provides significant advantages. In low demand situations, the GTM simply directs end users to the origin servers in the normal manner. As the demand increases, however, the GTM automatically senses the load changes and directs it to the CDN, where it can be more effectively managed by the distributed CDN infrastructure.
[0031] FIG. 4 illustrates how a customer Web site is integrated into the traffic redirection system to take advantage of the site insurance. It is assumed that the customer has a distributed web site of at least two (2) or more mirrored origin servers. Typically, the GTM system operates to load balance multiple subdomains/properties provided they are in the same data centers. As described in U.S. Pat. No. 7,111,061, integration simply requires that the customer set its authoritative name server 400 to return a CNAME to the GTM name servers 408 , which, thereafter, are used to resolve DNS queries to the mirrored customer site. Recursion is also disabled at the customer's authoritative name server. In operation of the GTM system, an end user 402 makes a request to the mirrored site using a conventional web browser or the like. The end user's local name server 404 issues a request to the authoritative name server 400 (or to a root server if needed, which returns data identifying the authoritative name server). The authoritative name server then returns the name of a name server 408 in the managed service. The local name server then queries the name server 408 for an IP address. In response, the name server 408 responds with a set containing one or more IP addresses that are “optimal” for that given local name server and, thus, for the requesting end user. As described in U.S. Pat. No. 7,111,061, the optimal set of IP addresses may be generated based on network maps created by testing the performance of representative common points on the network. The local name server selects an IP address from the “optimal” IP address list and returns this IP address to the requesting end user client browser. The browser then connects to that IP address to retrieve the desired content, e.g., the home page of the requested site. The above-described operation is augmented according to the present invention to include the site insurance functionality. The control mechanism 405 is illustrated in the drawing. Control mechanism 405 monitors for occurrence of the one or more triggering events to provide the site insurance functionality. This can be accomplished in a seamless manner by having authoritative name server 400 , upon occurrence of the event, simply return the name of whatever lower level CDN name server will manage the request. The CDN service provider may operate separate name server mechanisms for the GTM service and for the site insurance, or these functions can be integrated into the same CDNSP-managed DNS. When the triggering event occurs, the end user browser's local name server 404 is handed back the name of a CDN name server from which the local name server 404 obtains the IP address of a CDN edge server. This redirection occurs automatically and without user involvement or knowledge.
[0032] Representative machines on which the present invention is operated may be Intel Pentium-based computers running a Linux or Linux-variant operating system and one or more applications to carry out the described functionality. One or more of the processes described above are implemented as computer programs, namely, as a set of computer instructions, for performing the functionality described. | An infrastructure “insurance” mechanism enables a Web site to fail over to a content delivery network (CDN) upon a given occurrence at the site. Upon such occurrence, at least some portion of the site's content is served preferentially from the CDN so that end users that desire the content can still get it, even if the content is not then available from the origin site. In operation, content requests are serviced from the site in the usual manner, e.g., by resolving DNS queries to the site's IP address, until detection of the given occurrence. Thereafter, DNS queries are managed by a CDN dynamic DNS-based request routing mechanism so that such queries are resolved to optimal CDN edge servers. After the event that caused the occurrence has passed, control of the site's DNS may be returned from the CDN back to the origin server's DNS mechanism. | 7 |
This is a continuation of co-pending application Ser. No. 355,927 filed on May 23, 1989, now abandoned.
FIELD OF THE INVENTION
The present invention relates to implantable medical devices and, in particular, to features of an implantable combined defibrillator/pacemaker.
BACKGROUND OF THE INVENTION
In recent years, there has been a great deal of interest in the application of very low power analog/digital circuitry in battery powered biomedical systems. Much of this interest has centered around implantable cardiac pacemakers. These devices are used to treat cardiac arrhythmias, such as bradycardia (slow heart rate) or tachycardia (rapid heart rate), by assisting the heart's natural pacemaking function with relatively low voltage (5-10 V) pulses.
This type of treatment is, however, totally ineffective against fibrillation, which is characterized by very rapid, uncoordinated electrical activity in which the heart essentially stops pumping blood. Death quickly results unless emergency treatment, generally in the form of a defibrillating high voltage shock, is administered. It is estimated that each year in the U.S. about 300,000 people suffer sudden death from this condition.
As the technology for defibrillators improves, it becomes possible to more completely combine both pacing and defibrillation capabilities in a single implantable device. This results in significant performance improvements.
It is well recognized that biphasic defibrillation is more effective than monophasic defibrillation. Winkle et al., "Improved low energy defibrillation efficacy in man with the use of a biphasic truncated exponential waveform", American Heart Journal, January 1989, pp. 122-127.
U.S. Pat. No. 4,800,883 issued Jan. 31, 1989, to William L. Winstrom, discloses an apparatus for generating a multiphasic defibrillation waveform. The Winstrom apparatus is suitable for use in an implantable defibrillation system for automatically generating a multiphasic defibrillation pulse waveform in response to sensed fibrillation. A controller senses cardiac fibrillation and generates a control signal that causes a charging circuit to charge two series charge-storing capacitors to selected voltage levels in sequentially alternating charge generation and charge coupling cycles. A voltage level detector senses the stored voltage level, disables the charging circuit when the sensed voltage reaches a predetermined level and informs the controller that the capacitors are fully charged. The controller then communicates control signals indicative of pulse magnitude, duration and polarity to a multiphasic pulse generator that includes a number of high-power switches and corresponding switch drivers interposed in-circuit between the heart and the terminals of the charge storing capacitors. The drivers control the conduction states of the switches according to the control signals to establish selected circuit paths between the capacitor terminals and the heart, thereby delivering to the heart a multiphasic waveform having pulses with selected parameters of magnitude, duration and polarity.
SUMMARY OF THE INVENTION
The present invention provides an implantable system that includes both a pacemaker and a fully programmable defibrillator and, thus, may be used in the treatment of bradycardia and tachycardia as well as ventricular fibrillation.
The system design uses a minimum number of components, which enhances reliability, and includes safety features that reduce the leakage current to the patient.
Whether the defibrillation output stage is monophasic or biphasic, it is desirable to non-invasively ascertain whether a break has occurred in the defibrillating leads without having to subject the patient to a traumatic high voltage defibrillating pulse. Special features are included in the pacing output section of the system for this purpose.
An additional requirement for a combined pacemaker/defibrillator device is that the pacing circuit be able to deliver pacing pulses at an extremely high rate (50 per second) without droop to fibrillate the patient intentionally. This gives the physician the ability to non-invasively induce the patient's arrhythmia and thereby verify proper functionality of the automatic features of the device.
In conventional implantable defibrillators, large positive voltages are produced and pulsed into the heart to terminate ventricular arrhythmias. These large voltages would have the effect of destroying the low voltage pacing circuitry which is also connected to the cardiac tissue if high voltage protection were not present. Protection from such high voltages, without shunting current, requires a device which in the off state can standoff these voltages. Also, when "on", a protection device requires a low "on" resistance so as not to significantly increase the source impedance of the pacing circuitry. Ideally, this low "on" resistance must also be achievable with a controlling voltage no greater than the battery voltage. High voltage MOSFET devices which have the required characteristics are available at present. In general, only n-channel devices have the required voltage standoff of about 1 kV. This precludes the use of a battery in a negative power supply configuration. Thus, a voltage inverter is required to generate pacing pulses.
Accordingly, the present invention provides a combined defibrillator/pacemaker system whereby the pacing voltage and the defibrillation voltage are both regulated as positive voltages above ground. The system power supply is also a positive voltage above ground. Both phases of the defibrillation pulse are delivered as a positive voltage relative to ground, making protection of the pacing output simple. Pacing is delivered as a negative capacitor-coupled voltage for patient safety. The defibrillator output stage forms an H pattern of high voltage/high current switches allowing the load, i.e. the heart, polarity to be reversed. Depending on the phasing of the switches, monophasic or biphasic pulses of either initial polarity can be generated. In a preferred embodiment, MOS controlled thyristors are utilized to implement switching. Leakage current shunt resistors are strategically placed to reduce the possibility of direct current leakage to the patient while the switches are standing off high voltage. Snubber diodes in parallel with the shunt resistors protect the output stage from voltage spikes when switching inductive loads. The floating transistor on each of the ground stages has a protection circuit that keeps gate voltage spikes from turning on the stage inappropriately during defibrillation. If the stage were to inappropriately turn on, it would result in the destruction of the output. The oscillator which energizes the gate drive magnetics is configured to keep the peak magnetic fields relatively constant over the range of battery voltages experienced from beginning of battery life to end of service.
The use of defibrillation pulses that are positive with respect to ground allows the protection of the pacing output stage to be reduced to its simplest configuration. High voltage n-channel MOSFETs are placed in series with each of the active pacing leads and the pacing ground return leads. The gates of these devices are controlled by a signal which is normally at battery voltage, turning the MOSFETs on and allowing pacing to occur normally. Just prior to generating the defibrillation output and for a brief time thereafter, the gates of the MOSFETs are held low, turning them off and thereby protecting the pacing output stage.
A dual channel, i.e. atrial and ventricular, pacing pulse delivery circuit delivers, in programmable fashion, pulsatile voltages up to and including twice the open circuit battery voltage. The polarity of these pulses is negative with respect to ground, the battery voltage being positive. The configuration of switches that delivers the pacing pulses to the patient can also be used in a single channel pace pulse delivery circuit.
An alternate switch configuration provides a single channel pace pulse delivery circuit. The difference between this configuration and that referred to above is that it cannot standoff an external negative transient, i.e. from the other pace channel. The pacing ground return lead is switchable between one of the dedicated pacing return leads and one of the defibrillation electrodes to allow programmability between conventional bipolar pacing and a pseudo-unipolar pacing. The pseudo-unipolar pacing configuration can also be used with a minimal lead system configuration whereby the EKG sensing is also pseudo-unipolar rather than the conventional differential sensing.
By using a standard pacing impedance measuring scheme and allowing each of the patches to be switched to ground independently so the system can pace in a quasi-unipolar fashion with respect to either of the high voltage electrodes, the lead integrity of the defibrillation leads can be ascertained. Furthermore, the measurements can occur automatically and at regular intervals to provide an early warning of a defibrillation lead failure.
In summary, an implantable combined defibrillator-pacemaker system in accordance with the present invention provides a number of advantageous features not found in systems of the type taught by the '883 Winstrom patent. A biphasic waveform delivery circuit that utilizes MOS Controlled Thyristors (MCT) is disclosed. These devices are ideal for this application in that they can switch much higher currents than either IGFETs or MOSFETs. A biphasic waveform delivery circuit that utilizes eight IGFETs which can switch in excess of 800 V on both phases of the delivered waveform is disclosed; the type of high voltage switches and circuit disclosed by Winstrom limit the HV to substantially below this voltage. A biphasic waveform delivery circuit that utilizes six IGFETs is disclosed. This circuit limits the second phase voltage to a maximum of one-half the first phase voltage. A circuit technique which maintains magnetic field strength in the tranformers of the 8-IGFET and 6-IGFET delivery circuits approximately constant with respect to battery voltage is disclosed; this allows for more optimal magnetics design. To enhance patient safety, methods of reducing leakage currents to the patient utilizing a minimum number of components are disclosed. The use of snubber diodes to enhance the reliability of the biphasic waveform delivery circuits is disclosed. Methods of detecting defibrillation lead breakage without the necessity of delivering a high voltage shock to the patient are disclosed.
Other features and advantages of the present invention will be appreciated by reference to the detailed description of the invention provided below, which should be considered in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the general organization of an implantable combined defibrillator/pacemaker system.
FIG. 2 is a block diagram illustrating an embodiment of a combined defibrillator/pacemaker system in accordance with the present invention.
FIG. 3 is a block diagram illustrating an embodiment of pacemaker circuitry that can be utilized in the FIG. 2 system.
FIG. 4 is a schematic diagram illustrating an embodiment of pace pulse delivery circuitry that can be utilized in the FIG. 2 system.
FIG. 5 is a schematic diagram illustrating an embodiment of pace pulse delivery circuitry that can be utilized in a single channel configuration of the FIG. 2 system.
FIG. 6 is a schematic diagram illustrating an embodiment of level shifting circuitry that can be utilized in the pace pulse delivery circuitry shown in FIGS. 4 and 5.
FIG. 7 is a schematic diagram illustrating an embodiment of one of the channels of the ground switching circuitry of the FIG. 2 system.
FIG. 8 is a timing diagram illustrating switch drive and capacitive charging waveforms associated with a typical "A" channel pace cycle of the system shown in FIG. 2, including the interaction of a "V" channel pace cycle.
FIG. 9 is a schematic diagram illustrating a conceptual minimum configuration embodiment of HV delivery circuitry that can be utilized in the FIG. 2 system.
FIG. 10 is a schematic diagram illustrating a practical embodiment of the FIG. 9 HV delivery circuitry.
FIG. 11 is a schematic diagram illustrating a reduced component embodiment of the FIG. 10 HV delivery circuitry.
FIG. 12 is a schematic diagram illustrating an embodiment of the FIG. 9 delivery circuitry which utilizes MOS controlled thyristors as high voltage switches rather than IGFETS.
FIG. 13 is a timing diagram illustrating typical delivery waveforms associated with the FIGS. 9-11 HV delivery circuitry.
FIG. 14 is a timing diagram illustrating typical waveforms associated with the FIG. 12 delivery circuit.
FIG. 15 is a schematic diagram illustrating an embodiment of HV delivery oscillator circuitry that can be utilized in the FIG. 2 system.
FIGS. 16A and 16B are a simplified schematic diagram and timing diagram, respectively, illustrating the detection of defibrillation lead breakage in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 provides a block diagram showing the general organization of an implantable combined defibrillator/pacemaker system 1. The system 1 includes sensing, analysis and control circuitry 2, a voltage regulator circuit 3 and an 8-bit microprocessor 4. A static RAM 5 is used to store digitized EKG waveforms. External connections from pacemaker/defibrillator circuitry 6 to the heart 7 are provided by two high voltage electrodes DEFIB1 and DEFIB2 and pacing/sensing leads through which millivolt level EKG signals are sensed and which also carry pace pulses to the heart 7. Telemetry to and from an external programmer is carried via a coil-to-coil link 8. System software decides whether the EKG parameters indicate an arrythmia and, if so, the appropriate therapy is initiated. The raw EKG data can also be stored in memory 5 for later retrieval or be telemetered out of the system 1 in real time.
FIG. 2 shows a block diagram embodiment of defibrillator/pacemaker circuit 6 in accordance with the present invention with its full complement of cardiac leads. These leads comprise two high voltage defibrillation electrodes 10 and 12 and two sets 14 and 16 of pacing leads. The heart 18 is defibrillated by high voltage pulses which are delivered through leads DEFIB1 and DEFIB2 to electrodes 10 and 12, respectively.
The two sets 14,16 of pacing leads, each set comprising an active lead (14a,16a) and a ground return (14b,16b), are connected to pacemaker circuitry 20 and to ground switch circuitry 22, respectively, via high voltage protection MOSFETS Q1-Q4. The high voltage leads DEFIB1 and DEFIB2 are also connected to the ground switch circuitry 22 via protection MOSFETS Q5 and Q6, respectively. The function of MOSFETS Q1-Q6 will be described in greater detail below.
HV charge circuitry 24 charges a high voltage capacitor C HV or capacitor stack to a regulated voltage of up to 1 kV. More than one capacitor may be needed to stand off the required voltage; a second capacitor C' HV , illustrated in FIG. 1 in dotted lines, is representative of a capacitor stack. One of the embodiments of high voltage delivery circuit 26 discussed in greater detail below uses the center tap HV/2 of these two capacitors to allow for a reduced charging configuration.
HV delivery circuitry 26 is controlled by logic lines PW1 and PW2, as described below. HV delivery oscillator 28 provides timing signals OSC1 and OSC2 to HV delivery circuitry 26 in those embodiments that utilize IGFET delivery circuits; this is also discussed in greater detail below.
FIG. 3 shows an embodiment of the pacemaker circuitry 20. The pacemaker circuitry 20 includes two substantially identical pacing channels "A" and "V", each including a pace pulse delivery circuit (30,32), charge regulation circuit (34,36), controller circuit (38,40), and pace pulse generation and delivery capacitors C1, C2, C3.
"A" and "V" channel pacing pulses are produced in response to assertion of control lines PACE"A" or PACE"V", respectively, by the system microprocessor 4 and associated sensing, analysis and control circuitry 2.
Similarly, the control bus 42 allows the pacing voltage amplitude to be programmed via the "A"/"V" DAC's which form part of the charge regulation circuit (34 and 36). This control bus 42 also allows the pacing mode to be programmed, i.e. whether the voltage amplitude is to be doubled by connecting capacitors C1 and C2 in series during pace delivery, or whether the capacitors are to be discharged between pace deliveries, or whether the charge regulation circuitry (34 and 36) is to be ignored during capacitor charging to allow charging to the open circuit battery voltage and, hence, achieve the maximum output pulse amplitude possible.
In the described embodiment, the atrial or "A" channel charge regulation circuit 34 and controller circuit 38 can also be used to regulate the voltage to which the HV charge circuit 24 charges the capacitor stack for delivery of defibrillation pulses. Note in FIG. 3 the addition of a multiplexor 44 which muxes both the pacing capacitor voltage and the HVSENSE line to the regulation circuitry 34.
The voltage on the HVSENSE line tracks HV using a resistive divider to scale into the active range of the regulation circuitry 34.
Conventional bipolar pacing takes place between the pacing outputs (PACEOUT"A"/"V") delivered to the heart by the active leads (14a,16a) and the switched ground return leads (14b,16b) (tip to ring). Pseudo-unipolar pacing takes place between the active pacing leads (14a,16a) and one of the high voltage defibrillation electrodes (10,12). In either case, the loading effect of the cardiac impedance can be modelled as a resistor with a nominal value of 500 ohms.
FIG. 4 shows a configuration of n-channel and p-channel MOS switches which comprise the pace pulse delivery circuit 30,32 used in the "A" and "V" channels, respectively. The circuit blocks marked "LS" in FIG. 4 are level shifters which shift the gate drive voltages to the n-channel switches negatively to track the negative going pace pulse. This is necessary to keep the appropriate switches off during pace delivery.
Capacitors C1 and C2 in FIG. 4 are the capacitors shown in FIG. 3 as C1"A"/"V" and C2"A"/"V", respectively. These are discrete capacitors which have values in the 10-30 microfarad range.
As further shown in FIG. 4, the switches of the pace pulse delivery circuit (30,32) are controlled by lines B through J, CH1N and CH2N. In FIG. 3, these control lines are shown as a bus marked "A"/"V" SWITCH DRIVERS (46,48).
FIG. 5 shows an alternate pace pulse delivery circuit (30,32) which can be used only in the single channel case.
Referring to FIGS. 2 and 8, the output PACEOUT"A" and PACEOUT"V" of channels "A" and "V", respectively, of the pacemaker circuitry 20 is a negative going pulse the width of which is controlled by the corresponding control line PACE"A"/"V" and the amplitude of which is a function of the capacitor voltages (C1,C2 in FIG. 3) and the mode in which the capacitors are stacked to provide the output. The total resistive impedance of the pacemaker circuitry 20, ground switching circuitry 22 and HV protection circuitry (devices Q1-Q6) should be a small percentage of the cardiac load impedance which, as stated above, is in the 500 ohm range. Hence, assuming 5% losses, the total impedance of these circuits cannot exceed 25 ohms.
Capacitors C3 "A"/"V" are not strictly necessary for circuit operation, but are included to fulfill a regulatory obligation that there not be a DC current path between the pacing electronics and the patient. Capacitor C3, however, also reduces the source capacitance of the pace pulses.
Referring to the pace pulse delivery circuitry (30, 32) shown in FIGS. 4 and 5, in each embodiment, the pace pulse delivery function is carried out by n-channel transistors M1 through M6. Switches M2 through M6 are designed to be very low impedance, since they either deliver the output pulse or carry charging current. A typical impedance value for these devices is 5 ohms.
Consider the case where capacitors C1 and C2 are initially charged to a voltage +V1, the top plates being at this positive potential and the bottom plates being connected to ground through switches M3 and M5, respectively. In this case, switches M1, M2, M4,and M6 are off and switches M3 and M5 are on. At this point, the output node "A"/"V"OUT is isolated. This is illustrated in FIG. 8 as a noisy trace on PACEOUT"A"/"V".
To generate a pace pulse, first switches M3 and M5 are switched off. If an output voltage equal to -2V1 is required, then switches M2, M4 and M6 are turned on simultaneously. The positive plate of capacitor C2 is thus connected to ground, thereby pumping its bottom plate to -V1. The bottom plate of capacitor C2 is connected via switch M4 to the positive plate of capacitor C1, thereby pumping the bottom plate of capacitor C1 to -2V1. This voltage is connected to the output node via switch M2. Note the configuration of the bulk connections of switches M1 through M6 to allow for operation below the negative power supply rail. It will be clear to those skilled in the art that this type of bulk connection implies the use of a P-well or twin tub CMOS process if integration of these devices is required.
The bulk connection of transistor M2 of FIGS. 4 and 5 should be inspected closely. In the dual channel case, i.e. the FIG. 4 embodiment, the bulk of transistor M2 and the "SENSE" inputs to the appropriate level shifter LS are connected to the output node "A"/"V"OUT. This results in a negative voltage appearing on the output node, i.e a pace pulse from the other pacing channel is blocked by transistor M2. In the single channel only case, i.e. the FIG. 5 embodiment, the bulk of transistor M2 is connected towards the negative plate of capacitor C1. Thus, a negative voltage on the output node is not blocked by transistor M2 and, hence, this circuit cannot be used in a dual channel pace pulse generator.
The advantage of the FIG. 5 single channel only configuration is the manner in which transistor M2 is biased during a pace pulse delivery. In this configuration, the bulk of transistor M2 is always guaranteed to be more negative than the output node, i.e. the drain of transistor M2. Hence, the intrinsic drain p-n junction is always reverse biased. Thus, to a first order, there is no limit to the current that may be delivered through transistor M2. Hence, delivering a pulse into a short circuit presents no difficulty.
In the dual channel case shown in FIG. 4, the drain of transistor M2, i.e. the end connected to capacitor C1, swings more negative than the bulk by a voltage equal to the product of the delivered current and the switch impedance. Hence, there is a possibility of forward biasing the drain p-n junction during pace pulse delivery. In general, because transistor M2 is on during pace pulse delivery, a forward biased drain diode should have no effect. However, at very high current levels, this configuration should be used with care due to the possibility of forward biasing the p-n junction.
As the source and, thereby, bulk connections of transistors M1 through M6 swing negatively, it is clear that to preserve the "off" condition of devices M1, M3 and M5, the gate drive of each of these devices must track its source voltage; hence, the use of level shifters LS.
An embodiment of the type of level shifter used in the FIG. 4 and 5 circuits is shown in FIG. 6. It will be clear to those skilled in the art that a logic low on the "IN" terminal will be translated to a logic low on the "OUT" terminal; the level of the output "low" tracks the voltage on the "SENSE" terminal.
As has been discussed above, in the dual channel pace delivery case (FIG. 4), a level shifter LS for transistor M2 is necessary to keep transistor M2 off when a pace pulse is generated in the other pacing channel. In the single channel case (FIG. 5), the level shifter LS associated with transistor M2 is not strictly necessary, but does help to isolate the output node "A"/"V"OUT when capacitor C1 is discharged.
FIG. 8 provides a timing diagram illustrating the switch phasing outlined above. Note the "A" pace pulse generation section. All switching is shown to be "break before make" to prevent a loss of capacitor charge due to switching transients. The broken lines associated with control lines CH2N, B and H illustrate the differences in switching if single capacitor pace pulse generation is required. In this case, only capacitor C1 is involved and the output pulse amplitude is -V1.
The voltage across capacitors C1 and C2 is labelled dVC1"A" and dVC2"A" in FIG. 8. The initial voltage on both capacitors is V1. During a pace pulse delivery, this voltage decays to a final value of V2. If it is assumed that the cardiac loading is purely resistive, then this decay will be exponential and easily calculated by considering the source capacitance of capacitors C1, C2 and C3 in series, the pace pulse width and the resistive loading.
This also allows for a measurement of the impedance of the high voltage defibrillating leads. Pseudo-unipolar pacing can take place using the high voltage leads DEFIB1/DEFIB2 as the ground return. The total lead impedance can then be estimated by measuring the initial and final values of voltage on the pacing capacitors. This is illustrated in FIGS. 16A and 16B which show pseudo-unipolar pacing with respect to one of the HV leads DEFIB1/DEFIB2. The size of the difference between the initial and final pace pulse voltages, shown as dVp, is indicative of the resistive loading on the pacing capacitors. This difference can either be measured by an on-board analog-to-digital converter or through a surface electrogram as disclosed in U.S. Pat. No. 4,337,776, which is hereby incorporated by reference.
In the particular embodiment disclosed herein, the "A"/"V" controller circuit (38, 40) can configure the pace pulse delivery switches such that capacitors C1 and C2 can be discharged after a pace pulse delivery. This allows for a clean transition to a lower pace delivery voltage between successive pulses. This action is illustrated in FIG. 8.
Referring back to FIGS. 4 and 5, the capacitor charging and sensing circuitry comprises p-channel transistors M12 and M13 and two CMOS transmission gates M11/M8 and M9/M10. Operation is as follows: In the two capacitor mode, i.e. when both capacitors C1 and C2 are to be charged, both transmission gates M11/M8 and M9/M10 are on at all times except during a pace pulse delivery. Therefore, the positive plates of capacitors C1 and C2 are tied together. As shown in FIG. 4, the center point of the transmission gates M11/M8, M9/M10 is used as the sense node Csense for the charge regulation circuit (34, 36). Based on a comparison of the DAC voltage and the sensed voltage Csense, the charge regulation circuit (34, 36) signals the controller circuit (38, 40) whether charging is appropriate or not. Assuming charging is required, the controller (38, 40) initiates capacitor charging by putting a logic low on lines CH1N and CH2N. In this embodiment, this occurs after a pace delivery and a possible discharge cycle are completed. The capacitors C1 and C2 are charged until the charge regulation circuit (34, 36) indicates, by changing state, that the programmed voltage has been reached. Lines CH1N and CH2N then return high, terminating charging. It is notable that any mismatch in the charging rates of capacitors C1 and C2 is compensated by the fact that they are resistively tied together through the sensing transmission gates M11/M8 and M9/M10. The impedance of these gates should be relatively low; in the described embodiment, the design value is in the 50 ohm range.
The FIG. 8 waveforms illustrate the above charging sequence. As has been noted above, single capacitor operation is illustrated by the broken lines on the switch phasing.
As stated above, it is useful to have the ability to pace at relatively high rates (50 per sec) so as to induce ventricular fibrillation. As can be seen from FIGS. 4 and 5, the maximum rate at which the pacing capacitors C1 and C2 can be recharged is effectively determined by the impedance of devices M12 and M13. Thus, with suitable device sizing, high rate pacing is possible. It should further be noted that, in implantable defibrillators, the battery internal impedance must be very low (in the 1 ohm range); therefore, it will not significantly limit the charging rates of the pacing capacitors C1 and C2.
As stated above, the coupling capacitor C3 is charged somewhat during each pace pulse delivery cycle. Transistor M1 is configured to discharge the negative plate of capacitor C3 after each pulse. The impedance of switch M1 is substantially higher than that of switches M2 through M6. A typical value is 100 ohms.
FIG. 8 shows the action of switch M1 on the output node of the pace pulse delivery circuit (30, 32). The length of time that switch M1 is on is designed so that capacitor C3 is fully discharged. As illustrated, a PACE"V" pulse occurs before switch M1 turns off. The controller circuit logic (38, 40) is designed to inhibit switch M1 when the other pace delivery channel is active. Otherwise, the other channel's pulse (PACEOUT"V" in FIG. 8) would be loaded by switch M1.
FIG. 7 shows one channel of the ground switching circuit 22 which, depending upon the configuration of circuit 22, allows each pace channel to deliver pulses in a bipolar or pseudo-unipolar fashion. Transistor M22, which is a low impedance device, connects the output node "b" to ground or allows it to float when node "a" is high or low, respectively. The ground switching circuit 22 thus allows each of the pacing ground return lines (14b, 16b) or high voltage terminals (10, 12) to be shorted to ground or to float. Transistor M22 is configured to accommodate negative voltages on its source/bulk node and the level shifter LS is arranged such that device M22 can remain off when this node swings negative.
Referring back to FIG. 2, high voltage protection of the pace pulse output and ground switch circuits 22 is accomplished by high voltage MOSFETS Q1-Q6. The gates of these devices are driven by a PROTECTN control signal. The PROTECTN signal is normally high, ensuring that devices Q1-Q6 are on. The impedance of devices Q1-Q6 with a nominal 5 V gate drive should be in the 5 ohm range to ensure that it does not dominate the pace pulse source impedance. When high voltage protection is required, the PROTECTN control signal is switched low thus isolating the pacemaker circuitry 20 and ground switch circuitry 22 from the high voltage pulse which appears across the PACEOUT"A"/"V", ground return and HV delivery terminals. Note that the bulk connection of devices Q1-Q6 allows for protection from a positive going high voltage pulse only.
FIG. 9 shows a minimum configuration version of HV delivery circuitry 26. The FIG. 9 circuit basically consists of four high voltage, high current switches, shown as IGFETS IG1-IG4, configured in an "H" pattern with appropriate drive circuitry (50, 52, 54, 56, respectively) such that defibrillator output terminals DEFIB1 and DEFIB2 can be connected either to the high voltage source HV or to ground. Diode resistor pairs R1,D3 and R2,D4 protect the patient from current leakage through switches IG1 and IG3, respectively. Similarly, diodes D5 and D6 protect the patient from leakage through switches IG2 and IG4, respectively. Diodes D1 and D2 protect the circuitry from the effects of driving inductive loads.
Transformers TR1 and TR2 couple power from their respective primary windings to the floating gate drive circuits 50, 52 and the ground switch drive circuits 54, 56. Each ground switch drive circuit 54, 56 also has a corresponding switch SG1, SG2, respectively, associated with it which grounds the gate of the corresponding IGFET IG2, IG4, respectively, during alternate phase delivery to protect against inappropriate turn on due to Miller effect coupling of the drain voltage to the gate.
FIG. 10 shows a practical implementation of the HV delivery circuit of FIG. 9 where more than one high voltage switch (IGFET) is required in series to stand-off the high voltage HV. In the FIG. 10 embodiment, two floating gate switch drive circuits 58,60 and 62,64 are required to drive switches IG5,IG6 and IG7,IG8, respectively. On the ground switch side, IGFETS IG9 and IG11 are driven by slightly different floating gate drive stages 66 and 68, respectively, which include a passive scheme for protection against Miller capacitance coupled gate spikes.
FIG. 11 shows a reduced component version of the FIG. 10 embodiment which allows for biphasic waveform generation, but limits the second phase to a maximum of half the capacitor stack voltage, i.e. HV/2.
FIG. 12 shows an embodiment of the HV delivery circuit 26 which utilizes MOS controlled thyristors (MCT) as the high voltage switches rather than the IGFETS shown in the FIG. 9 embodiment. A MCT is a type of silicon controlled rectifier (SCR) which can be turned on and off by applying pulses to a single gate input; a conventional SCR can only be turned off by shunting current across it. Also, a MCT can carry higher current than an IGFET. See Goodenough, "MOS-Controlled Thyristor Turns Off 1MW in 2 uS", Electronic Design, Nov. 10, 1988, pp. 57-60.
In the MCT-based biphasic delivery circuit shown in FIG. 12, The primary coils of transformers TR1 and TR2 are snubbed by resistor/capacitor combinations RP1/CP1, RP2/CP2 and RP3/CP3, RP4/CP4, respectively, to prevent ringing. The secondary driver coils are snubbed by corresponding resistor/capacitor combinations RS1/CS1, RS2/CS2, RS3/CS3 and RS4/CS4, also to prevent ringing. With the use of MCT devices as shown, Miller effect protection becomes unnecessary.
Referring back to FIG. 9, delivery of the first phase of a biphasic high voltage pulse to the patient entails switching IGFETS IG1 and IG2 "on" with IGFETS IG3 and IG4 "off". This connects the DEFIB1 and DEFIB2 terminals to HV and ground, respectively. During the pulse delivery, the high voltage capacitor(s) are discharged somewhat. Reversing the order of the IGFETs (i.e IG1,IG2 off; IG3,IG4 on) delivers a pulse of opposite polarity to the patient. The size of this pulse is determined by the residual charge on the capacitor(s).
The energy to switch the IGFETs on is magnetically coupled through transformers TR1 and TR2. Switches IG1 and IG3 require floating gate drives (50, 52) since their source terminals track the high voltage pulse. As stated above, switches IG2 and IG4 are driven by ground switch drive circuits (54, 56). The configuration of these drive circuits will be discussed in greater detail below.
A number of significant features with regard to patient leakage and inductive ringing protection should be noted. First, as stated above, resistor/diode pairs R1,D3 and R2,D4 provide protection against leakage from HV through switches IG1 and IG3, respectively. Small leakage currents I1 are shunted to ground through resistor R1 or R2. As long as the product of I1 and R1 or R2 is less than the Vbe(on) of diodes D3 or D4, the patient will see negligible current from the HV source. Second, diodes D5 and D6 isolate the patient from leakage due to switches IG2 or IG4 during pacing. Third, diodes D1 and D2 act as snubber diodes to protect against inductive ringing below ground on the DEFIB1 and DEFIB2 terminals. Fourth, switches SG1 and SG2 (shown for generality as relays) ensure that IG2 and IG4 cannot turn on inappropriately during HV delivery. Failure to provide this protection could allow the HV pulse to be Miller capacitor coupled from drain to gate such that the device would switch on. This would short the HV to ground through essentially no load, destroying the device.
As stated above, FIG. 10 shows a practical embodiment of the circuit concept illustrated in FIG. 9. In this case, the HV to be switched is assumed to be in excess of the voltage that the IGFETs can stand off. This is quite realistic since presently available IGFETS or MOSFETS tend to be limited to 600 V at reasonable current levels (typical defibrillation voltages range up to 800 V). Hence, eight devices are required. Referring to FIGS. 10 and 12, the primary side of MOSFET M140 is driven by OSC1, a square wave. During OSC1 high time, current is built up in the primary coil of transformer TR1. When OSC1 switches low, the drain of device M140 flies back, coupling energy through the magnetics to the secondary coils. Current is supplied through diodes D101, D111, D121, D131 to the gates of devices IG5, IG6, IG9, IG10, respectively, turning them on and delivering the first half of the biphasic pulse. On each cycle of OSC1, energy is coupled across to counteract the effect of the passive pull down resistors R10 through R13. Zener diodes D10 through D13 protect the IGFET gates from overvoltage. Capacitors C10 through C13 reduce the voltage ripple seen at the IGFET gates.
At the termination of the PW1 pulse, OSC1 returns low and passive pull downs R10-R13 switch off the IGFETs. This terminates the first phase of the biphasic waveform.
Generation of the second phase of the biphasic waveform is achieved by simply activating the second transformer via OSC2. During this time, it should be noted, device MI30 is on, thus grounding the gate of switch IG10 and ensuring that it remains off regardless of Miller capacitance coupling of the HV pulse from gate to drain. The floating gate drive of switch IG9 is protected by the arrangement of circuit elements Q12, R121, C121, D122. It will be clear to those skilled in the art that this arrangement is equivalent to a capacitor of value C121 * Beta of Q12 connected in parallel with C12. This capacitance is only apparent transiently when device Q12 is turned on by positive going (Miller capacitance) spikes on its emitter. Hence, the turn on time of switch IG9 is unaffected.
As stated above, FIG. 11 shows a circuit configuration which requires fewer components than the circuit illustrated in FIG. 10. In this case, switches IG7 and IG10 only have to stand off HV/2 which is taken from the centertap of the high voltage capacitor stack, as shown in FIG. 2. This means that the second phase of the high voltage pulse can only reach a maximum value of HV/2, assuming no load. Otherwise operation of this circuit is identical to that shown in FIG. 10 Note that the pull down devices M130 and M140 can be replaced by bipolar devices Q130 and Q140 as shown.
One of the problems associated with the IGFET-based HV delivery circuits discussed earlier is that, as the battery voltage Vbatt drops under load, or through life, the maximum energy per cycle which can be coupled to the transformer secondaries drops in proportion to Vbatt squared. In fact, the power developed in the primary is given by
P=(Vbatt).sup.2 *T/2L
where: T is the periodic time of the of the cycle (assuming square wave) and L is the inductance of the primary.
Hence, the transformer has to be substantially overdesigned so as to be able to couple sufficient energy to the secondaries at all battery voltages.
The type of oscillator circuit shown in FIG. 15 helps to alleviate this problem somewhat.
FIG. 15 shows an embodiment of a HV delivery oscillator circuit which is used to generate a 50% duty cycle output which has a periodic time which varies approximately linearly with battery voltage. This relationship is exploited to keep the peak magnetic fields in the HV delivery circuit transformers approximately constant with battery voltage. This allows for a greatly optimized transformer design.
It can be shown that for this oscillator that its periodic time T has the following relationship to battery voltage:
T=K/(Vbatt-Vtp)
where Vtp is the threshold voltage of the p-channel transistors in FIG. 15.
Substituting this value into the equation for P provided above gives
P=Kl*(Vbatt).sup.2 / Vbatt-Vtp
Assuming Vbatt much greater than Vtp, then
P=Kl*Vbatt
Hence, the power level would drop only linearly with battery voltage. Furthermore the maximum current present in the primary can be shown to be:
Imax=K2/(L*(1-Vtp/Vbatt))
Hence, when Vbatt is significantly larger than Vtp, the maximum current, and thus the maximum magnetic field, will increase slowly with battery voltage. This permits a much more optimized transformer (size) than would otherwise be possible.
It is intended that the term "biphasic" as used in this document cover the case where the pulsewidth of the second defibrillation phase is zero, i.e. when the high voltage delivery is essentially monophasic.
It should also be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that structures and methods within the scope of these claims and their equivalents be covered thereby. | The present invention is directed to various features of an implantable combined defibrillation/pacemaker system. The system's defibrillation delivery circuit provides for delivery of a multi-phase defibrillation waveform. It also includes features for insuring low patient current leakage. Protection circuitry is provided for protecting the pacing circuitry from damage by the high voltage defibrillation output. The dual channel cardiac pacing circuit accommodates bipolar and pseudo-unipolar pacing. The system includes the ability to detect defibrillator lead breaks without delivering a defibrillation pulse to the patient. An additional advantage of the disclosed system is its ability to use the pacing output stage for extremely high rate pacing to induce ventricular fibrillation. | 0 |
FIELD OF THE INVENTION
This invention relates generally to improved semiconductor solar cells and their fabrication and more particularly to an all-polycrystalline compound semiconductor solar cell which may be fabricated at a relatively low cost.
BACKGROUND
Solar cells fabricated with various III-V compound semiconductors, such as galium arsenide (GaAs) and indium phosphide (InP), are generally well known in the solar cell art and have been fabricated with layers of both monocrystalline P-type and monocrystalline N-type materials to define the PN junction of the cell. Alternatively, these cells have been constructed using a combination of polycrystalline and monocrystalline semiconductor layers to form a PN heterojunction therebetween.
Examples of an all monocrystalline type of compound semiconductor solar cell are disclosed in Applied Physics Letters, Vol. 26, p. 457-467 (1975). An example of a combination monocrystalline-polycrystalline solar cell with a PN heterojunction is disclosed, for example, by S. Wagner et al in Applied Physics Letters No. 26, page 229 (1975).
While the above generally described cells represent some improvements relative to certain prior art solar cell fabrication techniques, their requirement for at least one monocrystalline semiconductor layer clearly limits the fabrication cost reduction of the cells as a result of the well-known refined process requirements for growing monocrystalline semiconductor materials. Therefore, because of the widespread interest in reducing the cost of solar cell fabrication while maintaining an acceptable conversion efficiency for same, the desirability to provide a commercially feasible all polycrystalline solar cell is manifest.
THE INVENTION
The general purpose of this invention is to provide an all-polycrystalline solar cell which exhibits an acceptable conversion efficiency and overall operational performance while at the same time being adaptable to relatively low cost fabrication at high yields. To accomplish this purpose, we have discovered and therefore developed a polycrystalline solar cell structure including a PN junction therein for generating power and defined by a first layer of one polycrystalline semiconductive material of a first conductivity type adjacent a second layer of another polycrystalline semiconductive material of a second conductivity type. The second layer has a thickness which is greater than the optical absorption length, Λ, therein by a predetermined amount, and the first and second layers have grain boundaries of approximately the same dimensions and locations. These dimensions are greater than Λ by an amount sufficient to permit substantial numbers of photon-generated carriers in the second layer to cross the PN junction of the device without reaching the grain boundaries therein. Therefore, this structure enables relatively low cost polycrystalline deposition techniques to be used in the fabrication of both the first and second semiconducting layers of the device and thus minimizes overall fabrication cost for our solar cell.
Accordingly, it is an object of the present invention to provide a new and improved solar cell which may be constructed of different polycrystalline semiconductive materials.
Another object is to provide an all polycrystalline solar cell of the type described which may be fabricated using existing polycrystalline deposition techniques for forming P and N-type semiconductor layers of the cell.
Another object is to provide a polycrystalline solar cell of the type described which may be fabricated at relatively low costs when compared to prior art solar cells requiring one or more monocrystalline semiconductor layers.
A feature of this invention is the provision of a solar cell having polycrystalline P and N-type layers with grain boundaries of similar dimensions and spacings, and which dimensions exceed the optical absorption length, Λ, in one of the layers by an amount sufficient to enable substantial numbers of photon-generated carriers in one of the layers to cross the PN junction of the structure without reaching the grain boundaries therein.
These and other objects and features of the invention will become more readily apparent in the following description of the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a-1e represent schematically one sequence of processing steps which may be utilized in constructing a polycrystalline solar cell according to our invention.
FIG. 2 is a perspective view of our completed solar cell and illustrating the large crystallites and grain boundaries therein. The right hand end of FIG. 2 corresponds to FIG. 1e.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1a, there is shown a substrate 10 of amorphous transparent glass, which is the starting material for our process. The glass substrate 10 may be a commercially available glass capable of withstanding temperatures of at least 500° C. and preferably a type of glass upon which a thin coating 12 of indium-tin-oxide (ITO) may be evaporated or sputtered. The ITO layer 12 may be deposited as shown in FIG. 1b with good adherance and bonding using standard state-of-the-art ITO deposition techniques such as those described by Thornton et al, Journal of Vacuum Science Technology, Vol. 13, No. 1 Jan./Feb. 1976 at pages 117-121.
The indium-tin-oxide layer 12 in FIG. 1b is deposited on the amorphous transparent glass substrate 10 in order to provide an anti-reflective coating for the solar radiation received at the opposite substrate surface 13. This ITO layer 12 also provides a good strong mechanical bond between the glass substrate 10 and a subsequently deposited polycrystalline layer 14 of cadmium sulfide (CdS) as indicated in FIG. 1c. Briefly, the CdS polycrystalline film 14 is evaporated in a recrystallization process wherein the CdS is subsequently heat treated in a gaseous mixture of H 2 and H 2 S at approximately 500° C. for about 30 minutes. This heat treatment induces a change in the crystal structure of the CdS film 14 and in fact increases the size (lateral dimension) of the crystallites in the CdS film from approximately 1 micrometer to approximately 20 micrometers, for a 12 micrometer thick CdS film. The indium-tin-oxide (ITO) layer 12 between the N-type cadmium sulfide layer 14 and the glass substrate 10 also serves as a conducting contact for the cadmium sulfide layer 14. The CdS layer 14 provides a good lattice match to a subsequently deposited indium phosphide (InP) layer 16 to thereby reduce surface states and excessive minority carrier recombination in the P-type InP layer 16. This InP layer 16 is subsequently evaporated in polycrystalline form as shown in FIG. 1d on the upper surface of the cadmium sulfide layer 14, and in a manner to be further described.
Prior to the InP layer 16 deposition and after the cadmium sulfide layer 14 has been evaporated on the indium-tin-oxide layer 12, as shown in FIG. 1c, the CdS layer 14 is recrystallized to form a quasi-single-crystal N-type material characterized by large crystallites with grain boundaries spaced on the order of 20 micrometers or greater. This dimension is identified as T3 in FIG. 2 and is discussed further below with reference to FIG. 2. Thus, the terms "polycrystalline" and "quasi-single-crystal" are used synonymously herein, and the term "quasi-single-crystal" simply refers to a polycrystalline semiconductor material having large crystallites defined by very large grain boundaries. These grain boundaries are spaced by a dimension (T3) which is typically on the order of about 20 micrometers or greater, but which necessarily must be much greater than Λ, ie., T3>> Λ. One useful process for forming such a quasi-single-crystal layer 14 of N-type cadmium sulfide is disclosed, for example, in a copending application by Lewis M. Frass et al, Ser. No. 563,890, filed Mar. 31, 1975 and assigned to the present assignee. Such application is, of course, fully incorporated herein by reference.
After the recrystallization of the N-type cadmium sulfide layer 14 in FIG. 1c has been completed by suitable annealing, the structure of FIG. 1c is transferred to an indium phosphide deposition station where a thin layer 16 of P-type indium phosphide is deposited as shown in FIG. 1d to form a PN junction 18 located between the P and N-type layers 14 and 16. The P-type indium phosphide layer 16 is also quasi-single-crystal in form and has a crystallographic structure with large crystallite grain boundaries having lateral dimensions which closely match those of the previously formed cadmium sulfide layer 14. The thickness of the P-type InP layer 16 is typically on the order of about 1 micrometer, but may be deposited, economically as thick as 4 micrometers. The layer 16 is deposited at approximately 375 degrees centigrade and under a pressure of 10 -4 Torr using, for example, the phosphine gas (PH 3 ) deposition technique disclosed in a copending application Ser. No. 631,981, filed Nov. 14, 1975 and assigned to the present assignee. Briefly, the planar reactive deposition (PRD) process of Serial No. 631,981 involves evaporating indium metal from a planar source including a cavity integral therewith into which phosphine gas, PH 3 , is introduced and decomposed. The decomposition reaction products, P 2 and H 2 , are emitted from within the source cavity and through a perforated top plate thereof, and the combined In - P - H vapor stream from the source forms the InP film 16 upon arrival at the CdS layer 14. Using this PRD process of Ser. No. 631,981, the lateral grain boundaries of the first or CdS layer 14 can be replicated in the much thinner InP layer 16. This replication results from the tendency of epitaxial growth to occur at the exposed upper surfaces of the large CdS crystallites in the previously deposited CdS layer 14.
After the indium phosphide layer 16 has been deposited using for example the procedures set forth in the above copending application Ser. No. 631,981, an upper ohmic contact member 20 is evaporated thereon using suitable metal evaporation techniques. Advantageously, either a zinc-gold layer or a copper layer may be utilized to form a good upper ohmic contact 20 for the P-type layer 16. This ohmic contact 20 may only cover a selected portion of the upper surface of the P-type layer 16, as indicated in FIG. 2; and FIG. 1e is the cross-section view shown in the right hand end of the perspective view of FIG. 2.
Referring now to FIG. 2, the quasi-single-crystal layer 14 of cadmium sulfide has a thickness T1 which is typically on the order of five to twenty times the optical absorption length Λ in the indium phosphide layer 16. Λ is defined as the average distance that light will travel after entering a semiconductor body before being absorbed to thereby create carriers of opposite charge. The thickness T2 of the indium phosphide layer 16 is typically one to four times Λ, and the value of Λ in the indium phosphide layer 16 is between 0.5 and 1.0 micrometers. Therefore, the carriers generated in the indium phosphide layer 16 by incident photon radiation will have to travel, on the average, from between 0.5 and 1.0 micrometers before crossing the PN junction 18. Therefore, a very substantial number of photon-generated carriers in the P-type indium phosphide layer 16 will cross the PN junction 18 and generate power without reaching a grain boundary of one of the large crystallites which form the P and N-type layers 14 and 16. As mentioned previously, these boundaries are spaced apart by a dimension T3, which will average approximately 40 micrometers or greater. Therefore, this carrier propagation across the PN junction 18 and wholly within the multiple single crystal regions or crystallites 22, 24, 26 and 28 has the effect of generating the voltage and current at conducting contacts 12 and 20 which are responsible for producing solar cell output power.
Obviously, some of the photon-generated carriers produced in these individual large crystallites 22, 24, 26, and 28 will be propagated into the grain boundaries 30, 32, and 34, respectively, and thus be channeled therethrough without generating any power in the solar cell structure. But a very large majority of these photon induced carriers will indeed cross the PN junction 18 of the structure either before or without reaching these grain boundaries 30, 32, and 34. It is this physical phenomenon which is responsible for the production of substantial amounts of output power from the solar cell structure.
Thus, for an optical absorption length Λ of about 0.5 micrometers in the indium phosphide layer 16, and with thickness dimensions T1 and T3 of more than twenty times Λ, or 20 micrometers, it is seen that the photon-induced carriers generated in the indium phosphide layer 16 would, on the average, have to travel no more than about 0.5 micrometers from within the layer 16 to cross the PN junction 18. But these carriers may have to travel as much as 40 times that far from the central portion of the crystallites 22, 24, 26 and 28 in order to reach the nearest grain boundary 30, 32, or 34 as shown in FIG. 2. | The specification describes a compound semiconductor solar cell and fabrication process therefor wherein both the P and N-type layers of the cell are polycrystalline semiconducting material and have large crystallites with grain boundaries of similar dimensions and spacings. These grain boundaries are spaced apart by a distance substantially greater than the optical absorption length, Λ, in one of the layers and by an amount sufficient to permit substantial numbers of photon-generated carriers in that one layer to cross the PN junction between the layers. Thus, substantial power is generated without the requirement for using expensive monocrystalline semiconductive materials. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to the field of pressure regulators, and, more particularly, to an improved pressure regulator which automatically prevents further flow of fluid therethrough if a sensed back pressure exceeds a predetermined pressure by a sufficient amount.
2. Description of the Prior Art
Pressure regulators are commonly used to step-down a relatively-high supply pressure to a lower regulated pressure, which, in turn, is subsequently supplied to an appliance. For example, such pressure regulators are typically used in the supply of liquified petroleum gas (LPG) or propane to gas grills and the like.
Others have recognized the desirability of disabling a regulator, so as to terminate further flow therethrough, in the event that the regulated back pressure substantially exceeds a desired value. Examples of such prior art regulators incorporating such a safety shut-off feature may be shown in one or more of the following U.S. Pat. Nos.: 2,698,026 (Roberts et al.); 4,295,489 (Arends et al.); and 2,969,802 (Rich).
SUMMARY OF THE INVENTION
With parenthetical reference to the corresponding structure or surfaces of the disclosed embodiment for exemplary purposes only, the present invention provides an improved pressure regulator (e.g., 10) which broadly includes: a body (e.g., 11) having a first end (e.g., 35), a second end (e.g., 36), an opening therethrough communicating these body ends, and having a portion extending into the opening to form an abutment surface (e.g., 50) facing toword the body first end, the body first end being exposed to fluid at a relatively-high supply pressure and the body second end being exposed to such fluid at a relatively-low pressure-to-be-regulated; an element (e.g., 12) arranged in the body opening and having a first end (e.g., 61), a second end (e.g., 62), and having a through-bore communicating these ends, the element being mounted for sealed sliding movement along the body opening toword and away from the abutment surface; a regulating poppet (e.g., 13) mounted for movement toword and away from the element second end for controlling the flow of fluid through the bore; an actuator (e.g., 14) arranged to sense the magnitude of the pressure-to-be-regulated and selectively operable to permit the regulating poppet to move away from the element second end when such sensed pressure is less than a predetermined pressure, to cause the regulating poppet to close the element bore when such sensed pressure is substantially equal to the predetermined pressure, and to exert on the element second end a force substantially proportional to the magnitude of the sensed pressure above the predetermined pressure which urges the element to move away from the abutment surface; and a seat (e.g., 128) arranged within the body opening and operative to sealingly close the element first end when the element has moved sufficiently away from the abutment surface to engage the seat, and to thereafter maintain such closed condition until manually reset.
Accordingly, the general object of the invention is to provide an improved pressure regulator.
Another object is to provide an improved pressure regulator having a high back pressure shut-off feature.
Another object is to provide an improved pressure regulator which requires a manual reset operation, as by disconnecting and reconnecting the regulator from the source of supply pressure, in the event of an excessively-high back pressure condition.
Still another object is to provide an improved pressure regulator which is particularly suited for use with domestic appliances, such as gas grills and the like.
These and other objects and advantages will become apparent from the foregoing and ongoing specification, the drawings, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is a longitudinal vertical sectional view of the improved pressure regulator.
FIG. 2 is a fragmentary transverse vertical sectional view thereof, taken generally on line 2--2 of FIG. 1.
FIG. 3 is an enlarged longitudinal vertical sectional view of the high pressure poppet.
FIG. 4 is an enlarged longitudinal vertical sectional view of the element.
FIG. 5 is an enlarged longitudinal vertical sectional view of the regulating poppet.
FIG. 6 is a fragmentary view similar to FIG. 1, and showing the regulating poppet as being in its normal flow-preventing closed condition.
FIG. 7 is a fragmentary view similar to the view of FIG. 6, but showing the regulating poppet as having been moved away from the element to a flow-permitting open condition.
FIG. 8 is a fragmentary view similar to the view of FIG. 6, but showing the actuator as having displaced the regulating poppet and the element leftwardly relative to the body to engage the high pressure poppet.
FIG. 9 is a fragmentary view similar to the view of FIG. 8, but showing the regulating poppet, the element, and the high pressure poppet, as having moved rightwardly relative to the body from the position shown in FIG. 8.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
At the outset, it should be clearly understood that like reference numerals are intended to identify the same portions or structure consistently throughout the several drawing figures, as such portions or structure may be further described or explained by the entire written specification of which this detailed description is an integral part.
Referring now to the drawings, and, more particularly, to FIG. 1 thereof, this invention provides an improved pressure regulator of which the presently-preferred embodiment is generally indicated at 10. The improved regulator is depicted as broadly including a multi-part body 11, an element 12 within the body, a regulating poppet 13, an actuator 14, and a high pressure poppet 15 provided with a seat 16.
Body 11 is shown as including a left part 18, a right part 19, and a mounting collar 20 sandwiched therebetween.
The body left part 18 includes an annular vertical left end face 21; an annular vertical right end face 22; an outer surface including a cylindrical surface 23 extending rightwardly from left end face 21, a leftwardly-facing annular vertical surface 24, a cylindrical surface 25, a rightwardly-facing annular vertical surface 26, and a cylindrical surface continuing rightwardly therefrom to join right end face 22; and an internal through-opening bounded by a cylindrical surface 28 extending rightwardly from left end face 21, a leftwardly-facing annular vertical surface 29, a cylindrical surface 30, a rightwardly-facing frusto-conical surface 31, a cylindrical surface 32 continuing rightwardly therefrom, and an internally-threaded portion 33 continuing to join right end face 22. A disc-like filter 34 is positioned in the leftward open end of the body left part to screen and separate contaminants from fluid passing therethrough.
The body right part 19 is a specially-configured member having annular vertical left and right end faces 35, 36, respectively; an outer surface including an externally-threaded portion 38, a cylindrical surface 39, a leftwardly-facing annular vertical surface 40 arranged to abut body left part right end face 22, a cylindrical surface 41, a rightwardly-facing annular vertical surface 42, a cylindrical surface 43, a rightwardly-facing annular vertical surface 44, an externally-threaded surface 45 continuing rightwardly therefrom, a rightwardly-facing annular vertical surface 46, and a cylindrical surface 48 joining right end face 36; and a stepped through-opening bounded by cylindrical surface 49 extending rightwardly from left end face 35, a leftwardly-facing annular vertical abutment surface 50, a cylindrical surface 51, a leftwardly-facing annular vertical surface 52, a cylindrical surface 53, a rightwardly-facing annular vertical surface 54, a cylindrical surface 55, and a rightwardly-divergent frusto-conical surface 56 joining right end face 36.
The body mounting collar 20 is a somewhat cup-shaped member having an in-turned annular vertical flange 58, the marginal end portion of which is captured between left part surface 26 and right part surface 40, and has an internally-threaded cylindrical portion 59 extending leftwardly therefrom. This mounting collar is provided to facilitate attachment of the regulator to a suitable source (not shown) of fluid at a relatively-high supply pressure. An example of such source might be a container or "bottle" of liquified petroleum gas (LPG), propane, or the like.
The collective body is formed by assembling the body left and right parts 18, 19, and the mounting collar 20, together as shown. Left part threaded portion 33 is matingly received in right part threaded portion 38, with a sealing O-Ring 60 compressed between the facing surfaces of these body parts. As previously noted, the mounting collar is captured between surfaces 26 and 40.
Referring now to FIGS. 1 and 4, element 12 is a specially-configured member having annular vertical left and right end faces 61, 62, respectively; an outer surface including frusto-conical surface 63 diverging rightwardly and away from left end face 61, cylindrical surface 64, rightwardly-facing annular vertical surface 65, cylindrical surface 66 from which an annular groove or recess 68 extends into the body, a rightwardly-facing annular vertical surface 69, and a cylindrical surface 70 continuing rightwardly therefrom to join right face 62; and a stepped axial through-bore bounded by cylindrical surface 71 extending rightwardly from left end face 61, a leftwardly-facing annular vertical surface 72, and a cylindrical surface 73 continuing rightwardly therefrom to join right end face 62. As best shown in FIG. 4, a radial hole 74 communicates bore surface 73 with outer surface 70 immediately to the right of surface 69. Surface 70 is further provided with a longitudinally-extending groove or recess 75 which begins to the right of hole 74 and continues rightwardly to join right end face 62. Groove 75 does not communicate directly with radial hole 74 because of the presence of a portion of surface 70 therebetween. The element is mounted in the body opening as shown in FIG. 1, with an O-Ring 76 received in element recess 68 so as to sealingly and slidably contact body opening surface 51. Another O-Ring 78 continuously engages body surfaces 51 and 52, and sealingly and slidably engages a proximate portion of element surface 70. Thus, the element is mounted in the body opening for axial sliding movement toword and away from body abutment surface 52. When the element is shifted rightwardly relative to the body to its maximum permissible extent, element surface 65 will engage body abutment surface 50, and O-Ring 78 will engage the portion of element surface 70 between radial hole 74 and longitudinal groove 75, thereby sealingly separating this hole and groove (i.e., FIGS. 1, 6, 7, and 9) for a purpose hereinafter explained. If desired, the proximate portion of the body could be provided with an annular groove or recess (not shown) to receive O-Ring 78 and to insure that it will be retained in this position when element 12 moves relative to the body.
As best shown in FIG. 5, the regulating poppet 13 is a stepped cylindrical solid member having circular vertical left and right faces 79, 80, respectively; and having an outer surface which includes cylindrical surface 81 extending rightwardly from left face 79, a leftwardly-facing annular vertical surface 82, and a cylindrical surface 83 continuing rightwardly therefrom to join right face 80. A solid cone 84 of a resilient material has its circular base arranged to engage left face 79, and has its leftwardly-pointed apex arranged to form a cushioned "nose" of the regulating poppet. As best shown in FIG. 1, the regulating poppet is mounted within the right marginal end portion of the body opening for axial movement toword and away from the right end 80 of the element. When moved sufficiently toword the element, the cushioned "nose" of the regulating poppet will sealingly engage the annular edge between element surfaces 62, 73, and thereby prevent further flow through the element's bore.
Adverting now to FIG. 1, actuator 14 is shown as including a two-part housing having an upper part 85 and a lower part 86 mounted on the body.
The housing upper part 85 is an inverted specially-configured somewhat cup-shaped member having a downwardly-facing and out-turned annular rim or lip 88, a meandering side wall 89, and an uppermost central collar 90 provided with a tapped vertical through-hole 91. A radial hole 92 penetrates the collar 90. A ring 93 is threaded into tapped hole 91 to provide an adjustably-positionable abutment surface for one end of coil spring 94. A retaining ring 95 is mounted in the upper mouth of hole 91 to protect ring 93.
The housing lower part 86 is a specially-configured cup-shaped member having an uppermost annular flange 96 bent to capture and hold the out-turned portion of the upper part rim, a side wall 98, and a bottom 99. Two diametrically-opposite tapped holes 100, 101 are provided through the lower part side wall 98. Hole 100 is adapted to receive threaded insertion of body portion 45. Hole 101 is adapted to receive threaded insertion of a suitable fitting (not shown) by which the regulator may communicate with, and supply fluid to, a suitable appliance (not shown) at a predetermined pressure. The lower part is shown as being further provided with a narrow-mouthed recess 102 immediately beneath hole 100.
A circular diaphragm 103 has a marginal portion adjaced its peripheral edge suitable captured and held between the connected rims of the two housing parts, and sealingly separates the space within the thus-assembled housing into an upper chamber 104 and a lower chamber 105. The upper chamber 104 is vented to atmospheric pressure through hole 92. The lower chamber 105 contains fluid at a pressure-to-be-regulated, this being less than the supply pressure. A plate-like member 106 is mounted on the horizontal upper face of the diaphragm, and is engaged by the other end of compressed coil spring 94. A member 108 depends from the underside of the diaphragm. The central portion of the diaphragm is sandwiched between plate 106 and member 108, and is held in this position by a fastener 107 which holds plate 106 and member 108 securely together. Member 108 is provided with an annular recess adjacent its lower end. This recess is bounded by a downwardly-convergent frusto-conical surface 109, a narrowed cylindrical surface 110, and an upwardly-convergent frusto-conical surface 111.
The actuator 14 is also shown as including a member 112 pivotally mounted on the housing. To this end, member 112 has a horizontal portion 113 and a vertical portion 114. The left marginal end portion 115 of the horizontal portion is received in recess 102, and is struck downwardly relative to the plane of horizontal portion 113 to prevent unintended withdrawal of member 112 from the recess. Adjacent its rightward end, the horizontal portion is provided with a hole 116 which is adapted to encircle surface 110 and be retained in this position by frusto-conical surfaces 109, 111 above and below surface 110. However, member 112 may pivot relative to member 108 because the diameter of hole 116 is greater than the diameter of surface 110. The vertical portion has a leftward convex or rounded surface 118 which is adapted to selectively engage regulating poppet right face 80.
As previously noted, upper chamber 104 is at atmospheric pressure, while lower chamber 105 contains fluid at a pressure to be regulated. Spring 94 is compressed between ring 93 and diaphragm plate 106, and urges the diaphragm to move downwardly. This downward bias is opposed by the pressure of fluid in lower chamber 105, which acts upwardly on the underside of the diaphragm. Thus, the equilibrium position of the diaphragm will be determined by a force balance between the downward force exerted by the spring (F=kx), and the opposing upward force exerted by the pressure of fluid (F=pA) in chamber 105. It should be noted that rounded surface 118 of member 112 will move pivotally toword and away from the body right face 36 as the diaphragm moves upwardly and downwardly, respectively. Thus, the actuator is arranged to continuously sense the pressure in chamber 105, and to translate such sensed pressure into the position of rounded surface 118 relative to body right end face 36.
Referring now to FIGS. 1 and 3, the high pressure poppet 15 is shown as being a specially-configured member having a square transverse cross-section, a left face 119, and a right face 120. A recess, bounded by cylindrical surface 121 and circular vertical bottom surface 122, extends rightwardly into the high pressure poppet from its left face 119. Another recess, bounded by cylindrical surface 123, leftwardly-facing annular vertical surface 124, cylindrical surface 125, and rightwardly-facing annular vertical bottom surface 126, extends leftwardly into the high pressure poppet from its right face 120. A circular disc 128 of resilient material is received in the high pressure poppet right recess. The rightwardly-facing circular vertical surface of disc 128 forms seat surface 16.
As best shown in FIG. 1, a coil spring 129 has its left end arranged to bear against seat surface 16, and has its right end arranged to bear against element surface 72. Spring 129 continuously urges the high pressure poppet and the element to move away from one another. The action of spring 129 urges the polygonal edge 130 of the high pressure poppet, this edge being formed by the intersection of the square outer surface and planar vertical left face 119, to normally abut body surface 31. However, because edge 130 is polygonal and body surface 31 is frusto-conical (FIG. 2), fluid may normally flow around the high pressure poppet to enter the through-bore of element 12.
So as to make explict that which is implicit, the various cylindrical surfaces of the body, the regulating poppet, the element, and the high pressure poppet, are severally generated about horizontal axis x--x.
Operation
The operation of the improved regulator is comparatively illustrated in FIGS. 6-9. The regulating poppet 13 constitutes the primary means for regulating the pressure in chamber 105. As such, the regulating poppet is continuously exposed to fluid at the pressure in chamber 105, while the high pressure poppet 15 is continuously exposed to the relatively-high supply pressure.
Normal operation of the regulator is illustrated in FIGS. 6 and 7. In this condition, it should be noted that spring 129 urges the high pressure poppet to its extreme leftward position, at which the corners of polygonal edge 130 engage body surface 31 at substantially four points, and also urges the element to move to its extreme rightward position, at which element surface 65 engages body abutment surface 50. O-Ring 78 engages element surface 70 between hole 74 and groove 75, and sealingly separates these two flow passageways. Thus, fluid, at the relatively-high supply pressure, enters body 11 through filter 34, passes around the high pressure poppet, and enters the element through-bore. The diaphragm continuously senses the pressure in chamber 105. When such sensed pressure equals a predetermined pressure, the diaphragm moves to a position such that rounded surface 118 will cause the regulating poppet to move toward and close the rightward end of the element through-bore (FIG. 6), thereby preventing further flow into chamber 105.
However, should the pressure in chamber 105 fall below the predetermined value, as by fluid in chamber 105 having been delivered to the serviced appliance (not shown), the diaphragm will move downwardly, thereby causing the rounded surface 118 to move away from the body right edge 36. This allows the relatively-high supply pressure in the element through-bore to displace the regulating poppet rightwardly until its right face bottoms against surface 118 (FIG. 7), and also permits fluid to enter chamber 105. The relative positions of the element and the regulating poppet are somewhat exaggerated in FIG. 7 for illustrative purposes only. In actual practice, the right end face of the regulating poppet will be in continuous contact with rounded surface 118.
When supply pressure is so admitted to chamber 105, the pressure therein may begin to rise, depending upon the demand requirements of the appliance at that point in time. Ultimately, the pressure in chamber 105 will rise, thereby causing the diaphragm to move upwardly, and, concomitantly, causing rounded surface 118 to displace the regulating poppet leftwardly to again seat against and close the right end of the element through-bore when such pressure again equals the predetermined pressure.
Should the pressure in chamber 105 substantially exceed the predetermined pressure, the diaphragm will move further upwardly and cause the rounded surface 118 to displace the regulating poppet and the element leftwardly until the element left end sealingly engages high pressure poppet seat surface 16, as shown in FIG. 8. Such movement is accommodated by further compression of spring 129. Such leftward movement of the element establishes fluid communication between element hole 74 and groove 75. Thus, the pressure in the element through-bore will equalize with the pressure in chamber 105 even though the regulating poppet is in fluid-tight sealing engagement with the right end of the element. Since the left end of the element is sealingly engaged with seat surface 16, the relatively-high supply pressure is prevented from entering the element through-bore.
FIG. 9 illustrates the relative positions of the various parts should the over-pressure condition in chamber 105 subsequently fall from that which caused the condition in FIG. 8, to a value lower than the predetermined pressure. As previously noted, the pressure in the element through-bore was permitted to equalize with the pressure in chamber 105 (FIG. 8). Hence, the differential pressure between the supply pressure and the pressure in the element through-bore, will continue to hold the high pressure poppet tightly against the element left end. However, should the pressure in chamber 105 now fall, rounded surface 118 will move away from the body right end. The relatively-high supply pressure will displace the high pressure poppet, the element, and the regulating poppet, rightwardly as a unit relative to the body until element surface 65 again bottoms on body abutment surface 50. If the pressure in chamber 105 continues to fall, rounded surface 118 may actually separate from the right end face of the regulating poppet because there is no flow through the element through-bore. The various parts will remain in this flow-preventing condition until release of the supply pressure acting on the high pressure poppet, as by disconnecting the regulator from the source. Thus, the improved regulator incorporates the feature of requiring a manual reset in the event that the pressure in chamber 105 exceeds the predetermined pressure by an amount needed to cause the condition shown in FIG. 8. Persons skilled in this art will appreciate that the leftward force exerted by rounded surface 118 on the regulating poppet will be substantially proportional to the magnitude of the amount by which the pressure in chamber 105 exceeds the predetermined pressure. It should also be noted that if the pressure in chamber 105 rises to some intermediate value greater than that needed to cause the regulating poppet to simply seat against the element right face (FIG. 6), but less than that need to cause the element left end to seat against surface 16 (FIG. 8), the element will move leftwardly for a distance determined by the magnitude of such pressure, but then return rightwardly to its normal position (FIG. 6) if such pressure is released.
Of course, the invention contemplates that many changes and modifications may be made. The shape and configuration of the various parts may be changed to the extent desired, albeit consistent with their intended purpose and function. Other types of actuators may be substituted for actuator 14. The serviced fluid may be either a liquid or a gas. Of course, the various parts may be formed either integrally or separately, as desired.
Therefore, while the presently-preferred embodiment of the improved pressure regulator has been shown and described, and several changes and modifications thereof 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. | A pressure regulator has an element slidably mounted in a body. A through-bore in the element is arranged to be selectively opened and closed in response to the magnitude of a sensed pressure relative to a predetermined pressure. If such sensed pressure substantially exceeds the predetermined pressure, the element is displaced relative to the body to seat against a high pressure poppet. Such closure of the element through-bore by the high pressure poppet is thereafter maintained, even should the sensed pressure subsequently fall below the predetermined pressure, and requires a manual reset. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to apparatus for controlling the exposure corrections in cameras having automatic exposure controls.
In automatic exposure controlled cameras, the apex indicating values B V , A V and S V of brightness of an object to be photographed, diaphragm value of the lens, and the sensitivity of the film, respectively, are utilized in an electronic circuit which determines and controls the shutter speed T (apex value T V ) according to the apex indicating formula: T V = B V + S V - A V .
When the values B V , A V and S V have been determined, the shutter speed becomes fixed in accordance with those values, irrespective of the photographer's intention, in special cases, to provide a different exposure. For example, when taking a photograph of a person against a very bright background, e.g. snow-crowned mountains, the above formula will result in the shutter speed being too great for proper photography of the person. This is because the background results in a large value of B V . Thus a deviation or error exists between a proper exposure value intended to be determined by the photographer and an exposure value automatically determined by the camera, so that it becomes necessary to correct the electric information manually. This type of correction is commonly referred to as a correction of exposure. One method of accomplishing exposure correction is to alter the value of S V set in the camera. For example, if the film speed dial of a camera is set for film of ASA 200 (S V =6), when the film in the camera has an ASA of 100 (S V =5), the shutter speed determined by the circuitry will be halved so that the face of the person who backs against snow-covered mountains will not be underexposed on the film. A problem with this technique is that the film sensitivity indicated is not the true film sensitivity, and errors can result from if the photographer does not remember the true sensitivity of the film loaded in the camera. Therefore, so-called X V devices have been employed for the exclusive use of making exposure corrections.
Another instance of corrections which the camera can not effect automatically are those which may be considered as being dependent upon the technical level of photographers. Thus, for example, a given photographer with experience may prefer to take all or most photographs at an exposure slightly in excess or slightly below that exchange lens group and the kind of film to be used in a which would be automatically set by the camera based on film speed, brightness, and operature opening. Such correction, which is referred to as setting a reference level, can be made by means of the above-mentioned X V device. However, because the purpose of the correction in this instance is different than the purpose of typical X V correction confusion can occur caused in the course of correction of the value X V , first as in the case of correction of the value S V . In brief, since the photographer employs a certain kind of lens, when it is desired to correct the reference level by one E V and take a photograph with a correction made by means of the X V device, and where it is necessary to make a further correction by means of the X v device for the purpose of effecting a correction under the above-mentioned photographing conditions, the reference level will deviate from the original value and so confusion is liable to occur. For this reason, it is convenient to separately provide a device capable of effecting correction of reference level (including the indication thereof). This will be referred to hereinbelow as the O V device.
SUMMARY OF THE INVENTION
The present invention has for its object to provide an effective correcting device for cameras by installing in combination the above-mentioned X V and O V correcting devices and incorporating the two sets of devices in a film speed setting device, S V , which incorporates a transducer for converting the settings into an electrical quantity for use in the exposure control circuit.
The object is achieved by providing a construction wherein three rings for setting S V , X V , and O V , respectively, are mechanically interrelated so as to control a single transducer, while at the same time being individually set by the operator.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of a setting dial, in accordance with the present invention, for setting and indicating the S V , X V and O V selections.
FIG. 2 is a cross sectional side view of the setting mechanism in accordance with the present invention.
FIGS. 3 and 4 are top views of parts of the mechanism of FIG. 2 illustrating the lacking arrangement between certain rings.
DETAILED DESCRIPTION
In FIG. 1 there is shown a dial protruding above the top of the camera housing 2. The dial is capable of individually selecting an X V value, an O V value, and an S V value. The X V value is indicated by a pointer on body 2 which points to an X V number on an X V indicating ring 7. The O V value is indicated by a pointer on ring 7 which points to an O V number on an O V indicator ring 19. The latter numbers are visible through a window in ring 7. The S V value (i.e., film ASA or DIN) is indicated by a pointer on ring 19 which points to an S V number on an S V indicator ring 20. The latter numbers are visible through windows in rings 19 and 7. It is noted that the S V viewing window in ring 7 must be larger that the S V viewing window in ring 19 to permit S V viewing irrespective of the relative positions of rings 7 and 19 resulting from the O V selection.
Also in FIG. 1 there are shown, an O V unlocking lever 16, an X V unlocking member 11, and a film rewind crank 40. Although the dial is arranged around the film winding crank in the embodiment shown, this is for the purpose of conserving space and is not a requirement for the practice of the present invention. All thru indicator rings, 7, 19 and 20, can be rotated by turning the operating ring 8. Lever 16 and pin 11 provide controls for selecting which of the rings rotate and which are held stationary. Any rotation of operating ring 8, however, moves a moveable contact of a variable resistor to alter the value set into the electronic exposure control circuit (not shown).
In FIG. 2 there is shown the moveable contact 22, which moves along a resistance formed on plate 3. The plate 3 is attached to a camera body 1 by means of a setscrew 4. An insulator 5 is fixedly secured to a bearing 6, and the contact 22 is secured to the insulator 5 by means of screws not shown. A projecting portion 8a of the operating ring 8 is fitted into recess 5a of the insulator 5 so as to be rotationally interlocked therewith. The contact 22 and the operating ring 8 rotate as an integral unit about, the X V indicator ring 7 and contact 22 slides on the plate 3.
An X V interlocking ring 9 is sandwiched between the upper cover plate 2 and the plate 3 and is adapted to rotate in contact with the inside of the cover plate 2. An X V locking member 10 has a projecting portion 10a which is inserted into a recess 9a of the X V interlocking ring 9, to prevent rotation or the latter, when member 10 is in the locking position illustrated. Further, a projecting portion 9b of the X V interlocking ring 9 is fitted into a recess 12a of an X V interlocking ring 12, and the latter is fixedly secured to the X V indicator ring 7 by means of setscrews 13. An X V unlocking button 11 which is attached to the cover plate 2 by a spring plate (not shown) is attached at the bottom thereof to locking member 10. Depression of the button moves the locking member 10 and the projecting portion 10a out of engagement with the recess 9a of the X V interlocking ring 9. This permits rings 9, 12 and 7 to rotate. The X V indicator ring 7 is prevented from vertical play, by screwing setscrews 15 into an unwinding shaft bearing 14, and is permitted to rotate about the unwinding shaft bearing 14.
The O V unlocking lever 16 is secured to the X V indicator ring 7 by means of fixing members 17. The O V unlocking lever 16 rests against projecting portion 7a of the X V indicator ring 7 and extends through a groove 7b therein to form a handle which can be depressed by the operator. Moreover, a projecting portion 16a of the O V unlocking lever lever 16 is engaged with a recess 18a of an O V interlocking ring 18, as shown in detail in FIG. 3, and such engagement can be unlocked by the operator depressing the O V unlocking lever 16. Further, the inner part of the O V interlocking ring 18 rests against the X V interlocking ring 12 and is positioned just below the X V indicator ring 7. The ring 18 is capable of rotating relative to ring 12. One end 18b of the O V interlocking ring 18 rests against the buttom and inner diameter of the S V indicator ring 20 to position the latter. One upper end 18c of ring 18 secures the O V indicator ring 19 fixedly so that the O V interlocking ring and the O V indicator ring 19 rotate as an integral unit. Further, as best shown in FIG. 4, the O V interlocking ring 18 is engaged with the operating ring 8 by means of projecting part 8b of ring 8 and recess 18d of ring 18. The operating ring 8 rests at its lower part against the X V interlocking ring 12, and is controlled or positioned at its upper part by a coiled spring 21. Raising operating ring 8 unlocks the lock between rings 8 and 18. Projecting portion 20a of the S V indicator ring 20 is fitted into the hole 8c of the operating rod 8 shown also in FIG. 4 so that the S V indicator ring 20 can rotate with the operating rod 8 as an integral unit. Reference numeral 23 denotes an unwinding crank, and 24 an unwinding knob.
The operation of the device can easily be understood by the following example.
Assume first, the photographer desires to make an O V adjustment. To accomplish this, rings 19 and 20 must be rotated as a unit independent of ring 7. Lever 16 is depressed and operating ring 8 is rotated. The rotation of operating ring 8 rotates, S V indicating ring 20 via projection 20a, O V interlocking ring 18 via locking projection 18d, and O V indicating ring 19, which is secured to ring 18. On the other hand, because of the locking of ring 9 by locking member 10, and the desengagement of lever 16 from a locking relationship with ring 18, rings 9, 12, and 7 will remain stationary. Ring 5 and contact 22, of course, rotate with every rotation of operating ring 8. As a result of the latter operation, the contact 22 changes the resistance in the circuit, the X V indication is unchanged, the S V indication is unchanged, but the O V indication is changed depending on the amount of rotation of operating ring 8.
Next assume the photographer wants to change the S V indication. This is accomplished by pulling up and turning operating ring 8, resulting in rotation of S V indicating ring 20. The pulling up of ring 8 releases the lock between rings 8 and 18. Rings 9, 12, 18, 19 and 7 remain stationary. Of course, the contact 22 is also rotated.
Finally assume the operator wants to alter the X V indication. This is accomplished by depressing button 11 and rotating operating ring 8, resulting in the rotation of all three indicating rings, 19, 20 and 7, as a unit. Specifically, the depression of button 11 unlocks ring 9, which, as explained previously is rotationally fixed to ring 12 and X V indicating ring 7. The S V indicating ring rotates integrally with ring 8 because of projection 20a. The O V indicating ring 19 rotates integrally therewith because of the fixed attachment to ring 18 and the lock between rings 18 and 8. The X V indicating ring 7 rotates integrally therewith because of the engagement of lever 16 and the friction between rings 12 and 18.
The above-mentioned example is constructed with priority given to the camera's unwinding shaft, however, it is needless to say tht similar arrangement can be applied to other component parts of the camera. It goes without saying that the method of indication in the above-mentioned embodiment is only an example, and if the relationship of engagement and disengagement with the indicator members is followed, the number of sets can be increased, and the combination of indications can be changed as desired. | A dial mechanism in a camera is disclosed having the capability of indicating multiple related settings, all of which control a single transducer input to an exposure control rotation of one or more indicating rings in dependence upon manually actuable control elements. | 6 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 USC §119(e) to U.S. Provisional Application Ser. No. 60/573,130, filed 21 May 2004, the entirety of which is hereby incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The invention relates generally to an animal chew product and specifically to a dog chew comprising a highly nutritious, digestible, dehydrated sweet potato.
BACKGROUND OF THE INVENTION
[0003] Animals, especially dogs, enjoy chewing hard objects. As animals receive a number of benefits from chewing hard objects, a multitude of digestible animal chew products exists. However, many ingredients used in conventional animal chews cause allergic reactions. For instance, most conventional animal chews contain such ingredients as wheat, gluten, corn, soy, milk, whey, casein, beef, pork, chicken or artificial flavors and colors. Recent studies show that approximately 20-50% of dogs are allergic to such ingredients. Further, some conventional animal chews can also contain animal products such as rawhide, bull penises (bully sticks), pig ears or pig snouts which can cause serious infections and stain animal owners' carpeting and furniture. Other conventional animal chews use synthetic materials such as ethylene copolymers, nylon and rubber. However, these materials can be swallowed whole or in part by animals, causing discomfort and/or injury to the animals' digestive tract. Conventional animal chews often contain highly refined starches, fats and animal digests, resulting in high calorie, low fiber products. Conventional animal chews are typically manufactured using high temperature injection molding, compression molding and/or baking. However, high temperatures destroy most nutrients and compression frequently requires palatability enhancers.
[0004] Therefore, a need exists for a nutritious, digestible animal product made without animal by-products, highly processed ingredients or synthetic materials.
SUMMARY OF THE INVENTION
[0005] The present invention is directed to an animal chew comprising a sliced sweet potato having a moisture content of between about 7 and 35%. The present invention is more specifically directed to an animal chew comprising a dehydrated sweet potato having a thickness between about 0. 5 and 1.5 inches; a moisture content between about 11 and 20%; a hard, furrowed surface; and added nutrients and flavorants to increase the nutrition, taste and effectiveness of the animal chew.
[0006] The present invention is further directed to a process for making an animal chew comprising trimming at least two sides of the sweet potato to allow for adequate steam penetration and uniform dehydration; cutting the sweet potato to a desired thickness and shape; blanching the cut sweet potato for a time sufficient to remove all debris and cease enzymatic activity; and drying the cut sweet potato to a moisture content of not greater than 20%.
[0007] The present invention is more specifically directed to a process for making an animal chew comprising washing a sweet potato to remove all dirt and debris; heating the washed sweet potato at a temperature of about 60 to 90° F. (16 to 32° C.) for a time sufficient to reduce breakage of the sweet potato; trimming the sweet potato on at least two sides to a length sufficient to allow even blanching and dehydration; slicing the trimmed sweet potato into segments of desired shape and thickness with a furrowed surface; heating the segmented sweet potato to a temperature between about 200 and 220° F. (93 and 104° C.) for a time sufficient to eliminate any debris; steaming the segmented sweet potato at a temperature and time sufficient to stop all enzymatic activity; dehydrating the steamed sweet potato to a moisture content of between 1 1 and 20%; storing the dehydrated sweet potato in a moisture-controlled environment for up to three weeks; and treating the dehydrated sweet potato with additional nutrients or flavorants.
[0008] The product of the present invention comprises a nutritious, flavorful, digestible animal chew product made from a dehydrated sweet potato having not less than about 1 1% moisture. The animal chew is non-allergenic and has a striated, deeply furrowed surface to improve the oral hygiene (teeth, gums and oral cavity) of an animal. The animal chew is low in calories, high in vitamins, minerals, anti-oxidants and fiber, and contains no animal or synthetic products. Because the animal chew does not contain any animal products or synthetic products using colorants, the animal chew will not stain carpets or furniture. Further, the animal chew produces no foul odors and can provide up to 38% of the recommended vegetables and fruits in an animal's diet.
[0009] The preferred furrowed, striated surface of the animal chew also provides a beneficial oral hygiene device. The furrowed surface provides a superior mechanical cleaning of the animals' teeth and gums, while the highly flavorful sweet potato improves the animals' breath. Further, the animal chew contains relatively high moisture levels compared to conventional animal chews (see Table 1), making the animal chew digestible and preventing it from lodging in the throat or intestine of the animal.
TABLE 1 Animal Chew Composition Crude Protein Not less than 5% Crude Fat Not less than 0% Crude Fiber Not more than 2% Moisture Not more than 35%
A summary list of the advantages of the animal chew of the present invention follows:
1. Furrowed striated surface providing superior mechanical cleaning of the teeth; 2. Reduction in fears of rawhide intestinal impaction or throat lodging; 3. Highly flavorful (palatable) to dogs; 4. High fiber content, which dramatically improves digestive health; 5. High nutrient content, especially necessary to animals and particularly to dogs, such as vitamin A, B 6 , calcium, potassium, phosphorus, iron, thiamin, riboflavin, niacin; 6. Will not stain carpets, a common complaint made against rawhides, pig ears, flavor enhanced rawhide or color-added chews. 7. Produces no foul odors; 8. Helps meet canine dietary requirement for up to 38% vegetables and fruits in their diet; 9. Low in calories-high in anti-oxidants; 10. No highly processed materials, such as wheat gluten, corn starch, casein, plastics or polymers. Just pure food—sweet potato; and 11. Effective as a dental chew.
[0021] The animal chew of the present invention is particularly well-suited for use by dogs, but other animals such as cats, rabbits, guinea pigs and birds will also benefit from a nutritious, digestible animal chew.
[0022] The scope of the invention will appear more fully from the following detailed description of the preferred embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0023] The animal chew of the present invention comprises a dehydrated sweet potato having a furrowed surface made using a two-step blanching and dehydrating process. Sweet potatoes having orange flesh, such as the Beauregard, Jewels, Garnet, Morning Glory or Redskin varieties, are preferred, with sweet potatoes of the Morning Glory family, Ipomoea batatas genus, being the most preferred. However, all varieties of sweet potato may be used in the present invention.
[0024] The animal chew of the present invention is highly nutritious. Using sweet potatoes capitalizes on the high levels of nutrients, anti-oxidants and fiber inherent to the sweet potato. Sweet potatoes are an excellent source of vitamin A, potassium, vitamin C, vitamin B6, riboflavin, copper, pantothenic acid, folic acid, calcium and phosphorus. The animal chew of the present invention is also low in calories and high in fiber.
[0025] The animal chew product of the present invention is manufactured by segmenting, blanching and dehydrating a sweet potato. The sweet potatoes can be of any variety, although orange-fleshed sweet potatoes of the Morning Glory variety are preferred. The sweet potatoes can be of any size, although extra large sweet potatoes are preferred, as a single potato can create several animal chews.
[0026] After washing the potatoes to remove all dirt and debris, the sweet potatoes are heated to between 60 and 90° F. (16 to 32° C.), preferably 70 and 80° F. (21 and 27° C.), for a time sufficient to reduce breakage of the sweet potato during cutting. After washing and heating, the sweet potatoes are trimmed on at least two sides and cut into individual segments. The sweet potato must be trimmed to allow adequate steam penetration during the blanching process and to provide a uniform, even dehydration process.
[0027] Each sweet potato is preferably segmented into thin, wide slabs or can be segmented into a long, narrow “French fry” shape. Sweet potatoes having a square, box-like shape between 4 and 7 inches long are best cut into long, narrow “French fries,” while conventional, oval-shaped sweet potatoes of all lengths are best cut into wide slabs of various thicknesses. For “French fry” segments, the sweet potato peel should be trimmed on all four sides of the sweet potato. For slab-cut segments, two opposing sides of the sweet potato peel should be trimmed.
[0028] The sweet potatoes can be cut or sliced using a hand-held crinkle cut blade or a mechanical slicer, such as a Model DiversaCut 2110 by Urschell, or a 20″ Vegetable Slicer by Commercial Slicers. Both the hand-held and mechanical slicers cut a series of deep furrows in the sweet potato segment. Deeper furrows cause more exaggerated ripples in the finished product, providing a more abrasive dental chew to the animal. The deep furrows also provide at least 25-35% more surface area as compared to a sweet potato segment with a flat cut surface, increase heat penetration of the sweet potato segments during both the blanching and the dehydration steps and prevent the segments from sticking during dehydration.
[0029] Regardless of the size or shape, the segments are preferably cut along the length of the sweet potato so as to keep the skin of the sweet potato intact. Keeping the skin intact contains the many nutrients and minerals safely within the sweet potato, providing a highly nutritious animal chew.
[0030] The segments preferably range in thickness from about 0.25 to 2.0 inches, with a preferred thickness of between about 0.5 and 1.5 inches, with a most preferred thickness of about 1.0 inch. The segments can be anywhere from about 2 to 12 inches long, depending on the size of the sweet potato. In a preferred version, the sweet potato segments are between about 3 and 8 inches long, with a most preferred length of between about 5 and 7 inches. The thickness can be manipulated depending on the size and needs of the animal. For instance, senior dogs may require a softer chew. The thicker segments may require perforation by knife, bristle or paddles to achieve the desired moisture contents.
[0031] Once the sweet potatoes are washed, heated and segmented, the segments are blanched using a two-step process. Blanching stops all enzymatic activity in the sweet potato while eliminating bacteria, molds and fungi. Blanching also ensures a more uniform and quicker dehydration and helps maintain a brighter, more attractive, orange color. In step one of the blanching process, the sweet potato segments are exposed to water heated to between 200 and 220° F. (93 and 104° C.), preferably between 206 and 21 1° F. (97 and 99° C.). This temperature eliminates any sand or soil particles remaining on the surface of the sweet potato segment and begins the heat process required to stop enzymatic activity in the sweet potato segments.
[0032] In step two, the sweet potato segments are steam treated to stop all enzymatic activity in the sweet potato. The temperature of the steam and length of exposure may vary, depending on the size and thickness of the sweet potato segments. For instance, a “French fry” segment approximately 0.5 inches thick and 5 inches long will require an estimated 1 to 8 minutes of steam. A small to medium slab-cut segment approximately 1 inch thick and 5 inches long will require an estimated I to 10 minutes of steam. A medium to large slab-cut segment approximately 1.5 inches thick and 5-12 inches long will require an estimated 1 to 12 minutes of steam. If the segments have a flat surface instead of the preferred furrowed surface, the blanching process will take approximately one to two minutes longer for each size.
[0033] After blanching, the sweet potato segments may optionally be cut into various shapes such as a pig's ear, a bone, etc. A hand-held cutout may be used, as well as an automated die-cut machine.
[0034] After the segment is in the desired shape, the blanched sweet potato segments are dehydrated to a moisture level between 11 and 20%. The segments may be dehydrated using an electric dehydrator or one that uses hydrocarbon fuel. Both types of dehydration are well known to the art in the food industry. The length of time required for dehydration depends on the size and thickness of the segments, as well as the type of apparatus used. For instance, small to medium segments require an estimated 1 1 to 40 hours of dehydration, while medium to large segments require up to 15 to 48 hours. The sweet potato segments are preferably dehydrated until hard and appear dry, yet with a slight flexibility. The dehydrating apparatus should be housed in an area that provides adequate ventilation so that the moisture generated during the dehydration is vented off.
[0035] After the desired moisture content has been achieved, the dehydrated sweet potato segments are stored in moisture-controlled bins, known to the art, for 1 to 3 weeks to equalize the moisture content of the chews. This is a critical step in creating a chew with consistent hardness and texture.
[0036] After the required storage time, the resultant animal chew may be treated with additional nutrients and/or flavorants. For instance, nutrients such as vitamin A, vitamin C, vitamin E, zinc, nettles, mullein, alfalfa, chlorophyll, Echinacea, methyl-sulfonyl-methane, glucosamine, chondroitin, shark cartilage powder and green lipped mussel powder will help to increase the shelf life of the animal chew, maintain the distinctive sweet potato color and provide additional nutrients to the animal.
[0037] Likewise, flavorants such as beef broth, poultry broth, vegetable broth, peanut-butter broth, peppermint, mint, spearmint, chamomile, garlic, parsley, tarragon, fennel, ginger and green tea will help to enhance the flavor and palatability of the chew and help control malodorous breath in animals. The nutrients and flavorants are preferably applied to the animal chew using an oil mist or dry baste of the substance on the surface of the animal chew.
[0038] The animal chews may be stored at room temperature in moisture-controlled packages for at least one year from the date of dehydration. Preferred packages are airtight poly or cellophane bags, with appropriate shelf life stamps provided.
[0039] In an alternate version, the animal chew of the present invention is manufactured as discussed above, with an additional rehydration step. In this version, after the sweet potato segments have been blanched and cut into the desired shape, they are dehydrated to a moisture content between 18 and 28%. The time required to reach these moisture levels depends on the size and thickness of the segments. For instance, small to medium segments require an estimated 8 to 36 hours of dehydration, while medium to large segments require 10 to 42 hours. Once the segments have been dried to the desired moisture levels, they are rehydrated with a flavored broth to a moisture level of between 30 and 40%. The rehydration can be accomplished using a spray-on application for a continuous conveyor or by immersion in the broth for a specific time. After the segments have been immersed in the broth, the segments can be spun- or drip-dried. The rehydration acts to trap the flavor and nutrients of the broth in the sweet potato segment.
[0040] The rehydrated sweet potato segment is then dehydrated again to a moisture content of between 11 and 20%. Depending on the size and thickness of the segment, this can take an additional 1 to 12 hours of dehydration. The broth preferably contains beef, poultry or peanut butter, although other additives such as peppermint, alfalfa, chamomile and parsley may be used. This version provides additional flavor and nutrients to the animal chew while remaining vegetarian and digestible.
[0041] Various makes and models of all the equipment discussed above are available and a manufacturer familiar with the art will be able to select appropriate equipment to meet production and facility requirements.
[0042] It is understood that the invention is not confined to the particular construction and arrangement of parts herein illustrated and described, but embraces such modified forms thereof as come within the scope of the following claims. | A nutritious, flavorful, digestible animal chew made from a dehydrated sweet potato is provided. The animal chew is non-allergenic and has a striated, deeply furrowed surface to improve the oral hygiene of an animal. The animal chew is low in calories, high in vitamins, minerals, and fiber and contains no animal-based or synthetic products. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 13/777,568, filed Feb. 26, 2013, which is a continuation of U.S. patent application Ser. No. 11/738,367 filed Apr. 20, 2007, which is incorporated herein by reference in its entirety.
FIELD OF THE DISCLOSURE
The present disclosure relates generally to media devices, and more specifically to a system for presenting media programs.
BACKGROUND
Multimedia systems can be configured or integrated with an interactive entertainment set-top box (STB). STBs generally require that customized devices of media programs (e.g., MP3 and/or MP4 players) either be copied to the hard drive of the STB or streamed thereto. This can be a time consuming and tedious process, particularly where a large number of smaller media files are involved, such as music files. Additionally, the user interface (UI) of the STB can be complicated, and unfamiliar to the user for playback of the transferred media programs, especially for a user who is accustomed to the UI of the media player that supplied the media programs to the STB.
A need therefore arises for a system for presenting media programs.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts an exemplary embodiment of a communication system;
FIG. 2 depicts an exemplary method operating in the communication system; and
FIG. 3 depicts an exemplary diagrammatic representation of a machine in the form of a computer system within which a set of instructions, when executed, may cause the machine to perform any one or more of the methodologies disclosed herein.
DETAILED DESCRIPTION
Embodiments in accordance with the present disclosure provide a system for presenting media programs.
In a first embodiment of the present disclosure, a multimedia system can have a controller element to receive a request from a set-top box (STB) for an emulator that emulates a user interface of a media player, wherein the request identifies the media player, retrieve the emulator according to the identification of the media player, and transmit to the STB the emulator for emulating the user interface of the media player by way of the STB.
In a second embodiment of the present disclosure, a computer-readable storage medium in a presentation device can have computer instructions for activating an emulator that emulates a user interface of a media player.
In a third embodiment of the present disclosure, a media player can have a controller element to receive operational instructions from an STB according to an emulator activated by the STB that emulates a user interface of the media player.
FIG. 1 depicts an exemplary embodiment of an internet protocol television (IPTV) communications system 100 having portions that can be configured for managing and presenting media stored on one or more media players (MPs) 102 . In a typical IPTV backbone, there is at least one super head office server (SHS) 106 which receives national media from satellite and/or media servers from service providers of multimedia broadcast channels. The SHS 106 forwards IP packets associated with the media content to video head servers (VHS) 108 via a network of video head offices (VHO) 110 according to common multicast communication method. The VHS 108 then distributes multimedia broadcast programs to commercial and/or residential buildings 112 housing a gateway 114 (e.g., a residential gateway or RG). The gateway 114 can distribute broadcast signals to receivers such as Set-Top Boxes (STBs) 116 which in turn present broadcast selections to media devices 118 such as display systems (e.g., computers, LCD or CRT monitors, and LCD or CRT televisions) or audio systems managed in some instances by a wired or wireless media controller 117 (e.g., infrared or RF remote controls).
Unicast traffic can also be exchanged between the STBs 116 and the subsystems of the IPTV communication system 100 for services such as delivery of media to STBs 116 . Although not shown, the aforementioned system 100 can also be combined with analog broadcast distributions systems.
An STB 116 operating in the system 100 can comprise a memory element, a controller element, a network interface, and a MP interface. The memory element can utilize common storage technologies (e.g., hard disk drives, flash memory, etc.) for retrieval and storage of various data including audio media, moving image media, and still image media, in one or more local or remote locations managed by the controller element. The controller element can utilize common audio, visual, and video processing technologies (e.g., Moving Pictures Experts Group (MPEG), Joint Photographics Experts Group (JPEG), Graphic Interchange Format (GIF), H.264, high definition TV, standard definition TV, etc.) to manage and present media on a media device 118 . The network interface can utilize common networking technologies (e.g., LAN, WLAN, TCP/IP, etc.) to manage communication with the gateway 114 and the IP network via wireline (e.g., Ethernet or cable) or wireless communications (e.g., WiFi). The MP interface can utilize common wireline (e.g., USB or Firewire) and/or wireless (e.g., WiFi or Bluetooth) technologies to manage communications between the STB 116 and the MP 102 .
FIG. 2 depicts an exemplary method 200 operating in portions of the communication system 100 . Method 200 has variants as depicted by the dashed lines. It would be apparent to an artisan with ordinary skill in the art that other embodiments not depicted in FIG. 2 are possible without departing from the scope of the claims described below.
Method 200 begins with step 202 where the MP 102 is connected with the STB 116 . The connection can be wireless or by wireline, and can be passive or active. For example, the user can connect a MP 102 to a USB port of the STB 116 . In another example, the STB 116 can be configured to automatically detect and connect to MPs 102 having a wireless interface, such as Bluetooth or WiFi connection. In yet another example, the user can transmit a signal from one or both of the MP 102 and the STB 116 to establish a connection.
MPs 102 can include any type of device for the presentation of media that can be connected to a STB 116 via the MP interface, including personal or portable media devices. Media presented by MPs 102 can include audio media, visual media, and audio/visual media. For example, a MP 102 can be an audio-only device (e.g., MP3 music player or a satellite radio device), a video-only device (e.g., a digital camera), or an audio-visual device (e.g., a portable video and audio media player, a camera phone, or a digital video camera). Additionally, an MP 102 can be configured to store other files, including files associated with the media, such as playlists.
In response to the MP 102 being connected to the STB 116 , the STB in step 204 can identify the connected MP. In some instances, the STB 116 can be configured to automatically identify the MP 102 on the basis of identifying information transmitted between the STB and the MP. Identifying information can include a model number, a serial number, or a description of the MP 102 . For example, a MP 102 can be configured to automatically transmit identification information to the STB 116 , such as an identifier string including model information. Alternatively or in combination, the STB 116 can be configured to allow a user to manually identify the MP 102 . For example, after connection of the MP 102 to the STB 116 , the STB can be configured to allow a user to identify the MP by prompting the user to select from a list of MPs. Additionally, such a manual entry configuration can be used when the STB 116 fails to automatically identify the MP 102 . For example, a manual entry can be used by the user to identify a legacy MP 102 which may not be configured to provide an identifier string or a newer model of MP.
Once MP 102 is identified by STB 116 , the STB can activate an emulator which emulates a user interface of the connected MP to allow users to manage and present media from the MP via the STB. Separately or in combination with step 204 , the STB 116 in step 206 can be configured to identify an emulator that corresponds to the identified MP 102 . For example, the STB 116 in step 206 can access a database listing emulators corresponding to various MPs 102 . Additionally, a database containing MP 102 identification information can also include emulator identification information.
However, identification of a corresponding emulator can vary depending on the type of MP 102 and the configuration of emulators available to the STB 116 . In some instances, one to one correspondence between emulators and MPs 102 can exist. That is, for each MP 102 , a separate corresponding emulator can also exist. However, emulators can be configured to correspond with more than one MP 102 or even to an entire family of MPs. For example, a single emulator can be configured to correspond and operate with an entire line of MP products. In some instances, however, the STB 116 may not be able to identify an emulator corresponding to the identified MP 102 . In such instances, the STB 116 can be configured to generate a corresponding error message for the user. Alternatively, or in combination, the STB 116 can be configured to automatically identify an alternate emulator. For example, the STB 116 can be configured to automatically identify an emulator for MP 102 from the same manufacturer, such as an emulator corresponding to a MP having a similar model number. In another example, the STB 116 can be configured to automatically identify a generic emulator associated with a particular MP 102 . Such generic emulators can be configured to allow a user to control at least basic functions of the MP 102 . For example, a generic MP3 player emulator can be configured to include at least a basic set of controls (e.g., play, stop, skip forward, skip back, volume control, etc.) common to all MP3 players.
Subsequently, or in combination with steps 204 and 206 , the STB 116 in step 208 can be configured to automatically retrieve the identified emulator from a memory element. However, the location of the identified emulator can vary and can include locations in local memory elements of the STB 116 or in remote memory locations. These locations can be determined in several ways. For example, when the STB 116 accesses one or more databases to identify an emulator for the MP 102 in step 206 , additional entries in such databases can be configured to include the location of the emulator. In another example, all emulators can be stored in one or more designated memory elements, and the STB 116 can be configured to automatically access these memory elements to retrieve the emulator. In some instances, at least some emulators can be stored in a local memory element of the STB 116 . For example, a local memory element can store emulators for more common MPs 102 or emulators for MPs that have been previously connected to the STB 116 . In other instances, an emulator can be stored within a memory element in the MP 102 .
Once the emulator has been retrieved from a memory element by the STB 116 , the STB in step 210 can activate the retrieved emulator. Subsequently, the user can use the emulator to manage and present media within the MP 102 via the STB 116 . However, an emulator can be configured to operate and interact with the MP 102 in various ways. In some cases, an emulator can be configured to provide a complete emulation of the MP 102 itself. That is, the emulator would perform on the STB 116 all the functions that the hardware and/or system software of the MP 102 would perform to manage and present the media on the MP 102 . For example, the STB 116 can be configured to transfer the currently selected media from the MP 102 to the STB 116 . Subsequently, the emulator would access and process the transferred media just as the MP 102 would, and output the media via the media device 118 .
However, in other cases, the emulator can be configured as only an input and output interface for the MP 102 . In such instances, the STB 116 can transmit user inputs received by the emulator directly to the MP 102 . Subsequently, the response or output generated by the MP 102 can be transmitted back to the STB 116 and the emulator can output via the media device 118 connected to the STB. For example, the output of audio media from the MP 102 to the STB 116 can be configured as an audio stream received by the STB and the emulator can output the audio stream to an audio system connected to the STB.
To facilitate user interaction with the MP 102 via the STB 116 , the emulator can be configured to include a graphical user interface (GUI) 120 (shown in FIG. 1 ) that emulates the user interface for the media player. The emulator GUI 120 can be presented on a display device of the media device 118 or a media controller 117 . For example, the emulator can configure an emulator GUI 120 to duplicate the user interface of an MP3 player connected to the STB 116 on a display device connected to the STB 116 . Such a configuration allows the user to operate the emulator via the emulator GUI 120 , and can allow the user to view and select media stored on the MP 102 as if the user were operating the MP.
However, the emulator GUI 120 is not intended to be limited to only duplicating the user interface of the MP 102 . For example, the emulator can rearrange the input and output interfaces in the emulator GUI 120 as needed, required or desired. In some instances, the emulator can rearrange the input and output interfaces of the emulator GUI 120 to provide a more practical or usable interface. For example, if a MP 102 is configured with user input and output interfaces located on different surfaces of the MP 102 , the emulator GUI 120 can be rearranged to allow for a two dimensional presentation on a display device. Alternatively, an emulator can provide a rearranged emulator GUI 120 in order to provide a compact footprint on the media device display.
The emulator GUI 120 can also include additional user inputs. For example, the emulator GUI 120 can provide user inputs to allow users to select a compacted version of the emulator GUI. In another example, the emulator GUI 120 can include a user input for the user to select a different emulator. In yet another example, the emulator GUI 120 can include a user input for transferring one or more files from the MP 102 to the STB 116 .
Once the emulator is activated, the STB 116 can begin to receive user inputs and the emulator in step 212 can analyze the commands associated with such user inputs. User inputs can be received from a media controller, a user interface of the STB 116 or the media device 118 , the MP 102 , or any combination thereof. In some instances, each button on a media controller 117 , STB 116 , media device 118 , or the MP 102 can be associated with a specific command. In other instances, the user can navigate the emulator GUI 120 using a D-pad or arrow buttons on a media controller 117 , and input commands by selecting inputs for the emulator GUI using the media controller 117 .
After analyzing the command associated with user input, the emulator in step 214 can determine whether the command corresponds to a valid command for the current MP 102 . That is, the emulator can be configured to determine whether the MP 102 would normally respond to such a user input. For example, if a user input to increase volume is received by the STB 116 and the volume is already at a maximum level, the emulator can determine that the command is invalid and take no action. Similarly, if a command to proceed to the next track in an album or playlist is detected and no subsequent tracks exist, the emulator can determine that the command is invalid and take no action. Therefore, if the emulator determines that the user input received by the STB 116 does not correspond to a valid command for the MP 102 in step 214 , the emulator can continue to monitor for and analyze other user inputs received by the STB 116 .
If on the other hand the emulator does determine in step 214 that a user input corresponds to a valid command for the MP 102 , then the command can be processed and the corresponding action can executed by the emulator according to steps 216 - 234 . For example, the emulator in step 216 can determine whether the command received by the emulator corresponds to a command to exit the emulator. Such a command can correspond with a user input activating a power button in the emulator GUI 120 or on the MP 102 itself. In some instances, the emulator can include an additional button in the emulator GUI 120 to terminate the emulator. Additionally, the STB 116 can be configured to automatically generate a termination command for the emulator whenever the STB 116 detects that the MP 102 has been disconnected from the STB. Once a command to terminate the emulator is detected, the emulator can terminate in step 218 and cease displaying the emulator GUI 120 .
Separately, or in combination with step 216 , the emulator can also process user inputs in step 220 and execute corresponding commands for other functions of the MP 102 in steps 222 - 236 . However, how the emulator interprets such user inputs can depend on how the emulator, the emulator GUI 120 and/or the MP 102 are configured. For example, some MPs 102 can be configured to include an input interface with one or more analog input devices, such as wheels, sliders, levers, or knobs. In such instances, the emulator can be configured to accept alternate types of input to activate such analog input devices. For example, for a volume control knob, the emulator can be configured to accept an input from volume up and down buttons on a remote control. However, the emulator can be configured to allow the user to select the “knob” in the emulator GUI 120 and to allow the user to adjust the position of the “knob” using repeated depressions of a D-pad, an arrow key, or other buttons on the media controller 117 . Additionally, in instances where analog input devices are configured with maximum or minimum positions, such as in a volume or tuning knob, the emulator can provide an emulator GUI 120 having multiple selectable positions for the analog input device corresponding to various positions available for the analog input device. In one embodiment, the emulator can be configured to allow a user to input MP 102 commands for the emulator via the MP 102 without having to provide an alternative means for providing user inputs for such analog input devices.
Once the emulator determines that the user input, corresponds to a valid command for the MP 102 and is not a command to exit the emulator, the emulator in step 220 can determine whether the user input corresponds to a command to present new media. If the emulator determines in step 220 that the user input corresponds to a command to present new media, the emulator in steps 222 - 228 can retrieve and present the media on the media device 118 connected to the STB 116 .
However, the response of the emulator to a command to present new media can depend on how the emulator is configured to operate with the MP 102 . For example, the emulator in step 222 can directly retrieve the new media from the MP 102 . Subsequently, the emulator in step 224 can present the retrieved media through the GUI 120 on a media device 118 connected to the STB 116 .
In another embodiment, the emulator can be configured as an input and output interface for the MP 102 . In such instances, a command corresponding to selecting new media can be transmitted to the MP 102 in step 226 . The MP 102 in step 228 can retrieve and present the selected media and transmit the output of the MP 102 back to the STB 116 . The emulator in step 224 can then present the transmitted media to the user via the media device 118 .
Subsequently, or in combination with steps 222 - 228 , the emulator can adjust the current presentation of the emulator GUI 120 in step 230 to reflect the new media being presented. For example, an emulator GUI 120 for an MP3 player can display audio program information for the newly selected audio program, such as artist name, album, and title of the audio program. In another example, for an MP3 player emulator presenting audio media, information displayed in the emulator GUI 120 , such as elapsed time or time remaining, can be automatically adjusted by the emulator or retrieved from the MP 102 .
Alternatively, the emulator can determine in step 220 that the user input corresponds to a command unrelated to selecting new media. In such cases, the emulator can execute the command associated with the received user input in step 232 and if necessary, adjust the emulator GUI 120 in step 230 to reflect the executed command. However, where the command is actually executed varies according to the configuration of the emulator, the STB 116 , and the MP 102 . Therefore, in some instances the emulator in step 234 can transmit the command to the MP 102 and the command can be executed by the MP 102 in step 236 . For example, a command to increase or decrease volume for audio media can depend on the delivery of the audio media to the media device 118 . If the emulator is configured to process the audio media directly from the MP 102 , as in steps 222 and 224 , then a command to increase or decrease volume would be executed by the emulator only, as a volume change on the MP 102 would not affect the output. In contrast, where the MP 102 is configured to retrieve and transmit the audio media as an audio stream to the STB 116 , as in step 228 , a volume change on the MP 102 can affect the output, therefore the command can be executed by the MP 102 . In either case, the emulator in step 230 can adjust the emulator GUI 120 to reflect the results of the command being executed. Afterwards, the emulator in steps 212 and 214 can continue to monitor for and analyze user inputs of the STB 116 and repeat steps 216 - 236 to process any subsequent commands for the MP 102 .
Upon reviewing the foregoing embodiments, it would be evident to an artisan with ordinary skill in the art that the present disclosure can be modified, reduced, or enhanced without departing from the scope and spirit of the claims described below. For example, the system 100 can comprise a cable media system, a satellite media system, an IPTV system, or any combination thereof. Therefore, the aforementioned steps in whole or in part can operate in one or more portions of one or more of the aforementioned systems. For example, the steps for the STB 116 to select and execute the emulators from databases can be executed in one or more portions of the cable media system, while other steps can be executed in an IPTV system. In another embodiment, the STB 116 and the MP 102 can frequently exchange media data during an on-going media presentation in order to accelerate presentation of the media after a media has been paused by caching media at the STB. In still another example, an STB 116 can be configured to copy all media from the MP 102 to a memory of the STB 116 , and the emulator can process the media without having the access the MP 102 . In yet another embodiment the media controller 117 , media device 118 , STB 116 , the MP 102 , and remote databases can in whole or in part be integrated to perform the methods described herein.
These are but a few examples of modifications that can be applied to the present disclosure without departing from the scope of the claims. Accordingly, the reader is directed to the claims section for a fuller understanding of the breadth and scope of the present disclosure.
FIG. 3 depicts an exemplary diagrammatic representation of a machine in the form of a computer system 300 within which a set of instructions, when executed, may cause the machine to perform any one or more of the methodologies discussed above. In some embodiments, the machine operates as a standalone device. In some embodiments, the machine may be connected (e.g., using a network) to other machines. In a networked deployment, the machine may operate in the capacity of a server or a client user machine in server-client user network environment, or as a peer machine in a peer-to-peer (or distributed) network environment.
The machine may comprise a server computer, a client user computer, a personal computer (PC), a tablet PC, a laptop computer, a desktop computer, a control system, a network router, switch or bridge, or any machine capable of executing a set of instructions (sequential or otherwise) that specify actions to be taken by that machine. It will be understood that a device of the present disclosure includes broadly any electronic device that provides voice, video or data communication. Further, while a single machine is illustrated, the term “machine” shall also be taken to include any collection of machines that individually or jointly execute a set (or multiple sets) of instructions to perform any one or more of the methodologies discussed herein.
The computer system 300 may include a processor 302 (e.g., a central processing unit (CPU), a graphics processing unit (GPU, or both), a main memory 304 and a static memory 306 , which communicate with each other via a bus 308 . The computer system 300 may further include a video display unit 310 (e.g., a liquid crystal display (LCD), a flat panel, a solid state display, or a cathode ray tube (CRT)). The computer system 300 may include an input device 312 (e.g., a keyboard), a cursor control device 314 (e.g., a mouse), a disk drive unit 316 , a signal generation device 318 (e.g., a speaker or remote control) and a network interface device 320 .
The disk drive unit 316 may include a machine-readable medium 322 on which is stored one or more sets of instructions (e.g., software 324 ) embodying any one or more of the methodologies or functions described herein, including those methods illustrated above. The instructions 324 may also reside, completely or at least partially, within the main memory 304 , the static memory 306 , and/or within the processor 302 during execution thereof by the computer system 300 . The main memory 304 and the processor 302 also may constitute machine-readable media.
Dedicated hardware implementations including, but not limited to, application specific integrated circuits, programmable logic arrays and other hardware devices can likewise be constructed to implement the methods described herein. Applications that may include the apparatus and systems of various embodiments broadly include a variety of electronic and computer systems. Some embodiments implement functions in two or more specific interconnected hardware modules or devices with related control and data signals communicated between and through the modules, or as portions of an application-specific integrated circuit. Thus, the example system is applicable to software, firmware, and hardware implementations.
In accordance with various embodiments of the present disclosure, the methods described herein are intended for operation as software programs running on a computer processor. Furthermore, software implementations can include, but not limited to, distributed processing or component/object distributed processing, parallel processing, or virtual machine processing can also be constructed to implement the methods described herein.
The present disclosure contemplates a machine readable medium containing instructions 324 , or that which receives and executes instructions 324 from a propagated signal so that a device connected to a network environment 326 can send or receive voice, video or data, and to communicate over the network 326 using the instructions 324 . The instructions 324 may further be transmitted or received over a network 326 via the network interface device 320 .
While the machine-readable medium 322 is shown in an example embodiment to be a single medium, the term “machine-readable medium” should be taken to include a single medium or multiple media (e.g., a centralized or distributed database, and/or associated caches and servers) that store the one or more sets of instructions. The term “machine-readable medium” shall also be taken to include any medium that is capable of storing, encoding or carrying a set of instructions for execution by the machine and that cause the machine to perform any one or more of the methodologies of the present disclosure.
The term “machine-readable medium” shall accordingly be taken to include, but not be limited to: solid-state memories such as a memory card or other package that houses one or more read-only (non-volatile) memories, random access memories, or other re-writable (volatile) memories; magneto-optical or optical medium such as a disk or tape; and carrier wave signals such as a signal embodying computer instructions in a transmission medium; and/or a digital file attachment to e-mail or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. Accordingly, the disclosure is considered to include any one or more of a machine-readable medium or a distribution medium, as listed herein and including art-recognized equivalents and successor media, in which the software implementations herein are stored.
Although the present specification describes components and functions implemented in the embodiments with reference to particular standards and protocols, the disclosure is not limited to such standards and protocols. Each of the standards for Internet and other packet switched network transmission (e.g., TCP/IP, UDP/IP, HTML, HTTP) represent examples of the state of the art. Such standards are periodically superseded by faster or more efficient equivalents having essentially the same functions. Accordingly, replacement standards and protocols having the same functions are considered equivalents.
The illustrations of embodiments described herein are intended to provide a general understanding of the structure of various embodiments, and they are not intended to serve as a complete description of all the elements and features of apparatus and systems that might make use of the structures described herein. Many other embodiments will be apparent to those of skill in the art upon reviewing the above description. Other embodiments may be utilized and derived there from, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Figures are also merely representational and may not be drawn to scale. Certain proportions thereof may be exaggerated, while others may be minimized. Accordingly, the specification and drawings are to be regarded in an illustrative rather than a restrictive sense.
Such embodiments of the inventive subject matter may be referred to herein, individually and/or collectively, by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept if more than one is in fact disclosed. Thus, although specific embodiments have been illustrated and described herein, it should be appreciated that any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description.
The Abstract of the Disclosure is provided to comply with 37 C.F.R. §1.72(b), requiring an abstract that will allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the foregoing Detailed Description, it can be seen that various features are grouped together in a single embodiment for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed embodiments require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive subject matter lies in less than all features of a single disclosed embodiment. Thus the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separately claimed subject matter. | A system that incorporates the subject disclosure may use, for example, a method for sending a set-top box an identification of the media player, receiving operational instructions from the set-top box according to the emulator executed by the set-top box that emulates a user interface of the media player by presenting a representation of the media player in a graphical user interface, and transmitting media content to the set-top box according to the operational instructions. The emulator can be supplied to the set-top box by way of a multimedia system communicatively coupled to the set-top box. The user interface presented by the set-top box by way of the emulator substantially mimics functions of the media player. Additional embodiments are disclosed. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
Not applicable.
STATEMENT OF FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable.
BACKGROUND OF THE INVENTION
The present invention relates to toilets, and more particularly to toilet valves controlling the outflow of waste from a toilet bowl to a toilet trap.
Although flushing toilets greatly aid in the sanitary disposal of human excrement, water usage is impacted by such devices. As the need and desire to conserve water increases, there is a corresponding desire to reduce the volume of water used per average flush of a toilet.
A typical toilet includes a valve upstream of the toilet bowl, such as at the bottom of a water storage tank. When the toilet is flushed, the valve in the water tank opens, and the tank water is able to flush into the toilet bowl.
With these conventional toilets there is typically a delay between the beginning of the flushing cycle and the time that most of the crude waste has been removed from the bowl. An undesirably large amount of flushing water is required just to move the main waste out of the bowl, and a further amount is needed to provide the final rinse.
One way of reducing this problem is to provide a trap configured with an inlet valve and shaped such that when the inlet valve is opened most of the waste water will drop out of the bowl regardless of any new flush water entering. Examples of this approach include U.S. Pat. Nos. 168,613, 234,570, 279,048, 299,333, and 4,016,609.
However, such valves are necessarily placed in a blocking position relative to the outflow of waste from the bowl. Even when fully open they typically impede the flow of fluid and waste out of the bowl to some extent. Moreover, they sometimes result in clogging, maintenance or wear problems. Also, they may be expensive to produce or install, or be unreliable over prolonged usage.
For example, U.S. Pat. No. 4,016,609 disclosed a toilet having a bendable member for controlling waste outflow from a toilet basin. The resiliency of the bendable member was critical for proper operation, which resiliency could degrade over time. Additionally, the valve was not easily installed into the toilet.
Hence, a need still exists for improved toilet trap valve assemblies, particularly those which facilitate flushing with reduced amounts of water.
SUMMARY OF THE INVENTION
In one aspect the present invention provides a toilet having a bowl with a discharge outlet, a trap in fluid communication with the discharge outlet, and a valve positioned to control outflow from the discharge outlet to the trap. This valve is in the form of a cartridge unit having a first housing part, a second housing part linked to the first housing part so as to define a cavity there between, and a pivotable gate positioned in the cavity so as to be able to swing between a first position essentially closing off flow through the discharge outlet to a second position permitting flow from the discharge outlet to the trap.
Particularly in accordance with the present invention the cavity has a recess along one of its walls. When the pivotable gate is in the second position a portion of the pivotable gate is housed in the recess. This helps move the gate out of the way and thereby increases the efficiency of the water force flowing out of the bowl. This then further reduces the need for as much water to complete an effective flushing cycle.
In preferred forms of the invention pivoting of the pivotable gate can be driven by movement of a mechanical or hydraulic linkage that extends outside of the housing parts. This can be connected to a controller which also controls initiation and ending of the water flush.
In other preferred forms the pivotable gate carries a deformable seal suitable to seal against a housing part when the pivotable gate is in the first position, and the pivotable gate has an inwardly dished side facing the toilet bowl when the pivotable gate is in the first position. This helps the flow when the gate is in the open position to occur much more smoothly. There can also be an outwardly dished side of the gate which is configured to face a housing part when the pivotable gate is in the second position.
In another preferred aspect of the invention the trap has a normal trap water level to restrict back flow of sewer gases to the bowl, and the pivotable gate is positioned above that water level. Further, the valve cartridge can provide a flow path that bends from an essentially vertical path adjacent the bowl discharge outlet to a path at least somewhat horizontal.
In another aspect of the invention the invention can provide such a cartridge valve suitable to connect to such a toilet.
In a further aspect of the invention there can be provided a toilet trap way for carrying waste from a toilet bowl to a toilet trap. The trap way has a gate valve at its inlet end in the form of a pivotable gate movable between a first position essentially closing off flow through the trap way and a second position permitting flow through the trap way. The trap way has a recess along one of its walls and when the pivotable gate is in the second position a portion of the pivotable gate can be housed in the recess.
The present invention advantageously reduces the amount of water needed to complete a flush cycle with a given degree of cleaning. Further, the incidence of maintenance problems is reduced by keeping the gate above the normal trap water level in an air pocket. Further, if maintenance issues arise, the valve cartridge can be replaced without having to dispose of the trap or bowl when the cartridge unit forms of the valve are used.
These and still other advantages of the present invention will be apparent from the detailed description which follows and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical cross-sectional view through a toilet in which is installed an embodiment of the present invention;
FIG. 2 is a perspective view of an outlet valve of FIG. 1 ;
FIG. 3 is a perspective view of one of the housing halves, and the gate, of the valve of FIG. 2 ;
FIG. 4 is an enlarged cross-sectional view taken along line 4 - 4 of FIG. 2 ;
FIG. 5 is an exploded perspective view of the valve of FIG. 2 ;
FIG. 6 is a perspective view of a second embodiment of a valve according to the present invention;
FIG. 7 is a cross-sectional view taken along line 7 - 7 of FIG. 6 ;
FIG. 8 is an exploded perspective view of the valve of FIG. 6 ;
FIG. 9 is a perspective view of a third embodiment of a valve according to the present invention;
FIG. 10 is a cross-sectional view taken along line 10 - 10 of FIG. 9 ; and
FIG. 11 is an exploded perspective view of the valve of FIG. 9 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring first to FIG. 1 , there is shown the lower portion of a toilet 20 which includes a bowl 22 having a discharge outlet 24 , a trap 26 in fluid communication with discharge outlet 24 , and a discharge valve cartridge 28 in accordance with the present invention located between bowl 22 and trap 26 .
Toilet 20 will typically include other elements such as a water tank or other water supply source (not shown), a seat, a lid and/or other covering elements on the bowl (again all not shown). A control mechanism (again not shown) can be mechanically or otherwise linked to a flush mechanism which both starts the flush cycle and pivots the gate 40 from a closed position to an open one, and then back again. Alternatively, one could manually move the gate by rotating stem 52 manually.
Toilet 20 can include a flange 30 near the bottom of bowl 22 , and/or other connecting elements such as fasteners (not shown), and a gasket 32 , for connecting valve cartridge 28 at flange 33 . In any event, trap 26 has a trap water level 34 for preventing return of sewer gas, and can be connected to valve cartridge 28 at collar 35 with a flexible piece of rubber and/or other elements such as clamps (all not shown). Valve cartridge 28 permits the passage of waste and fluid from bowl 22 to trap 26 .
Referring more particularly to FIGS. 2-5 , valve cartridge 28 includes a first housing part 36 , a second generally mirror image housing part 38 connected to first housing part 36 , and a pivotable gate 40 mounted inside a cavity defined between the first and second housing parts 36 / 38 .
Gate 40 includes an inwardly dished side 42 and an outwardly dish side 44 which includes a contour 46 . The contour 46 mimics a contour 48 formed on the inside wall of the cavity formed by the housing parts.
As shown in FIG. 4 , when gate 40 is pivoted by rotatable stem 52 , it pivots down and against contour 48 . This moves the gate out of the blocking/sealing position.
It should be appreciated that between flushes waste material will not normally stay in the trap above trap water level 34 . Thus, waste won't typically collect against contour 48 . Note also that valve cartridge 28 has a gasket 50 to help maintain a proper seal between the outer edge of the gate and the trap wall. Note further that the presence of an air pocket 54 also facilitates maintenance of the stem 52 .
During a flushing cycle, one trips a flush initiator which ultimately pivots the gate 40 out of the closed position permitting waste to rapidly evacuate through inlet 56 of the valve cartridge. It is preferred that the start of the flush water will be delayed slightly to permit most of the evacuation to occur before clean flush water starts to rinse the bowl.
After a defined period the flap valve will return to the FIG. 1 closed position, and preferably be latched in that position so that some water can be positioned in the bowl above the flap between flushes. The inlet water will then be shut off, ending the flush cycle.
Stem 52 is inserted into socket 58 , and through socket 60 for connection to a torque element (not shown) as was previously discussed. The first housing part 36 and second housing part 38 are preferably joinable along a plane approximately parallel to a direction of flow 62 . Pins 64 in second housing part 38 , and corresponding holes 66 in first housing part 36 , allow for proper alignment of the two housings 36 , 38 .
Referring now to FIGS. 6-8 , a second discharge valve 70 can be used with a toilet (not shown). It has a 90° elbow bend between the discharge outlet of the bowl and the beginning of a trap or other waste conduit.
Discharge valve 70 does not have two mirror image housing halves. Rather, there is a main housing part 72 , a covering housing part 74 . There is, however, still a pivotable gate 76 installed between the parts 72 / 74 .
Gate 76 includes an inwardly dished side 78 facing the bowl (when the valve is closed) and an outwardly dished side 80 facing the trap, where side 80 includes a contour 82 . First housing part 72 includes a recess 84 complementary in shape to contour 82 .
When gate 76 opens it pivots into recess 84 , and contour 82 positions in recess 84 . This reduces resistance to flow, and prevents waste material from collecting behind gate 76 .
Discharge valve 70 has a valve gasket 86 to help maintain a proper seal, and a shaft 88 connected to gate 76 . Note also air pocket 90 and bushings 92 . Pin 94 can connect into shaft 88 for connection to a torque element (not shown) as previously discussed.
Discharge valve 70 includes a main flow channel indicated at 96 , and air pocket 90 is located offset from main flow channel 96 and above the trap water level. Shaft 88 is inserted into bushings 92 , and placed in shaft channel 98 , where second housing part 74 constrains the flat surfaces 100 of bushings 92 , and shaft 88 , and correspondingly gate 76 , rotate within bushings 92 .
First housing part 72 and second housing part 74 are joinable along a plane transverse to direction of flow 102 , and can be connected to the toilet bowl at second housing part 74 , and to the trap at flange 104 using a variety of fasteners (not shown).
Referring now to the embodiment of FIGS. 9-11 , valve 110 can be positioned in replacement for valve cartridge 28 in fluid communication with a toilet bowl and trap. It primarily differs with respect to its seal configuration on its flap.
There is a first housing part 112 , a second housing part 114 connected to first housing part 112 , and a pivotable gate 116 mounted there between. Gate 116 includes a side 118 and a side 120 , where side 120 includes a contour 122 . Housing parts 112 , 114 include a recess 124 for tightly receiving contour 122 .
Valve 110 has a valve gasket 126 to help maintain a proper seal. There is also a shaft 128 connected to gate 116 . First housing part 112 includes an air pocket 130 . Shaft 128 is connected to housing parts 112 , 114 in air pocket 130 at sockets 132 , 134 , respectively.
Shaft 128 can be connected to a torque element (not shown) as previously discussed. Valve 110 includes a main flow channel indicated at 136 , and air pocket 130 is located offset from main flow channel 136 and above the trap water level. First housing part 112 and second housing part 114 are joinable along a plane approximately parallel to direction of flow 138 .
Valve 110 connects to the toilet bowl at flange 140 , and connects to the trap at flange 142 , and in both instances can use a variety of fasteners (not shown). Pins 144 in second housing part 114 , and corresponding holes 146 in first housing part 112 , allow for proper alignment of the two housings 112 , 114 .
Regardless of the embodiment, the flap valve can be housed in a separate cartridge unit which facilitates assembly and replacement if needed. Further, the likelihood of maintenance being needed is reduced by minimizing the exposure of the flap valve rear side to waste.
While preferred embodiments of the present invention have been disclosed, it should be appreciated that still other modifications and variations to the preferred embodiments will be apparent to those skilled in the art, and are intended to be within the spirit and scope of the invention. For example, while the trap valve could be used with a metallic bowl and/or trap, it could also be used with toilet components made of other materials (e.g. vitreous; plastics). Further, the concave/convex nature of the trap and rear side of the flap can be reversed.
Therefore, the present invention is not to be limited to just the described most preferred embodiments. To ascertain the full scope of the invention, the claims which follow are referenced.
INDUSTRIAL APPLICABILITY
The invention provides toilets which have a discharge valve controlling flow from the bowl to the trap, where the discharge valve is designed to reduce impingement on water flow during the flush cycle. | Disclosed are valve assemblies for controlling flow from a toilet bowl to a trap way. In one form there is a cartridge unit in which a pivotable gate is mounted. The gate can swing from a blocking/closing position to a position in which it is essentially hidden away in a recess out of the main flow path. The surface of the gate facing the bowl is inwardly dished to further facilitate flow optimization. | 4 |
BACKGROUND OF THE INVENTION
This invention relates generally to hot air heating systems and, more particularly, to a support structure for a tubular heat exchanger element therein.
In rooftop air conditioning systems which have been traditionally used to condition the air being provided to the building by a way of ducts, the air is cooled during the warmer seasons and heated in the cooler seasons. In such systems, heating is provided by way of gas burners incorporated into the unit such that the rooftop unit can provide the full heating and cooling needs for the building. Such a unit is called a year-round, packaged, air conditioning system.
Where gas is used to provide the supplementary heat in such a system, the heat exchanger apparatus by which the heat is transferred from the gas fired burners to the indoor air stream comprises a plurality of multi-path tubes disposed in parallel relationship in the indoor air stream. The tubes are preferably suspended in a predetermined location within the indoor air stream such that the heat transfer efficiency is optimized. It is therefore necessary to provide proper support structure for the installation, placement and support of these tubes within the unit. In order to adequately perform its function, the supporting structure should have the strength and integrity to not only prevent movement and/or vibration of the tubes during operation, but should also be capable of maintaining the proper alignment during shipping and installation of the system. On the other hand, since the support structure must necessarily be placed within the indoor air stream, the cross sectional area of the support structure is preferably minimized so as to reduce the resistance that is offered to the flow of the air stream.
Another consideration that is given to the heat exchanger support structures is that of ease of installation into the system. One approach has been that of employing a sheet metal plate with a plurality of holes formed therein for receiving the tubes of the heat exchanger. These tubes are individually laced into the opening of the plates, and then the plates, with the installed tubes, must be fastened within the housing by way of welding or the like. Such an assembly process is difficult and time consuming. Further, such a plate tends to offer substantial resistance to the flow of air across the heat exchanger tubes.
It is therefore an object of the present invention to provide an improved heat exchanger support apparatus.
Yet another object of the present invention is the provision for a heat exchanger support structure that is rigid and sturdy, but one which offers little resistance to air flow across the tubes.
Still another object of the present invention is the provision for installing heat exchanger tubes into a heating unit in an efficient and simple assembly process.
Yet another object of the present invention is the provision for a heat exchanger support structure that is economical and practical to make and yet effective and reliable in use.
These objects and other features and advantages become more readily apparent upon reference to the following description when taken into conjunction with the appended drawings.
SUMMARY OF THE INVENTION
Briefly, in accordance with one aspect of the invention, the heat exchanger tubes of a gas fired heating system are supported by way of wire-formed brackets on either side thereof, one bracket being rigidly secured to and supported by the system framework and the other being movably spring loaded in place, in safety pin fashion, to rigidly secure the heat exchanger tubes therebetween. The wire formed brackets provide positive placement and positional stability while offering little resistance to the flow of indoor air there over.
In accordance with another aspect of the invention, the brackets are wavy in form to correspond to the shape of the tubes that are disposed in parallel relationship therebetween.
By yet another aspect of the invention, the moveable bracket is secured to the fixed bracket by way of hooks on either end of the movable bracket, with one hook being secured in a slot at one end of the fixed bracket and the other hook being secured in a slot at the other end of said fixed bracket by overcoming the spring bias of the wire formed piece to thereby maintain the heat exchanger tubes sandwiched therebetween in a tightly installed condition.
In the drawings as hereinafter, described, a preferred embodiment is depicted; however, various other modifications and alternate constructions can be made thereto without departing from the true spirit and scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a rooftop, year-round unit with the present invention incorporated therein.
FIG. 2 is a partial end view thereof showing the heat exchanger support apparatus of the present invention.
FIG. 3 is a perspective view of the lower member of the heat exchanger tube support.
FIG. 4 is a side view of the upper member of the heat exchanger tube support.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, the invention is shown generally at 10 as installed for the purpose of supporting one end 11 of a plurality of heat exchanger tubes 12 in a year-round, roof top air conditioning unit 13. The unit 13 has a condenser coil (not shown) in one end 14 thereof and an evaporator coil 16 in the other end thereof, with the two being interconnected in a conventional manner to provide a complete refrigeration circuit, with the coil 16 acting as an evaporator coil to cool the air during warmer ambient conditions and as a condenser coil to warm the returned air during cooler ambient conditions. The return air is caused to flow through the coil 16, in a draw-thru manner, by way of a blower 17 which is driven by a motor 18.
The unit shown is a so-called convertible unit which can be used either in the downflow or in the side discharge mode. If in the downflow mode, the opening 19 is covered and the return air flows, in the direction indicated by the arrow A, through the lower opening 21, through the coil 16, through the blower 17, through the heat exchanger chamber 22 and out the lower discharge opening 23 to the space to be heated/cooled as indicated by the arrow B. The side discharge opening 24 is closed off in such a downflow installation
In a side discharge installation, the openings 21 and 23 are closed off and the return air enters the opening 19 and, after passing through the heat exchanger chamber 22, exits the side discharge opening 24 to return to the space to be heated/cooled.
During the cooling mode of operation, the heat exchanger tubes 12 are not functional. Similarly where the ambient temperatures are moderate such that the heat pump function of the unit is sufficient to provide the needed warmed air, the heat exchange tubes 12 are inoperable. However, at lower ambient temperatures where it is necessary to add supplementary heat, gas burners (not shown) located near the other ends of the heat exchanger tubes 12 are actuated to heat the air which is caused to flow through the tubes 12 by way of an inducer. The return air is then heated as it flows over the outer surface of the tubes 12, prior to being discharged through the opening 23 or 24.
It will be seen that as the heat exchanger tubes 12 extend out into the heat exchanger chamber 22, there is a need to support their one ends 11, both for preventing movement and dislocation during shipping and installation, as well as from vibratory movement caused by the flow of air thereover during operation. At the same time, it will be understood that, because of the need to flow relatively large volumes of air over the tubes 12, it is desirable to have as little additional structure as possible since any such supporting structure will tend to offer resistance to the flow of air through the chamber 22. The present invention is therefore designed to provide the required support while at the same time offering little resistance to the flow of air over the tubes.
Referring now to FIG. 2, the support structure of the present invention is indicated generally at 24 and comprises a bottom, or supporting, element 26 and a top, or securing, element 27. The bottom element 26 is generally U-shaped in form with upstanding legs 28 and 29 interconnected by a cross member 31 which is wavy in form so as to register with the individual tubes 12 in a nesting manner. The upstanding legs 28 and 29 are secured by appropriate fasteners or the like, to the platform 32 which forms the upper boundary of the heat exchanger chamber 22. The top element 27 is also wavy in form to accommodate the form of the individual tubes 12 and is attached at its two ends to the upstanding legs 28 and 29 in a manner to be described hereinafter.
Referring now to FIGS. 3 and 4, where the bottom and top elements 26 and 27 are shown in more detail, it will be seen that the legs 28 and 29 have corresponding fastener plates 33 and 34, respectively, attached thereto by welding or the like. Fastener plate 33 has an elongate slot 38 formed in a lower edge 39 thereof for securing the top element 27 in the manner to be described.
The fastener plate 34 has a hole 41 formed near its lower edge 42 thereof, and a notch 43 with a small indent 44 formed in its side edge 46 thereof. Again, these are provided for securing the top element 27 thereto.
As will be seen in FIG. 4, the top, or securing element 27 comprises a wavy central portion 47, the straight end portions 48 and 49, and U-shaped hook portions 51 and 52. The U-shaped hook portions 51 and 52 terminate in ends 53 and 54, respectively. Assuming now that the bottom element 26 has been secured in place to the upper platform 32, in a supporting relationship with respect to the heat exchanger tubes 12, the top element 27 is installed as follows. The U-shaped hook portion 52 is installed such that a part of the straight end portion 49 rests in the indent 44 of the notch 43, and the end 54 of the hook portion 52 is inserted into the hole 41 of the fastener plate 34. The top element 27 is then biased downwardly over the upper surfaces of the heat exchanger tubes 12 until the other end 53 clears the lower edge 39 of the fastener plate 33 such that it enters the elongate slot 38 and springs upwardly to lock it into place in a manner similar to that exhibited by a safety pin. The spring tension that remains in the top element 27 then acts to hold that element in its fixed position.
While the present invention has been disclosed with particular reference to a preferred embodiment, the concepts of this invention are readily adaptable to other embodiments, and those skilled in the art may vary the structure thereof without departing from the essential spirit of the present invention. | Support for the heat exchanger tubes of a gas-fired, year round air conditioning unit are provided by a pair of interlocking, wire frame elements that sandwich the tubes therebetween and are, in turn, securely attached to the frame structure. The two elements are biasingly interlocked in a safety pin fashion, with the combination providing adequate support while, at the same time, offering little resistance to the flow of air over the supported tubes. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to a device for automatically detecting the end of a web, or of a break in the web, and for splicing therewith a new web. More particularly, the invention is intended for use in corrugated cardboard installations having a feed roller for feeding a web roll and preparing a new web roll for feeding through the installation when the first has been exhausted or breaks.
2. Description of the Prior Art
Corrugated cardboard installations with which the invention is intended for use generally include a control device which is movable, in dependence upon the feed web roll, into a state of readiness for automatic activation of a web-splicing operation. Such devices include web-sensing means which activate a control device to initiate splicing when the end of the web is reached or in the event a break in the web occurs. The control device controls operation of web-splicing means which include a web brake having a web storage space from which a fresh web supply is withdrawn during the web-splicing operation.
In order to achieve continuous feed of strip material to a processing machine, it is necessary to attach to the web which is being run to the machine on a first web roll a second web on a new supply roll at precisely the right time before the first web roll is exhausted. In order to keep waste of web material at a minimum, the first web roll should be unrolled as far as possible before the second web is attached.
A problem common to running a web of material through a processing machine is that the unused turns of web material at the end of the web roll may become damaged on the outer edges thereof, such that the web will tear before the roll is completely empty. After such a break in the web, the web must be re-fed into the processing machine resulting in down time of the machine. Furthermore, there is always a considerable amount of waste when a break occurs. It therefore is desirable to effect a web splicing operation at a time when there is as little as possible unused material on the web roll, and yet not too late such that a web break or tear may occur. A consideration in this regard is that when paper webs of relatively low quality are used in corrugated cardboard installations, the likelihood of a break near the end of the roll is high; even the slightest damage to such webs may result in breaking of the web.
It is known to employ devices for automatically splicing web material in web feeding installations. One such device is disclosed in U.S. Pat. No. 3,891,158 in which a control device is activated when the web roll reaches a given coil diameter. At the same time, the speed of the web running off the roll is slowed by a brake. At a subsequent work station, operations on the web supply continue. Sensors monitor the web which is travelling off the roll at decreased speed and detect any break or the end of the web. After the detection of such a break or the end, the feeding web is fully braked and stopped and the beginning of the new web is brought to the running-out end and attached to it. Thereupon the brake is released and the new web attached to the old web end is drawn off with increasing speed. The disadvantage with the patented device is that it requires extensive control equipment, as well as a large amount of web storage area. Additionally, such known devices are not capable of detecting web tears which may start at the edge of the web. If a web tear, as opposed to a break, is not immediately detected, activation of the web splicing process will take place too late. In such instances, automatic splicing operations are not practicable.
SUMMARY OF THE INVENTION
The purpose of the present invention is to improve upon the aforesaid known device in such a way that web splicing operations take place even in the case of a tear in the web edge. The invention also provides a construction which is less complex and thus cheaper than the prior known device; further, the invention provides for web storage which requires less space than in the prior device.
The invention solves the aforementioned problems by providing a web-sensing device having mutually opposed sensors positioned adjacent each web edge so as to detect web defects in the form of web edge tears. Such device enables timely activation and completely automatic execution of web splicing even when low quality web material is in use.
Further, in order to automatically determine the proper location of a web edge in the case of varying widths of a paper web, in addition to detecting a web edge tear, in another form of the invention the web-sensing device includes a photoelectric sensing system in which pairs of sensors are positioned adjacent to the web edge. For this purpose, each sensor pair is displaceable by a correction member from a first base position transverse to the running direction of the web, into a second sensing position. In this manner it is possible for the sensing device to be automatically adjusted to any web width and at the same time the sensing device detects any web edge tears.
According to a further aspect of the invention, the control device is moved into its readiness stage by a pre-adjustable sensor which reacts to the coil diameter of the supply web roll. Preferably, such movement of the control device is effected by a photoelectric sensor.
Additionally, the invention provides for decreased storage space required for the paper web supply. In this regard, the output of the electrical control device is connected to a following processing machine whose operating speed is reduced to a preselected value upon emission of the preparatory signal, and is again increased at the end of the web-splicing operation.
Other objects of the invention will occur to those skilled in the art as a description of the invention proceeds in connection with which a preferred embodiment is illustrated in the accompanying drawing and set forth in the accompanying specification.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic side view of a web splicing apparatus in a corrugated cardboard installation;
FIG. 2 is a front view thereof, and
FIG. 3 is an electrical block schematic thereof.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, the splicer 1 in a corrugated cardboard installation comprises a feeder roller 2, a web storage space 3 and a device for stopping, splicing and separating the web 4.
The feeder 2 may be of any suitable known design. As shown, the feeder 2 consists, for example, of a feeder roller support 5 with two vertical sides 6 rigidly connected to each other. Positioned between the sides 6 are pivoting supports 7 which are connected to each other by means of bearing shafts 8. Parallel arms 9 are disposed on the bearing shafts 8. Facing rotating cones 10 are located at the free ends of the arms 9. The rotating cones 10 are operable together and acted upon by a braking device 11, the braking power of which is adjustable. The roller 12 of the feeding web 13 is centered by the cones 10. A new roll 14 of web material rests in preparation on the cones of the arms 9'. The feeding web 13 is trained over a guide roller 15 of the feed roller 2 to a guide roller 16 in the web storage space 3. The web 13 runs in the form of a loop from the guide roller 16 in the web storage space 3 over a storage loop 17 to an additional guide roller 18. The web 13 then leaves the storage space 3 and moves to another cardboard processing machine, not shown.
The movable storage roller is supported in a carriage 19 which runs along the storage space 3, pulled by a drive mechanism (not shown), e.g., a hydromotor or the like, into the storage space shown in FIG. 1 (left end of the storage space); in this position the carriage 19 is held by a releasable catch, not shown.
The web holding, splicing and separating device 4 has a vacuum brake 20 positioned in front of the guide roller 16 of the web storer for the feeding web 13, and a transverse cutting device 21, the operation of which is controlled by an electrical control device. The electrical control device also controls the catch device of the storage carriage 19.
The web 22 of the prepared new roll 14 is led to a pressure roller which acts as a splicing device and which is supported on pivoting arms 24. The pivoting arms 24 can be pivoted, when released by the electrical control device, in the direction of the arrow (FIG. 1), counterclockwise, whereby the end 25 of the web 22, which is provided with an adhesive strip, can be fastened to the feeding web 13.
The diameter of the roll 12 of the feeding web 13 is sensed by a sensing device, consisting of a photocell with light source 26 and a reflector in the form of a mirror 27. The photocell with light source 26 may be movable to enable adjustment to a pre-selected coil diameter. As soon as the predetermined coil diameter has been reached, the beam emitted by the light source reaches the reflector 27 and is reflected to the photocell 26, whereby the photocell 26 emits a signal to the control device. Once the signal with respect to pre-determined coil diameter is received by the control device, the device is in a ready state for execution of an automatic splicing operation to be effected when an additional sensing device activates the splicing operation.
The additional sensing device consists of photocells with light sources 28, 29 which are positioned at a distance from each other adjacent to each edge 30 and 31 respectively of the web. There is a reflector 32, 33 for each photocell and light source pair 28, 29. The reflectors are attached to the arms 9 of the feed roll support 5 and lie transverse to the long axis of the feeding web 13 and extend a certain distance into the web. Each photocell and light source pair 28, 29 is connected to a correction element 34, 35 which is controllable by the electrical control device. These correction elements 34, 35 can shift the photocell light source pairs 28, 29 from their first position I shown in FIG. 2, to an outer second position II and back again.
The photocells with light sources 28, 29 and correction elements 34, 35 are installed on a traverse 36 disposed transverse to the web. The photocell light sources 28, 29 are attached firmly to slides carried on said traverse 36.
As best seen in FIG. 2, the vacuum brake consists of a perforated suction tube 20', over which the feeding web 13 is led. One end of the tube is connected to a blower 20 which can be switched on and off. On and off operation of the blower 20 is controlled by the electrical control device.
According to the block schematic shown in FIG. 3, the photocell 26 can give a signal over the circuit 40 to the electrical control device 41 when the pre-selected coil diameter of the web roll 12 is reached and light from the reflector 27 is reflected to the photocell 26. The electrical control device 41 is then prepared for the execution of an automatic splicing operation.
The preparatory condition of the electrical control device 41 is possible only if the additional electrical control device 42 has given an output signal to the control device 41; this occurs when all the devices necessary for the splicing operation are in their readiness positions. These readiness positions, e.g., storage output positions, etc., are fed via the inputs 44 to the control device 42.
Preferably, upon emission of a signal by the photocell 26, the control device 41 delivers a signal to the processing machine behind the storer 3. The signal is transmitted through the circuit 39 and the control device 42, for the purpose of reducing the working speed of the processing machine.
Upon input of a signal from the photocell 26 to the control device 41, the latter releases the correction elements 34, 35, which are connected via the circuits 45, 46 to the control device. The correction elements 34, 35 move the slides 37 for the photocells 28, 29 from position I outward to position II. The pair of photocells 28, 29 adjacent to the left web edge 31 is connected to the control device 41 by means of circuits 47, 48, and the pair 28, 29 adjacent to the right web edge 30, by way of circuits 49, 50.
When the two sensor pairs 28, 29 are moved from their position I to the position II, and upon passing beyond the particular respective edge of the web 13, the respective outer photocell sensor 28 delivers a signal by way of circuit 47 or 49 to the control device 41. The action causes the control device 41 to switch off the correction elements 34 or 35, respectively. The sensor devices remain in this last-assumed position.
If, as this operation continues, the left edge 31 of the web tears as indicated at 51 in FIG. 2, the inner-located photocell 29 also receives light by reason of uncovering of the reflector 33 in this area and transmits a signal to the control device through circuit 48. This signal fully activates the vacuum brake 20, which in a given case may already be in operation under partial load, whereby the running web 13 is slowed down or stopped. The activation signal of the control device 41 is given through the circuit 52 to the supplementary control device 42. This control device 42 is in turn connected to blower 20" for the vacuum brake, or with filtered-air impellers, in such a way that the running web 13 is stopped immediately by the vacuum brake 20.
Since the feeding web 13 is braked or stopped by the vacuum brake 20, but the following processing machine 53 continues to run, the length of web necessary for the continued handling is taken from the storage space 3. The storage roller 17 moves with the storage carriage 19 from its storage position (left position) little by little toward the guide roller 18.
Simultaneously with activation of the vacuum brake 20, the pivoting drive for the pressure roller 23 is also activated by the control device 42, whereby the end of the new web 22 of the roller 14 is spliced to the stopped feeding web 13.
By time delay or sequence operation the transverse cutting device 21, which cuts off the web 13, is activated by the control devices 41, 42.
Finally, the correction members 34, 35 receive via their circuits 45 and 46 a signal to move their sensors out of position II back to position I. The pressure roller 23 returns to its original position. The web 22, which is fixed to the end of the feeding roll 23, is pulled along and thereby pulled off of the roller 14. The drive for the storage carrier 19 moves the storage roller 17 little by little back into its left-hand storage position. The following processing machine 53 is again brought up to its normal speed.
After all these devices have reached their original positions and these positions are again announced via the inputs 44 to the control device 42 as preparedness position, the automatic splicing operation is completed.
The same splicing operation is activated when the feeding web 13 is unrolled to its end without encountering a tear 51. In this case, likewise, the photoelectric sensors 28, 29 receive light when the end of the web passes the reflectors 32, 33 and activate the control device by means of their signals.
It is to be understood that instead of photoelectric sensors 26, 27, 28, 29, 32 and 33, other sensing elements, e.g., mechanical mechanisms, can be used. | Apparatus for automatically detecting the end of or a tear in a web travelling through a corrugated cardboard installation or the like. A web sensing device having mutually opposed sensors positioned adjacent each edge of the web detects web tears or the end of the web. Automatic execution of a web splicing operation thereupon is effected by a control device which activates web-splicing means. | 1 |
PRIOR ART STATEMENT
Kirk-Othmer, Encyclopedia of Chemical Technology, 3d ed., Vol. 17, pp. 426 et seq., contain background information and detailed discussion of furnace grade phosphoric acid and wet-process phosphoric acid.
U.S. Pat. No. 2,650,157 Cochran teaches the chemical brightening of aluminum using furnace or thermal acid mixed with nitric or acetic acid.
U.S. Pat. No. 2,678,875 Spooner teaches the chemical brightening of aluminum using furnace acid plus nitric, acetic, or silicic acid. At operating temperature, this bath is viscous.
U.S. Pat. Nos. 2,593,448 and 2,593,449 (both to Hesch) teach the chemical brightening of aluminum using a composition consisting primarily of water with traces of furnace grade phosphoric acid, nitric acid, HF, CaO 3 , and Cu(NO 3 ) 2 .
The present invention teaches the use of wet-process phosphoric acid in a solution containing primarily phosphoric acid and does not require removal of the natural impurities found in the starting acid. The bath is not viscous at the operating temperature and does contain trace amounts of other substances which enhance the chemical brightening process.
UTILITY STATEMENT
The aluminum brightening bath of this invention is a useful, economical, and efficient brightening reagent for aluminum.
BACKGROUND
The conventional means of polishing or brightening aluminum uses phosphoric acid produced by the thermal process, known as the furnace process. This acid is manufactured in small quantities from elemental phosphorus, is more expensive and considerably more pure, and is usually reserved for processes requiring high purity phosphorus.
Wet process acid, on the other hand, is manufactured in large quantities directly from phosphate ores, is low cost and low purity, and is used primarily for fertilizers purified with a technical grade of phosphate salts.
Usually wet-process phosphoric acid is supersaturated with a group of sludge-forming components (Fe, Al, Ca, Mg, Cu, F, Na, K, Si, and SO 4 ) that must be removed if purified phosphate salts are needed. However, ths purification process is difficult and always results in the loss of phosphate values. Additionally, wet-process phosphoric acid is purified by solvent extraction, utilizing a number of different solvents including alcohols, such as amylbutylalcohol, or various ethers. These solvents tend to leave organic residues in the purified wet acid which react with the nitric acid in an aluminum polishing bath. For this reason, the aluminum cleaning industry customarily uses initially purer furnace grade phosphoric acid in its metal treatment processes due to the lower level of impurities.
The present invention teaches a new phosphoric acid bath and a new method for brightening aluminum. The primary acid is not the furnace acid customarily used, but wet-process phosphoric acid. This invention also teaches a method of producing an acid bath suitable for cleaning aluminum that is operable without the expensive extraction processes necessary to remove contaminants from wet-process acid. These contaminants, the ones listed above and in particular Mg, Fe, and Al, have heretofore reduced the effectiveness of conventional aluminum brightening baths. This invention also teaches a new aluminum brightening acid bath that does not require purifying the bath of all organic residues oxidizable in nitric acid. Other objects and advantages of this invention will become obvious to those skilled in the art from the following description.
In the typical process, an aluminum piece is immersed in a polishing bath for 0.5 to 4.0 minutes at a temperature of 102° C. to 112° C. The brightening bath contains approximately 80-50% phosphoric acid and 3% nitric acid plus certain enhancers and defoaming agents.
The actual brightening of the metal surface is an electrochemical reaction--aluminum dissolves at the anodic sites and hydrogen evolves at the cathodic site. Microscopic galvanic cells cause an etching of the surface which, when properly controlled, produces a brightened surface. Chemical polishing occurs as minute protrusions on the surface of the metal are attacked, resulting in an increase in luminous reflectance. One method of controlling the polishing is the addition of heavy metal ions such as copper. These ions are cathodically reduced, forming a thin uniform precipitate on the surface of the aluminum.
Most brightening processes in the United States today use baths whose main constituent is phosphoric acid, a small amount of nitric acid, and a trace amount of copper. The present invention teaches a more complex bath, containing a variety of metal ions with 2 + and 3 + valences as well as specific amounts of sulfate and fluoride ions. The sulfate and fluoride ions inhibit the anodic attack while some of the metal ions are cathodically reduced to form a protective film on the aluminum surface.
DESCRIPTION OF THE INVENTION
Contrary to the conventional method of brightening aluminum using furnace grade phosphoric acid, the present invention uses a wet-process phosphoric acid as the basis for the brightening bath. Certain impurities common to wet-process phosphoric acid--the oxides of Fe, Cr, Al, and Mg--have, in the past, prevented practitioners from using wet process acid in aluminum brightening processes. By adhering to the following parameters, wet-process phosphoric acid is converted to an effective aluminum brightening reagent: (a) the bath must contain less than about 500 ppm organic substances oxidizable in nitric acid; (b) the brightening bath must not contain greater than about 3% dissolved metallic ions of Mg, Fe, and Al (as expressed in Al equivalents); (c) Cu ++ is present in the amount of 80-150 ppm.
Phosphoric acid of different strengths may be used as a starting material and is then diluted. Based on P 2 O 5 (70%), the preferred acid is H 3 PO 4 , orthophosphoric acid. Increasing the P 2 O 5 to stronger concentrations alters the acid from oily to a mixture of glossy and crystalline material. The actual acid is in the form of polyphosphoric acid, either di-, tri-, or tetra-phosphoric acid, also known as condensed phosphoric acid. Diluting the above acids from 80 to 50% calculated as P 2 O 5 (and preferred 70 to 54%) brings the concentration within the tenor of the present application.
Kirk-Othmer, Encyclopedia of Chemical Technology, Vol. 17, 3d ed, p. 435, defines wet-process phosphoric acid as "manufactured by digestion of phosphate rock (apatite forms) with sulfuric acid; H 3 PO 4 is separated from the resultant calcium sulfate slurry by filtration. Fresh wet-process phosphoric acid is supersaturated with a group of sludge-forming components (Fe, Al, Ca, Mg, Cu, F, Na, K, Si, and SO 4 ) that must be removed to produce high quality phosphate salts." This invention uses the wet-process phosphoric acid (starting concentration 94-70%) prior to the removal of the sludge-forming components (a process which is difficult, uneconomical, and produces a loss of phosphate values). The three metals that are primary constituents of wet-process phosphoric acid are Al, Fe, and Mg. These metals are usually present as Al +++ , Fe ++ , Fe +++ , or Mg ++ . A variety of processes for the removal of these metals exist; however, the purification process is costly and inefficient. This invention, however, obviates the need for removal of these metals, provided that the original wet-process acid contained sufficiently low concentrations. Maintaining a total Fe, Al, and Mg concentration below about 3% by weight produces an effective brightening bath; when these metals exceed the 3% amount, the bath crystalizes and/or produces inferior brightening finishes.
The wet-process acid, containing the sludge-forming elements recited above, is filtered and then diluted with water from a concentration of about 70% P 2 O 5 to about 50-55% P 2 O 5 . Diluting the acid in such a manner precipitates F to such an extent that the phosphorus to F ratio increases from about 35:1 to 100:1 to even as high as about 300:1. The acid is again filtered, producing a clarified, low fluoride phosphoric acid suitable for aluminum brightening. This second filtering step removes solids from the acid which would result in pitting the surface of an aluminum piece.
With reference to other ions, optimum brightening occurs when the bath contains 570-640 ppm F - , 130-170 ppm Cr 3+ and 80-130 ppm Cu 2+ . The chromium affects the reduction of the oxidizing agents in the bath. The copper is considered an enhancer, stimulating the electrochemical process and improving brightness.
Nitric acid (concentration 68-73.5%) is added after the copper in a preferred amount of about 3% and an operational amount of 1-10%. The addition of nitric acid, however, presents some problems which are overcome by maintaining the level of organic compounds in the acid bath at a low level. Because the oxidizing strength of the polishing bath is very high, nitric acid readily attacks free carbons and organic compounds, thus reducing the brightening qualities of the bath. Accordingly, the level of organic substances oxidizable by nitric acid must be maintained below about 500 ppm.
A list of the ingredients follows:
______________________________________Phosphoric acid 80-50% by weightNitric acid 1-10% by weightSulfate ions 1.8-3.3% by weightFluoride ions 570-1640 ppmChromium (Cr.sup.3+) 130-170 ppmCopper (Cu.sup.2+ or Cu.sup.3+) 80-130 ppmOrganic substances <500 ppmFe, Mg, Al <3% by aluminum equivalentsFe (Fe.sup.3+ or Fe.sup.2+) 0.29-0.59%Fume Inhibitors______________________________________
Once these ingredients are added and sufficiently mixed, the bath's temperature is raised to an operating temperature of about 90°-120° and the specific gravity maintained at about 1.6-1.8. Immersion time for an aluminum sample can very between about 0.5 to 4.0 minutes.
EXAMPLE 1
A typical brightening bath was prepared starting with 80% wet-process phosphoric acid diluted with water to 58% concentration. To the acid was added 0.54% Fe +++ , 150 ppm Cr +++ , and 600 ppm F - . To this solution was added 100 ppm Cu ++ , 3.0% HNO 3 , and a small quantity of fume inhibitor. The specific gravity of the solution was about 1.72. The temperature was maintained at 105° C., and the aluminum samples were immersed for 3 minutes. This bath continued to function as an excellent polishing bath until the concentration of Al plus Fe reached 3%.
EXAMPLE 2
The above bath was prepared except that 0.38% Al, 0.55% Fe, and 0.25% Mg were present as contaminants in the raw acid. After adding 2.25% Al--producing a total concentration of the three metals to 3.43%--the resulting bath produced poor polishing.
EXAMPLE 3
Similarly, when 2.50% Al was added to give a total concentration of the three metals of 3.68%, the resulting bath produced very poor polishing.
EXAMPLE 4
In separate trials, 1.90% Al, 1.70% Al, and 1.50% Al was added. In each case the resulting bath produced good to very good polishing.
The results of these tests are charted below:
______________________________________Initial Con-centration in Total Con-Wet-Process centrationAcid Additive of Metals Results______________________________________0.38% Al0.55% Fe 2.25% Al 3.43% Pour0.25% Mg 2.50% Al 3.68% Very poor 1.90% Al 3.08% Good 1.70% Al 2.88% Very good 1.50% Al 2.68% Very good______________________________________ | This invention teaches the development of a chemical reagent useful as an aluminum brightening bath. The reagent's composition is primarily wet-process phosphoric acid to which has been added small quantities of nitric acid, copper, and optionally traces of several other substances. The reagent does not require expensive removal of the natural impurities found in wet-process phosphoric acid. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to a hydrostatic drive system for a vehicle, such as an industrial truck, with a hydrostatic traction drive system, a hydraulic work system and a hydraulic steering system.
2. Description of the Prior Art
On known hydrostatic drive systems for vehicles, such as for a fork-lift truck or a wheel loader, the hydrostatic drive system generally has an adjustable-delivery pump and at least one drive motor connected to the pump in a closed circuit. To provide power to the hydraulic work system, there is an additional pump with a constant delivery volume which operates in an open circuit and sucks hydraulic fluid from a reservoir and, when the hydraulic work system is not in operation, returns the hydraulic fluid to the reservoir. The steering system is supplied with hydraulic fluid by an additional pump that also has a constant delivery volume and is operated in an open circuit.
On such drive systems, therefore, a plurality of pumps, for example three, are required to supply the hydraulic energy users with hydraulic fluid. The drive system therefore takes up a great deal of space. Additionally, all the pumps are continuously driven by a drive motor, although as a rule only one or two pumps are used simultaneously during the operation of the vehicle. That results in corresponding idle losses which in turn result in a low efficiency for the drive system. The continuous operation of all the pumps also results in unnecessary wear.
Therefore, it is an object of this invention to provide a hydrostatic drive system that is compact and in which the energy utilization in the drive system is improved.
SUMMARY OF THE INVENTION
The invention teaches that this object can be accomplished if there is one hydraulic pump with an adjustable delivery volume operating in an open circuit to supply the traction drive system, the hydraulic work system and the steering system of the vehicle. The teaching of the invention is therefore to provide, instead of a plurality of pumps, a single pump that is operated in the open circuit and that is used for the simultaneous supply of the traction drive system, the hydraulic work system and the steering system. The unit is compact as a result of the elimination of the additional pumps. The use of only one pump with an adjustable delivery volume also makes it possible to adjust the delivery current or output of the pump to meet the delivery requirements of the users in corresponding operating situations, which results in an improved utilization of energy.
In one configuration of the invention, the hydraulic pump is connected to a delivery line in which there is at least one traction drive control valve. Upstream of the traction drive control valve in the delivery line of the pump, there is a priority valve for the hydraulic work system and upstream of the priority valve of the hydraulic work system there is a priority valve for the steering system. In the delivery line of the pump, therefore, first there is the priority valve of the steering system, the priority valve of the hydraulic work system and finally the traction drive control valve. Top priority is therefore given to the supply of hydraulic fluid to the steering system. The steering system, which is a safety-relevant component of a vehicle, is therefore supplied with sufficient hydraulic fluid under all operating conditions so that the vehicle can be steered at all times. After the steering system, the hydraulic work system is supplied with hydraulic fluid, thereby guaranteeing that under conditions in which the traction drive system and the hydraulic work system are operated simultaneously, the hydraulic work system will be supplied with hydraulic fluid first. The hydraulic fluid not required by the hydraulic work system will be available to supply the traction drive system. As a result of the priority supply of the steering system and the hydraulic work system, it is thereby possible to use a pump, the delivery volume of which is only slightly greater than the delivery volume of a pump of the prior art used to supply the traction drive system.
On a drive system with a feeding device for the hydrostatic traction drive system, one configuration of the invention provides that a feed line of the feeder device is connected to the delivery line between the priority valve of the hydraulic steering system and the priority valve of the hydraulic work system. The feeder device guarantees that any oil that leaks out of the hydrostatic traction drive system can be made up. Thus, there will always be sufficient hydraulic fluid available. The traction drive system is thereby protected from cavitation and prevented from running dry, because such conditions can lead to major damage to the traction drive system. As a result of the location of the feed line downstream of the priority valve of the steering system, the feeding device is supplied with second priority. The hydraulic work system is thereby pressurized with third priority after the steering system and the feeding device. The invention thereby guarantees that any lack of hydraulic fluid in the traction drive system will be made up, and cavitation in the drive motors is prevented.
In this case, it is particularly advantageous if the steering system is realized in the form of a load-sensing steering system. The priority valve for the steering system can be pressurized in the direction of a switching position that connects the delivery line with the inlet line of the steering system by a spring and the load pressure of the steering system and can be pressurized in the direction of a switching position that can bring the delivery line into communication with the inlet line of the hydraulic steering system and with the delivery line leading to the priority valve of the hydraulic work system by the pressure in the inlet line of the steering system. A steering system realized in the form of a load-sensing steering system does not require a constant delivery current. When the steering system is actuated, the steering system extracts hydraulic fluid only out of the feed line of the pump. Such a priority valve guarantees that the inlet line of the steering system will be pressurized with hydraulic fluid under all operating conditions. Only when the pressure level defined by the spring or when the steering system is actuated by the spring and the load pressure of the steering system is exceeded are the users located downstream of the priority valve, i.e. the feeder device, the hydraulic work system and the traction drive system, supplied with the hydraulic fluid not required by the steering system.
The priority valve for the hydraulic work system can with particular advantage be pressurized in the direction of a switching position connecting the delivery line with the inlet line of the hydraulic work system by a spring and the load pressure of the hydraulic work system, and in the direction of a switching position that can bring the delivery line into communication with the inlet line of the hydraulic work system and with the delivery line leading to the traction drive control valve by the pressure in the inlet line of the hydraulic work system. The priority valve of the hydraulic work system therefore guarantees in a simple manner that the hydraulic work system will be supplied with hydraulic fluid before the traction drive system.
It is particularly appropriate if there is a pressure reducing valve in the feed line. The pressure reducing valve can reduce the pressure in the feed line to conventional values in a simple manner.
With particular advantage, the feed line can be connected downstream of the pressure reducing valve to a return line of the steering system and with an outlet line leading to the reservoir. As a result of the connection of the feed line with the return line, sufficient hydraulic fluid is present in the feed line. In addition, the return fluid from the steering system does not flow into the reservoir unused, but is used to supply the feeder device. That results in an improved utilization of energy in the drive system. As a result of the connection of the pressure reducing valve to the reservoir, it is possible to limit the pressure in the feed line to a definable maximum value, whereby when the specified pressure level has been reached, the feed line is connected to the reservoir. Hydraulic fluid not required by the feeder device can therefore flow from the return line of the steering system to the reservoir.
In one embodiment of the invention, the traction drive control valve is realized in the form of a throttling, spring-centered directional control valve with a closed middle position that, depending on its flow status, opens an inlet orifice and an outlet orifice, whereby the traction drive control valve is connected to the delivery line and an outlet line that is connected to the reservoir, and to the delivery lines of the traction drive system as well as a load pressure signal line. Such a traction drive control valve makes it possible, in a simple manner, to define the speed and direction of travel of the vehicle, and to control the braking process.
It is particularly advantageous if, in the outlet line from the traction drive control valve, there is a flow regulator which, in a first switching position, interrupts the connection between the outlet line of the directional control valve and the reservoir, and in a second switching position connects the outlet line with a reservoir, whereby the flow regulator can be pressurized toward the first switching position by the pressure in the delivery line upstream of the traction drive control valve, and toward the second switching position by the force of a spring and the pressure in the outlet line downstream of the traction drive control valve. The flow regulator regulates the flow of hydraulic fluid flowing back from the traction drive system to the reservoir. The opening cross section of the outlet side of the traction drive control valve thereby forms the measurement throttle of the flow regulator. Under operating conditions in which the flow of hydraulic fluid in the outlet side of the traction drive system exceeds the flow of hydraulic fluid set at the measurement throttle of the traction drive control valve, the flow regulator is pressurized toward the first switching position and thus builds up a braking pressure. During braking, therefore, the vehicle retains the speed set on the traction drive control valve. In this case, it is particularly appropriate if the flow regulator is integrated into the spool valve of the traction drive control valve. Consequently, the traction drive control valve and the flow regulator occupy little space.
The inlet orifice and the outlet orifice of the traction drive control valve are preferably substantially the same size. It thereby becomes possible, in a simple manner, in any switching position of the traction drive control valve, to ensure that the quantity of hydraulic fluid flowing to the traction drive motors is equal to the quantity of hydraulic fluid flowing out of the traction drive motors, and thus the vehicle can be operated at the desired speed set on the traction drive control valve.
It is particularly advantageous if a precision control range is provided on the traction drive control valve, in which the outlet orifice is smaller than the inlet orifice of the traction drive control valve in response to a small modulation of the traction drive control valve. As a result, there is an initial pressure in the traction drive system, which means that a precise control of the vehicle becomes possible at low speeds of travel.
To minimize the losses at higher speeds of travel, the invention teaches that in the range of the maximum deflection of the traction drive control valve, the outlet orifice of the traction drive control valve can be larger than the inlet orifice of the traction drive control valve.
In one embodiment, the traction drive control valve can be actuated hydraulically, whereby downstream of the pressure reducing valve, a control pressure line branches off from the feed line and can be placed in communication with the traction drive control valve. In this case, the control surfaces of the traction drive control valve are pressurized by a control pressure, whereby the hydraulic fluid required for the purpose is taken from the feed device. The pump is therefore also used to supply the control circuit of the traction drive control valve, whereupon it becomes possible to actuate the traction drive control valve with little added effort.
The invention teaches that it is particularly advantageous if, in the control pressure line, there is a control valve that can be actuated by means of an actuator element and is effectively connected to the traction drive control valve for feedback on the deflection of the traction drive control valve. The control valve pressurizes the control surfaces of the traction drive control valve with control pressure. As a result of the feedback on the deflection of the traction drive control valve, when the position set on the actuator element is reached, the traction drive control valve is held in the corresponding position. It thereby becomes possible, in a simple manner, to convert a desired deflection of the actuator element into a corresponding position of the traction drive control valve. Because the traction drive control valve is piloted by means of the control valve, the actuator element or elements can also be isolated from the traction drive control valve, as a result of which the flow vibrations that are generated in the traction drive control valve are not transmitted to the actuator elements. In addition, as a result of the piloting, the actuator elements are isolated from the friction forces and the flow forces in the traction drive control valve, which results in more reliable operation of the traction drive control valve.
In one refinement of the invention, a flow control valve is located in an outlet line of the control valve. It thereby becomes possible to control the current of hydraulic fluid flowing from the control valve to the reservoir. The current of hydraulic fluid flowing to the reservoir determines the speed of actuation of the traction drive control valve, which also means that the control valve can be used to achieve a desired deceleration.
For this purpose, it is particularly advantageous if, in the outlet line of the control valve, there is a bypass valve for the flow control valve that can be pressurized by the pressure in the outlet line of the traction drive control valve upstream of the flow regulator in the direction of a closed position, and by the force of a spring in the direction of an open position. It is thereby guaranteed that the deceleration will be performed only if a corresponding braking pressure has built up at the flow regulator and thus a braking action can be initiated.
It is particularly appropriate if the traction drive control valve and the control valve are realized in the form of a rotary spool valve. A control valve realized in the form of a rotary spool valve can be deflected in a simple manner by means of actuator elements. The feedback to the control valve on the deflection of the traction drive control valve can also be achieved in a simple manner.
In one refinement of the invention, on the traction drive system there is a parking brake device that has a parking brake valve and a brake line leading to the parking brake device. The parking brake valve can be actuated by means of an actuator element and the brake line is connected to the delivery line upstream of the priority valve for the steering system. The pressure in the delivery line of the pump upstream of the priority valve of the steering system is thereby available at the parking brake valve, as a result of which the parking brake device, which can be a stored energy parking brake, for example, can be released at any time.
In this case it is particularly appropriate if the parking brake valve is realized in the form of a pressure reducing valve. It thereby becomes possible in a simple manner to limit the pressure applied to release the parking brake device.
In one refinement of the invention, there is a demand flow regulator that is effectively connected to an adjustment device of the pump and that can be pressurized by a load pressure available downstream of the traction drive control valve and by a spring in the direction of an increase in the delivery current, and in the direction of a reduction in the delivery current by the pressure in the delivery line upstream of the traction drive control valve. The delivery flow of the pump can thereby be adjusted under the appropriate operating conditions to the delivery current demand of the user, as a result of which there is a high energy efficiency of the drive system, and idle losses are reduced.
It is particularly advantageous if the load pressure signal line of the hydraulic work system has a pressure relief valve that is set to the maximum pressure of the hydraulic work system. The pressure in the circuit of the hydraulic work system can thereby be limited in a simple manner.
It is particularly advantageous if, in the load pressure signal line of the steering system, there is a pressure relief valve that is set to the maximum allowable pressure of the steering system. The pressure in the steering circuit can thereby also be limited if, when the pressure relief valve responds, the pressure in the load pressure signal line is limited, and thus the priority valve is pressurized into a switching position that supplies the additional users with hydraulic fluid.
In one configuration of the invention, there is an electronic control device that is effectively connected to a speed control device for the prime mover used to drive the pump, and the speed control device of the prime mover is controlled as a function of the setpoints of the traction drive system and/or of the hydraulic work system. In the event of an actuation of the hydraulic work system or of the vehicle traction drive system, the speed of the prime mover of the vehicle and thus the quantity of hydraulic fluid delivered by the pump can also be increased as required.
For this purpose, it is particularly advantageous if, on directional control valves of the hydraulic work system, there are sensor devices that measure the deflection of the directional control valves and/or on the actuator element of the hydraulic traction drive system there is a sensor device to define a setpoint for the electronic control device. The control device can thus modify the speed of the prime mover as a function of the setpoint signals of the sensor devices.
It is particularly advantageous if the electronic control device has a reducing regulator for the speed of the prime mover, whereby there is a sensor device that measures the actual speed of the prime mover. It is thereby possible to depressurize the prime mover in the event of an overload, e.g. caused by a reduction of the delivery of the pump, and thus to prevent a stalling of the prime mover.
Furthermore, it is particularly advantageous if there is a valve that influences the adjustment device of the pump, and which can be pressurized in the direction of a reduction of the delivery current by the pressure in the delivery line upstream of the priority valve of the steering system, and in the opposite direction by the force of a spring, whereby the spring is set to the maximum operating pressure of the drive system. It thereby becomes possible to achieve a pressure cutoff by reducing the delivery of the pump when the maximum pressure is exceeded. This characteristic eliminates the need for a pressure relief valve which, when the maximum pressure is exceeded, creates a connection between the delivery line and the reservoir and thus results in losses.
It is appropriate if the demand flow regulator or the valve which influences the adjustment device of the pump can be pressurized in the direction of a reduction of the delivery current by the electronic control system. The delivery of the pump can thereby be reduced in a simple manner when there is a reduction in the speed of the drive motor.
For that purpose, it is particularly advantageous if the demand flow regulator or the valve has a proportional magnet that is connected to the electronic control system. It thereby becomes possible in a simple manner to convert a signal into a force for the actuation of the demand flow regulator or of the valve, and to adjust the pump in the direction of a reduction of the delivery flow.
BRIEF DESCRIPTION OF THE DRAWING
Additional advantages of the invention are explained in greater detail below with reference to the exemplary embodiment illustrated in the accompanying schematic drawing figure. The figure shows a circuit diagram of a drive system of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of the description hereinafter, the terms "right", "left", "top", "bottom", "front", "rear" and derivations thereof shall relate to the invention as it is oriented in the drawing figure. However, it is to be understood that the invention may assume various alternative variations and step sequences, except where specified to the contrary. It is also to be understood that the specific devices illustrated in the attached drawing, and described in the following specification, are simply exemplary embodiments of the invention. Hence, specific physical characteristics related to the embodiments described herein are not to be considered as limiting.
The drive system illustrated in the drawing figure has a pump 1 which is driven by a prime mover 2, such as an internal combustion engine. The delivery volume of the pump 1 is set by a spring-loaded piston-cylinder system 3 that acts in conventional manner on an adjustment device of the pump 1. The pump 1 works in an open circuit and sucks hydraulic fluid out of a reservoir 4 via a suction filter 72 and feeds into a delivery line 5. In this case, the reservoir 4 is thereby preferably under a certain initial pressure.
In the delivery line 5, downstream of the pump 1, there is a priority valve 6 which, in the illustrated position, connects the delivery line 5 with the inlet line 7 of a steering system 8, which is preferably a load sensing steering system. In the illustrated switching position, the delivery current of the pump 1 is fed exclusively to the steering system 8. The priority valve 6 for the steering system can be pressurized in the direction of this switching position by a load pressure of the steering system 8 conveyed in a load pressure signal line 9 and by the force of a spring 10. The priority valve 6 can be pressurized in the direction of the switching position illustrated on the right in the figure by the pressure in the inlet line 7 of the steering system 8. As soon as the pressure difference between the inlet line 7 and the load pressure signal line 9 has reached a level sufficient to overcome the force of the spring 10, the priority valve 6 is pressurized into the switching position illustrated on the right in the figure, in which the additional users are supplied with hydraulic fluid. The hydraulic fluid not needed by the steering system 8 thus flows into a delivery line portion 5a of the delivery line 5 which is located downstream of the priority valve 6. In the load pressure signal line 9 of the steering system 8 there is a pressure relief valve 50 which is set to the maximum allowable pressure in the steering system 8.
From the delivery line portion 5a, a feed line 11 branches off, and in this feed line 11 there is a pressure reducing valve 12. The pressure reducing valve 12 limits the pressure in the feed line 11 to a set, specified value. Connected to the feed line 11, downstream of the pressure reducing valve 12, there is a return line 14 from the steering system 8. The return line 14 from the steering system 8 is also connected to a line 73 to the reservoir 4. In the line 73 there is a one-way valve 74 that opens in the direction of the return line 14 and thus to the feed line 11. The pressure reducing valve 12 can also be connected with an outlet line 13 that leads to the reservoir 4. If the pressure in the feed line 11 downstream of the pressure reducing valve 12 exceeds a set or specified value, the pressure reducing valve 12 opens the connection of the feed line 11 located downstream of the pressure reducing valve 12 to the outlet line 13, as a result of which the pressure in the feed line 11 is limited to an upper value. In the outlet line 13 leading to the reservoir 4, there is a cooler 70 and a bypass valve 71 to the cooler 70.
The feed line 11 leads to a feeder device 15 of the traction drive system 16, the feeder device 15 formed by combined pressure relief and anti-cavitation valves. The traction drive system 16 consists, for example, of two traction drive motors 17a, 17b, whereby the two sides of the traction drive system 16 can be connected to one another by means of the feeder device 15. The feeder device 15 protects the drive motors 17a, 17b against overload by means of the pressure relief valves, and by means of the anti-cavitation valves makes it possible to supply the drive motors 17a, 17b with fluid from the feed line 11. In this case, the drive motors 17a, 17b are realized with a constant delivery volume, although they can also be realized with adjustable delivery volumes. It is also possible to have any desired number of drive motors.
In the delivery line portion 5a, downstream of the feed line 11, there is a priority valve 18 which, in the switching position illustrated in the accompanying drawing, connects the delivery line portion 5a with the inlet line 19 of a hydraulic work system 20. In the switching position illustrated on the right in the figure, the delivery line portion 5a can be connected to the inlet line 19 and a delivery line portion 5b downstream of the priority valve 18. The priority valve 18 can be pressurized in the direction of the illustrated switching position by the pressure in a load pressure signal line 21 of the hydraulic work system 20 and the force of a spring 22. The priority valve 18 can be pressurized in the direction of the other switching position by the pressure in the inlet line 19. The delivery current of the pump 1 in the delivery line portion 5a is thus divided between the inlet line 19 and the delivery line portion 5b as soon as the pressure difference between the pressure in the inlet line 19 and the load pressure signal line 21 is sufficient to overcome the force of the spring 22. The hydraulic work system 20 has a directional control valve 64 for each user, such as the lifting cylinder and the tilting cylinder of a lifting mast of an industrial truck and any other users that may be connected to the system. The highest of the load pressures of the consumers connected downstream of the directional control valve 64 is delivered by means of a system of shuttle valves to the load pressure signal line 21. In the load pressure signal line 21 there is a pressure relief valve 51 that is set to the maximum allowable pressure in the hydraulic work system 20. An outlet line 13a of the hydraulic work system 20 is connected to the outlet line 13 leading from the pressure reducing valve 12 to the reservoir 4.
In the delivery line portion 5b, downstream of the priority valve 18, there is a traction drive control valve 23. Connected to the traction drive control valve 23 are traction delivery lines 24a, 24b which lead to the connections of the traction drive motors 17a, 17b. Also connected to the traction drive control valve 23 is a load pressure signal line 25 which measures the load pressure of the traction drive motors 17a, 17b downstream of the throttle point of the traction drive control valve 23. The traction drive control valve 23 can also be connected to a return line 26 that leads to the outlet line 13. Located in the return line 26 is a flow regulator 27 which can be pressurized in the direction of an open position by the pressure in the outflow or return line 26 and the force of a spring, and in the direction of a closed position by the pressure in the delivery lines 24b and 24a, and thus the pressure upstream of the throttle point of the traction drive control valve 23 in the return line 26.
In the illustrated middle position of the traction drive control valve 23, the connections are closed, as a result of which the traction drive system 16 is blocked. In the switching positions illustrated on the left and the right in the figure, the delivery line portion 5b is connected with the delivery lines 24a and 24b and the return line 26 with the delivery lines 24b and 24a, respectively, as a result of which the traction drive motors 17a, 17b can be operated in both directions.
To actuate the traction drive control valve 23 there is a control valve 28 that is connected to a control pressure line 29 that branches off from the feed line 11. The valve body of the control valve 28 can be actuated by means of an actuator element 30, for example by a system of two pedals. When there is a deflection of the actuator element, a control pressure is introduced in the control pressure branch lines 31a and 31b, which is available at the control surfaces of the traction drive control valve 23, and thus deflects the traction drive control valve correspondingly. To provide feedback from the deflection of the traction drive control valve 23, for example, the valve housing of the control valve 28 is effectively connected to the traction drive control valve 23. As a result, in the event of the deflection of the traction drive control valve 23 set by means of the actuator element 30 on the control valve 28, the control edges of the control valve 28 are closed and the deflection of the traction drive control valve 23 is limited. The illustrated switching position of the control valve 28 represents a floating position, so that the traction drive control valve 23 is deflected by the force of the springs into the middle position.
Located in an outlet line 32 from the control valve 28 there is a flow control valve 33 that is preferably realized in the form of a quantitative control valve and controls the speed of movement of the traction drive control valve 23 and thus governs the deceleration of the traction drive system 16. Connected to the flow control valve 33 is a bypass valve 34 to the outlet line 32, which has an open position and a closed position. The bypass valve 34 is pressurized in the direction of the open position by the force of a spring. A control surface of the bypass valve 34 that acts in the direction of the closed position is connected by means of a line 35 to the return line 26 upstream of the flow regulator 27.
The piloting of the traction drive control valve 23 by the mechanically actuated control valve 28 means that in the event of damage to the control pressure lines 31a, 31b or the control pressure line 29, and thus a drop in the pressure on the control surfaces of the traction drive control valve 23, the traction drive control valve 23 is deflected by the force of the return springs into the middle position and is held there. The feed of hydraulic fluid to the traction drive motors 17a, 17b is therefore interrupted on both sides. Hydraulic fluid can, however, flow through the anti-cavitation valves of the feeder device 15 to the suction side of the traction drive motors 17a, 17b, as a result of which cavitation and thus damage to the traction drive motors 17a, 17b can be prevented.
To pressurize the piston-cylinder system 3 of the adjustment device of the pump 1, there is a demand flow regulator 36 connected to the delivery line 5 by means of delivery branch line 5c. The demand flow regulator 36 can be pressurized in the direction of a reduction in the delivery of the pump 1 by the pressure in a control pressure line 37, in which the pressure is available downstream of the priority valve 18 and thus in the delivery line portion 5b. The demand flow regulator 36 can be pressurized in the direction of an increase in the delivery flow of the pump by the load pressure of the traction drive system 16 in the load pressure signal line 25 and by a spring. An additional valve 38 connected to the delivery branch line 5c downstream of the demand flow regulator 36 can be pressurized in the direction of a reduction in the delivery flow of the pump 1 by the pressure in the delivery branch line 5c. The valve 38 can be pressurized in the direction of an increase in the delivery of the pump 1 by the force of a spring, and can be set, for example, to a value that corresponds to the maximum pressure of the drive system 16. When the maximum pressure in the delivery line 5 is exceeded, the pump 1 is thereby pressurized in the direction of a reduction in the delivery flow, as a result of which the pressure can be cut off.
On each of the traction drive motors 17a, 17b there is a parking brake device 40a and 40b, respectively, which can be released by means of a pressure available in a brake line 41. The brake line 41 is connected to the delivery line 5 upstream of the priority valve 6 and has a parking brake valve 42 which can be actuated by means of a pedal 43, for example. The parking brake valve 42 is preferably realized in the form of a pressure reducing valve, by means of which the pressure available in the brake line 41 for releasing the parking brake device 40a, 40b can be limited.
There is also an electronic control device 60, the output side of which is effectively connected to a speed control device 61 of the prime mover 2 and the valve 38. For this purpose, the valve 38 has a proportional magnet 62, by means of which the valve 38 can be switched in the direction of a reduction in the delivery of the pump 1. On the input side, the electronic control device 60 is connected with a sensor device 63, such as a potentiometer, that measures the deflection of the actuator element 30. Also provided on the directional control valves 64 of the hydraulic work system 20 are sensor devices 65 that measure the deflection of the directional control valves 64. There is also a sensor device 66 that measures the current speed of the prime mover 2, and can be located, for example, on the output shaft of the prime mover 2.
The drive system claimed by the invention functions as follows:
In the starting position, the demand flow regulator 36, the valve 38, the priority valves 6 and 18 and the traction drive control valve 23 are in the illustrated positions as a result of the force of the corresponding springs. The pump 1 thereby delivers hydraulic fluid into the delivery line 5, as a result of which the pressure in the delivery line 5 increases. As soon as the pressure in the delivery line 5 and thus in the inlet line 7 of the steering system 8 is sufficient to overcome the force of the spring 10 on the priority valve 6, the priority valve 6 is pressurized into the switching position illustrated on the right in the figure, as a result of which the hydraulic fluid flows into the delivery line portion 5a and the feed line 11. The pressure reducing valve 12 limits the pressure in the feed line 11 to the specified value, as a result of which the hydraulic fluid reaches the feeder device 15. If the pressure in the delivery line portion 5a and thus in the inlet line 19 exceeds the value of the spring 22 of the priority valve 18, the priority valve 18 is deflected into the switching position illustrated on the right in the figure, as a result of which the delivery line portion 5b continues to be pressurized with hydraulic fluid. The pressure in the control pressure line 37 thereby increases, as a result of which, as soon as the pressure in the control pressure line 37 exceeds the value of the control spring of the valve 38, the demand flow regulator 36 is deflected into the switching position illustrated on the left in the figure. The piston chamber of the piston-cylinder system 3 is thereby pressurized by the pressure in the delivery line 5 and thus the adjustment device of the pump 1 is deflected into a position that reduces the delivery.
If no users are actuated, the drive system is in a sort of stand-by status, in which the pressure in the delivery line 5 is set to a pressure level that corresponds to the force of the spring of the piston-cylinder system 3. Thus, there is sufficient hydraulic fluid available in the brake line 41 of the parking brake device 40a, 40b and of the feed line 11.
If, beginning with this situation, the steering system 8 is actuated, the equilibrium at the priority valve 6 is disrupted, as a result of which the priority valve 6 is pressurized into the switching position illustrated on the left in the figure, and the steering system 8 is supplied with hydraulic fluid with first priority. Consequently, the pressure in the delivery line portions 5a and 5b, and thus in the control pressure line 37, is also influenced, as a result of which the equilibrium at the demand flow regulator 36 is also disrupted, and the pump 1 is actuated in the direction of an increase in the delivery. As soon as the pressure difference at the priority valve 6, which is formed by the difference between the pressure in the inlet line 7 and the load pressure of the steering system 8 in the load pressure signal line 9, exceeds the force of the spring 10, the delivery line portion 5a is pressurized with hydraulic fluid. The pressure in the delivery line portions 5a, 5b and in the control pressure line 37 then increases again, as a result of which the demand flow regulator 36 is pressurized into a switching position that reduces the delivery volume of the pump 1. The pump 1 therefore delivers the instantaneous demand of the steering system 8. The hydraulic fluid flowing back from the steering system 8 in the return line 14 is delivered to the feed line 11, as a result of which a drop in the pressure in the feed line 11 is prevented and it becomes possible to deliver a sufficient supply of hydraulic fluid to the feeder device 15. The pressure reducing valve 12 limits the pressure in the feed line 11 to a maximum value, whereby when this pressure is exceeded, the feed line 11 is connected with the outlet line 13 and the excess hydraulic fluid in the return line 14 can flow to the reservoir 4. The line 73 and the one-way valve 74 guarantee that in an emergency, the steering system 8 can extract hydraulic fluid from the reservoir.
If only one or more directional control valves 64 of the hydraulic work system 20 are actuated, the actions described above occur in the sequence indicated, as a result of which the pump 1 is switched to meet the instantaneous demand of the hydraulic work system 20. Additionally, however, the deflection of the directional control valves 64 is also detected by the sensor devices 65, as a result of which the electronic control device 60 acts on the speed control device 61 and thus the speed of the prime mover 2 is increased. Consequently a sufficient supply of hydraulic fluid to the hydraulic work system 20 becomes possible.
If only the steering system 8 or the operating hydraulic system 20 is actuated, the pump 1 therefore operates in the load-sensing mode, in which only if there is a decrease in the speed, i.e. if the actual speed of the prime mover 2 measured by the sensor device 66 drops below the setpoint speed set on the speed control element 61, does the electronic control device 60 exert an influence on the setting of the pump 1. The electronic control device 60 thereby controls the setting of the valve 38 by means of the proportional magnet 62, as a result of which the valve 38 is deflected into the position illustrated on the left in the figure and thus the delivery of the pump 1 is reduced.
In the event of an actuation of the actuator element 30, the control valve 28 is deflected into the corresponding switching position, as a result of which the control pressure line 29 is connected with the control pressure branch lines 31a and 31b respectively and thus the traction drive control valve 23 is switched accordingly. As a result of the mechanical coupling of the traction drive control valve 23 and the control valve 28, the traction drive control valve 23 can be deflected as a function of the direction and speed of travel specified by the actuator element 30.
Hydraulic fluid therefore flows via the delivery line portion 5b, as a function of the switching position of the traction drive control valve 23, to the delivery line 24a or 24b that forms the inlet side. The respective other delivery line 24b or 24a that represents the outlet side is connected to the return line 26. The flow regulator 27 is in the open position, so that the hydraulic fluid in the return line 26 flows to the outlet line 13 and thus to the reservoir 4.
The load pressure of the traction drive motors 17a, 17b is measured on the load pressure signal line 25 and is transmitted to the spring side of the demand flow regulator 36. The equilibrium at the valve 38 is thus disrupted, as a result of which the valve 38 is deflected to the left in the figure, and thus swivels the pump and delivers the demand flow to the traction drive system 16. The deflection of the actuator element 30 is detected by means of the sensor device 63, and the speed of the prime mover 2 is increased by the electronic control device 60. If there is a drop in the speed of the prime mover 2 during the acceleration of the vehicle, the delivery of the pump 1 can be reduced by means of the proportional magnet 62 located on the valve 38 by the electronic control device 60, so that the load is taken off the prime mover 2. The acceleration of the vehicle is therefore determined by the reducing regulator in the electronic control device 60.
When the vehicle is traveling downhill, the traction drive motors 17a, 17b act as pumps and suck hydraulic fluid out of the delivery line portions 5a, 5b. The pressure in the delivery line 24a or 24b forming the inlet side thereby decreases. The traction drive motors 17a, 17b attempt to deliver a larger quantity of hydraulic fluid through the outlet-side throttle point of the traction drive control valve 23 than corresponds to the setpoint speed of the vehicle set at the outlet-side throttle point. The outlet-side pressure upstream of the throttle point of the traction drive control valve 23 thereby increases, whereupon the flow regulator 27 is pressurized in the direction of the closed position. A braking pressure is thus built up in the return line 26 that decelerates the vehicle and keeps it moving at the specified speed of travel. As a result of the pressure drop in the inlet-side delivery line 24a or 24b and thus in the control pressure line 37, the pump 1 is thereby rotated by the demand flow regulator 36 in the direction of an increase in the delivery quantity. The electronic control device 60 keeps the prime mover 2 at a corresponding speed, so that the pump 1 delivers sufficient hydraulic fluid. Sufficient hydraulic medium is therefore available on the suction side of the traction drive motors 17a, 17b.
During a deceleration process, i.e. during the retraction of the deflection of the actuator element 30, the inlet-side and outlet-side throttle point on the traction drive control valve 23 is reduced by the movement of the traction drive control valve 23 into the middle position. As a result of the kinetic energy of the vehicle, however, the traction drive motors 17a, 17b are attempting to deliver a larger quantity of hydraulic fluid into the return side than corresponds to the quantity of hydraulic fluid set on the outlet-side throttle orifice of the traction drive control valve. The processes described above therefore take place, as a result of which the flow regulator 27 builds up a braking pressure. To make possible a defined braking process, i.e. a smooth deceleration, the quantitative flow control valve 33 is located in the outlet line of the control valve 28, which valve 33 controls the return movement of the traction drive control valve 23 into the middle position and thus specifies a braking deceleration. The deceleration becomes effective as soon as the bypass valve 34 is pressurized by the braking pressure build up in the line 35 into the closed position. The braking deceleration thus becomes active only when the braking action is initiated by the flow regulator 27. First the speed of the vehicle is adjusted to the speed specified by the outlet-side throttle point of the traction drive control valve 23 and is then decelerated in a defined manner. During a deceleration process, the speed of the prime mover 2 is reduced by the electronic control device 60.
When there is a simultaneous actuation of the traction drive system 16 and of the steering system 8, as a result of the load pressure of the steering system 8, the equilibrium on the priority valve 6 is disrupted, so that the steering system 8 is provided with a priority supply of hydraulic fluid. The hydraulic fluid not needed by the steering system 8 flows to the delivery line portion 5a and thus to the traction drive control valve 23. As a result of the pressure drop which then occurs in the control pressure line 37, the adjustment device of the pump 1 is set in the sense of an increase in the delivery volume, so that the pump 1 also delivers the amount demanded by the steering system, if and to the extent that the delivery volume of the pump 1 can be increased. The magnitude of the delivery volume can be defined so that at the maximum speed of travel, there is a reserve pivoting angle and thus an additional delivery current for the steering system 8 as well as for the feeder device 15. If the delivery flow demanded by the traction drive system 16 and the steering system 8 exceeds the delivery flow that can be supplied by the pump 1, the steering system 8 is supplied with first priority and the feeder device 15 with second priority. The hydraulic fluid not required by these users is available to the traction drive system 16, so that the forward propulsion of the vehicle is reduced. The traction drive system 16 is thereby in a free-running condition, in which the vehicle continues to roll as a result of its kinetic energy. The suction side of the traction drive motors 17a, 17b is supplied by the anti-cavitation valves of the feeder device 15 with hydraulic fluid, thereby preventing cavitation on the inlet side of the traction drive motors 17a, 17b. The vehicle reduces its speed of travel by coasting until the speed of travel has reached the speed that corresponds to the delivery current of the pump available for propulsion.
In the event of the simultaneous operation of the hydraulic work system 20 and of the traction drive system 16, essentially the sequences described above take place and the pump 1 also delivers the quantity demanded by the hydraulic work system 20, if and to the extent that the delivery volume of the pump 1 can be increased. The electronic control device 60 forms a total delivery demand of the pump 1 from the setpoints provided by the sensor devices 65 and 63 for the speed of movement of the users of the hydraulic work system 20 and of the traction drive system 16. The deflection of the directional control valves 64 and of the actuator element 30, which are measured by the sensor devices 65, 63, hereby each represent a defined demand for hydraulic fluid. A total delivery demand can thereby be calculated by addition in the electronic control device 60 and thus the delivery of the pump 1 can be increased by increasing the speed of the prime mover 2 to a maximum value. As a result of the location of the priority valves 6 and 18, the hydraulic work system 20 is supplied with hydraulic fluid after the steering system 8, the feeder 15 and before the traction drive system 16.
At the maximum speed of travel and with the simultaneous actuation, for example, of the lifting cylinder of the hydraulic work system 20, however, the delivery of the pump 1 is not sufficient to cover the demand for hydraulic fluid of the hydraulic work system 20 and of the traction drive system 16. The traction drive system 16 switches into a coasting status. After the parking brake device 40a, 40b and the steering system 8, hydraulic fluid is delivered into the feed line 11, as a result of which the suction side of the traction drive motors 17a, 17b is supplied with hydraulic fluid via the anti-cavitation valves of the feeder device 15. The remaining hydraulic fluid is delivered into the inlet line 19 of the hydraulic work system 20. Because there is no propulsion when the vehicle is coasting, the vehicle coasts down and reduces its speed of travel, as a result of which the remaining delivery for the hydraulic work system 20 increases. The vehicle thereby decreases the speed of travel until the required flow of hydraulic fluid is available to the hydraulic work system 20. This speed is retained as long as the hydraulic work system 20 is actuated. After the hydraulic work system 20 is no longer being actuated, the delivery flow from the pump is once again available to the traction drive system 16, as a result of which the vehicle is accelerated to the maximum speed.
If, in the event of the simultaneous actuation of the traction drive system 16, the hydraulic work system 20 and possibly also of the steering system 8, there is a reduction in the speed of the prime mover 2, the pump 1 is switched in the sense of a reduction in the delivery current, as a result of which, and on account of the location of the priority valves 6, 18, the delivery current flowing into the traction drive system 16 is reduced first. To prevent a reduction in the speed of the vehicle, the speed of the prime mover 2 can be increased to the maximum speed and thus the delivery of the pump 1 can be increased.
It will be readily appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed in the foregoing description. Such modifications are to be considered as included within the following claims unless the claims, by their language, expressly state otherwise. Accordingly, the particular embodiments described in detail herein are illustrative only and are not limiting to the scope of the invention which is to be given the full breadth of the appended claims and any and all equivalents thereof. | A hydrostatic drive system is provided for a vehicle, in particular an industrial truck having a hydrostatic traction drive system (16), a hydraulic work system (20) and a hydraulic steering system (8). The drive system is compact and the energy utilization in the drive system is improved by providing a hydraulic pump (1) with an adjustable delivery volume working in an open circuit to supply the traction drive system (16), the hydraulic work system (20) and the steering system (8). In one configuration of the invention, there is at least one traction drive control valve (23) in the delivery line (5b) of the pump (1), whereby upstream of the traction drive control valve (23) in the delivery line (5b) of the pump (1) there is a priority valve (18) for the hydraulic work system (20), and upstream of the priority valve (18) of the hydraulic work system (20) there is a priority valve (6) for the steering system (8). In one embodiment of the invention, a feed line (11) of a feeder device (15) can be connected to the delivery line (5a) between the priority valve (6) of the hydraulic steering system (8) and the priority valve (18) of the hydraulic work system (20). | 5 |
BACKGROUND OF THE INVENTION
[0001] Floor supported laundry appliances, such as washing machines and clothes dryers, experience significant vibrations during the spin and tumbling cycles of the machines. At times, these vibrations can cause the machine to skid on the floor away from its original location.
[0002] In an attempt to overcome this problem, it has been proposed to provide the supporting legs of the appliance with skid resistant and vibration dampening pads. While these pads initially provide the necessary skid resistance and vibration dampening, they soon become deteriorated and have to be replaced.
[0003] It has also been proposed to connect the appliance to a bracket which, in turn, is connected to the floor or adjacent wall. While this arrangement prevents the appliance from skidding, there is no provision for vibration dampening resulting in the floor or wall eventually cracking; thus releasing the bracket secured thereto.
[0004] After considerable research and experimentation, the securing bracket of the present invention has been developed which not only prevents skidding of the appliance on the floor but also dampens the vibration transmitted to the securing bracket.
SUMMARY OF THE INVENTION
[0005] The laundry appliance securing bracket of the present invention comprises an angle iron positioned on the floor adjacent to the rear of the appliance to be secured. A pair of channel members is adjustably mounted on the base of the angle iron and a pair of transversely extending spring biased J-bars is slidably mounted in the side walls of the channel members. The free end of each J-bar is provided with a hook portion for engaging the rear legs of the appliance. A lag screw extends through an enlarged opening in the vertical arm of the angle iron and is secured into a wall behind the appliance. A latch assembly is pivotally connected to the angle iron arm and is adapted to engage the stem of the lag screw adjacent the screw head to thereby detachably fasten the angle iron to the wall.
[0006] By this construction and arrangement, the J-bars not only prevent the appliance from skidding, but they also absorb the vibration of the machine to thereby prevent vibrations from being transmitted to the angle iron and its fixation to the wall. The latch assembly also facilitates the disconnection of the appliance from the wall for repairs or replacement.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a side elevation of the securing bracket of the present invention connecting a laundry appliance to an adjacent wall;
[0008] FIG. 2 is a top plan view of the securing bracket and appliance as shown in FIG. 1 .
[0009] FIG. 3 is an exploded perspective view of the securing bracket of the present invention;
[0010] FIG. 4 is a side elevational view of the securing bracket;
[0011] FIG. 5 is a top plan view of the securing bracket;
[0012] FIG. 6 is a front elevational view, partly in section, showing the vertical arm of the angle iron and associated latching members;
[0013] FIG. 7 is a view taken along line VII-VII of FIG. 5 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0014] Referring to the drawings and more particularly to FIGS. 1 and 2 , the securing bracket 1 of the present invention is positioned on the floor 2 between the rear of a laundry appliance 3 , such as a washing machine or dryer, and a wall 4 , the bracket being connected to the rear legs 3 a of the appliance 3 and the wall 4 , to be described more fully hereafter.
[0015] The details of the construction of the bracket 3 are illustrated in FIGS. 3, 4 and 5 , wherein an angle iron 5 is provided having a base portion 5 a and a vertical arm 5 b . The base portion 5 a is provided with a pair of longitudinally spaced slots 5 c upon which channel members 6 are positioned and secured thereon by carriage bolts 7 extending upwardly through the slots 5 c and square holes 6 a provided in the base or web of the channels 6 , the channels 6 being secured in place by lock washer-nuts 7 a threaded onto the bolts 7 .
[0016] Each of the channels 6 is provided with a J-bar assembly 8 comprising a bolt portion 8 a extending through a tube 8 b positioned within the channel 6 between the vertical walls 6 b of the channel 6 and aligned with apertures 6 c provided in the channel walls 6 b . The end of the bolt portion 8 a is threaded as at 8 c upon which a bushing 8 d is mounted and a lock nut 8 e is threaded. By this construction and arrangement, the bolt portion 8 a is slidably mounted in the tube 8 b . A coil spring 8 f is mounted on the bolt portion 8 a coaxial therewith and is biased between the exterior surface of the channel side wall 6 b and a plate 8 g having a pair of apertures 8 h and 8 i for slidably receiving the bolt portion 8 a and the threaded end 8 j of the hook portion of the J-bar 8 , respectively. The plate 8 g is secured to the J-bar 8 by a lock nut 8 k threaded onto the end portion 8 j.
[0017] As will be seen in FIGS. 1, 3 , 6 and 7 , the angle iron 5 is detachably secured to an adjacent wall 4 by means of a pair of lag screws 9 extending through elongated vertical slots 5 d provided in the vertical wall 5 b of the angle iron 5 , and into the wall 4 . The vertical slots 5 d communicate with enlarged openings 5 e in the base portion 5 a of the angle iron 5 .
[0018] A latch assembly 10 cooperates with the lag screws 9 for releasably securing the angle iron 5 to the wall 4 and comprises a pair of latch plates 10 a pivotally connected, as at 10 b , to the angle iron vertical wall 5 b . Each latch plate 10 a is provided with an arcuate slot 10 c at each end thereof for receiving the stem portions of the screws 9 . By this construction and arrangement, the latch plates 10 a can be pivoted in one direction to release the latch plates 10 a from the lag screws 9 and in the opposite direction to connect the latch plates 10 a to the screws 9 .
[0019] Tool receiving apertures 10 d are provided in the latch plates 10 a adapted to receive the hooked end of a tool, such as a length of wire (not shown), which is inserted downwardly in the space between the back of the appliance 3 and wall 4 , whereby the latch plates 10 a can be pivoted from a remote location.
[0020] The angle iron vertical wall 5 b is provided with a tab 5 f having an aperture 5 g adapted to receive the hook portion of a tool (not shown), whereby the angle iron 5 and associated latch assembly 10 can be lifted off the screws 9 wherein the screw stems and heads pass through the slots 5 d in the angle iron vertical wall 5 b and the apertures 5 e in the angle iron base 5 a , whereby the securing bracket 1 is disconnected from the wall 4 .
[0021] To secure the appliance 3 to the wall 4 , the angle iron 5 is secured to the wall 4 by inserting the lag screws 9 through the slots 5 d in the angle iron vertical wall 5 b . The channels 6 and associated J-bar assemblies 8 are slid on the angle iron base portion 5 a to position them for proper alignment with the two rear legs 3 a of the appliance 3 . The hook portions of the J-bars 8 are positioned around the appliance legs 3 a and the plates 8 g are then secured to the ends of the J-bars 8 by the lock nuts 8 k.
[0022] During the operation of the appliance 3 , vibrations therefrom are transmitted to the J-bar assemblies slidably mounted in the channels 6 and absorbed by the springs 8 f.
[0023] From the above description, it will be appreciated by those skilled in the art that the securing bracket 1 of the present invention is an improvement over heretofore employed skid resistant and vibration dampening pads and other securing brackets.
[0024] It is to be understood that the form of the invention herewith shown and described is to be taken as a preferred example of the same, and that various changes in the shape, size and arrangement of parts may be resorted to, without departing from, the spirit of the invention or scope of the subjoined claims. | A securing bracket for a floor supported laundry appliance, such as a washing machine or a clothes dryer. The securing bracket is connected between the rear legs of the appliance and an adjacent wall to prevent skidding of the appliance on the floor. The securing bracket also includes a shock absorber for dampening vibrations transmitted from the appliance to the securing bracket and an attached wall. | 3 |
BACKGROUND OF THE INVENTION
This invention pertains to means for forming a fluid seal in a void or recess which obtains between interengaged components, and in particular to such means which forms a static and sanitary seal, in a space, void or recess between such components which fairingly bridges across the space, void or recess to inhibit any collection of fluid thereat.
Typically, sealing means are embodied by an O-ring, used as a radial seal between interengaging components, the O-ring seal serving as a gland, or arranged as a face seal. Alternatively, such sealing means are provided by a flat gasket, in which the same serves as a face seal between the components. In the case where an O-ring is used to achieve a radial seal between interengaged components, it is necessary for the O-ring groove to be machined or formed so that it is somewhat below the outermost surfaces of the components. This is necessary to provide some manner of shoulder to keep the O-ring from extruding into the flow path of the fluid, as the O-ring is compressed, or extruded into the structures as a vacuum is created therewithin. The elastomers used for O-ring materials are flexible enough to extrude outwardly or inwardly, in the face of elevated or vacuum pressures. The distance between the face of the O-ring seal and the outermost surfaces of the interengaged, being-sealed components defines gaps and crevasses which will fill with product upon such product flowing thereacross. These gaps and crevasses are difficult and almost impossible to flush out and sterilize.
As pressures increase or decrease, within the being-sealed components, the O-ring moves back and forth, slightly, as it is compressed and allowed to expand due to the variances in the pressures, because of its highly elastic nature. As a consequence, small amounts of product become trapped in areas around or beneath the O-ring. Clearly, any bacteria that grows near or beneath the O-ring as a result of the entrapped product will be insulated from cleansing steam addressed to the site. Such O-ring sealing arrangements are most difficult or impossible to sanitize for, as noted, sanitizing steam will simply pass over the captured, shielded bacteria.
An O-ring seal used as a face seal also requires a same type of shoulder to retain it in place, and the aforesaid problems arise with this practice as well. Recesses, gaps and the like will be presented to collect fluid therein, and such discontinuities are fertile breeding grounds for tenacious bacteria.
A flat gasket used as a face seal is also subject to extrusion, inwardly or outwardly, under elevated or vacuum pressures due to its highly elastic nature. Also, because a flat gasket has to be compressed against comparatively large, flat surfaces, the use of such results in an arrangement that either has a significant, product-receptive recess at the outermost area of the structure, or defines gaps and crevasses such as are coincident with the O-ring sealing (as priorly noted), compromising the cleanliness and sterility of the arrangement.
In view of the aforenoted problems and disadvantages arising from the use of O-ring seals and/or flat gaskets, it is clear that there is an unmet need for a means for forming a static and sanitary seal which avoids the described problems and disadvantages.
SUMMARY OF THE INVENTION
It is an object of this invention to set forth a novel means for forming a static seal, and a sanitary seal, per se, and in combination with interengaged components. Particularly, it is an object of this invention to set forth means for forming a static seal in a recess between interengaging components, comprising a substantially non-extrudable, sealing element; wherein said element has a first surface for exposure thereof between said components in said recess, and fairingly bridging across said recess; said element has a second surface for interfacingly engaging a surface of one of said components; one of said first and second surfaces is flat; and the other of said first and second surfaces defines an obtuse angle relative to said one, flat surface.
Further objects of this invention, as well as the novel features thereof will become apparent by reference to the following description, taken in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 through 6 are partial, cross-sectional illustrations of prior art sealing arrangements for interengaged components; and
FIG. 7 is a partial, cross-sectional view of an embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 discloses interengaged male and female components 10 and 12, respectively, the two having an annular space or recess 14 therebetween. The male component 10 has an annular groove 16 formed therein in which an O-ring seal 18 is set. The groove 16, necessarily, has been formed somewhat inboard of the outermost surfaces of components 10 and 12, to keep the O-ring 18 captive. As a consequence, there is the annular gap 20 exposed to the product flow. The product, a liquid or vapor, can collect in the gap 20, and breed bacteria. Even when sterilizing steam is addressed to the outermost surfaces, and the gap 20, it will not necessarily sanitize the exposed surfaces and the minute, diminishing crevass which obtains between the radial outermost surface of the O-ring 18 and the confronting surface of the female component 12.
In the FIG. 2 arrangement the components 10a and 12a are both shaped by machining to define a captive arrangement for the O-ring 18, and to dispose the O-ring 18 more proximate to the outermost surfaces of the structure where the product flows. However, even with this concept, there remains a product-collecting gap 20a.
As priorly noted, with cyclical pressures of the product fluid, the flexible O-rings 18 will expand, contract, extrude and otherwise exercise, dynamically, and allow minute quantities of product fluid to insinuate themselves into the space or recess 14 and/or 14a, alongside the surfaces of the O-ring, or even therebehind where they will be substantially inextricable and unaffected by steam-cleaning sprays.
FIGS. 3 and 4 depict other, prior art arrangments in which O-ring seals are employed. In FIG. 3, the O-ring seal 18 is substantially encapsulated by an annular ledge 22 extending inwardly from the female component 12b. However, this configuration presents a large, recessed land 24, i.e., the outermost surface of the male component 10b, which subsists within the ledge 22. This land 24 can become a small reservoir for the product fluid, and of course, the jointing interface 26 of the ledge 22 and the land 24 presents an annular recess in which stale product can lodge and grow into bacteria.
The FIG. 4 arrangement is not greatly different from that depicted in FIG. 2, and it results in the same sort of problems. The O-ring will exercise, dynamically, to admit minute quantities of product therealong and perhaps therebehind, and again a product-collecting gap 20b is presented to the fluid flow.
The use of flat gaskets, as shown in FIGS. 5 and 6 do little to ameliorate the problem. The flat gasket 28 in FIG. 5, for being highly elastic, is susceptible of extrusion the same as the O-rings. Too, this arrangement, similar to the FIG. 3 arrangement, presents a recessed land 24a which is not readily drainable, and which offers opportunity for bacteria growth.
The FIG. 6 construction is not dissimilar to the FIG. 4 arrangement. Here is a same gap 20c in which product will surely collect, and defy reasonable efforts to flush the same for sanitizing.
The invention, then, as exemplified by an embodiment thereof in FIG. 7, substantially obviates the aforedescribed difficulties and problems. Here, the male and female components 10f and 12f, respectively, have an annular recess or gap 20d formed therebetween. In this recess 20d is disposed a substantially non-extrudable gasket, i.e., a teflon gasket 30. The female component 12f, in this embodiment, has an inwardly-directed, diagonal surface 32 at its outermost termination of the recess 20d. The gasket 30 has a first surface 34 which is externally exposed between the components 10f and 12f, and which fairingly bridges across the recess 20d; as a consequence, there obtains no crevass, no gap, no discontinuity of any sort in which product fluid can take refuge and occasion the growth of bacteria.
The sealing gasket 30 has a second surface 36 which comprises a diagonal shape complementary to surface 32, and which defines an obtuse angle relative to surface 34. Surface 36 interfacingly engages the confronting surface of female component 12f. Gasket 30 also has a radially innermost surface 38 which similarly effects an interfaced engagement thereof with the confronting surface of component 10f. This surface 38, a third surface of the novel gasket 30, defines a right angle with the first surface 34.
As can be seen, the gasket 30 has a first, innermost portion 40 of uniform width dimension, and a second, outermost portion 42 of uniformly varying width dimension. The latter defines the gasket with a taper which cooperates with the surface 32 to keep the gasket 30 captive in the recess 20d.
The FIG. 7 arrangement of the invention was designed so that the confronting edges of the male and female components 10f and 12f are as sharp as practical, and the configuration of the gap 20d is so defined as to insure that the exposed surface 34 of the gasket 30 is as small as possible. This provisioning, plus the flatness of the surface 34, virtually eliminates any crevasses or fluid traps for the product. The three, cooperating structures, the male component 10f, the gasket 30, and the female components 12f are tightly pressed or wedged against each other, and a smooth, faired, continuum is presented to the product flow. By keeping the exposed surface 34 of the gasket 30 to a minimum, and by making the gasket 30 out of an non-extrudable material, such as teflon, for example, the chances of extruding the gasket material into the flow path are virtually nil. An O-ring 44, or spring washer, or other such device can be installed behind the sealing gasket 30, in the bottom of the recess 20d, not as a sealing means, but as a method for compensating for any thermal displacement of the structures involved.
This novel sealing means can find especial use in any situation where a static, sanitary seal is necessary, and where drainability, or a flush, faired internal surface is imperative. Examples of such applications might be instrument ports, such as gage tees, sight glass fittings, in-line tube or pipe fittings, and covers for valves or other miscellaneous containers or vessels such as filter housings, pumps, and the like.
While I have described my invention in connection with a specific embodiment thereof, it is to be clearly understood that this is done only by way of example, and not as a limitation to the scope of the invention as set forth in the objects thereof, and in the appended claims. | A sealing element, formed of a substantially non-extrudable material, is configured with a taper at one edge or surface thereof. The element is set in a recess which obtains between interengaged components, with the tapered end exposed, externally. The tapered end is flat, and fairingly bridges across the recess to obviate any crevasses or notches, or voids in which product fluid can repose and create bacteria. | 8 |
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for transporting at least one can between a sliver furnishing fiber processing machine, e.g. a carding machine, and a sliver fed fiber processing machine, e.g. a drawing frame, by means of a transporting carriage.
The control mechanism of the copending U.S. application entitled "Apparatus For Automatically Transporting A Can Between A Sliver Furnishing And A Sliver Fed Spinning Industry Machine" filed on or about the same day as the present invention and based on Foreign Application No. FRG No. P 35 32 173.3 filed Sept. 10th, 1985 and FRG No. P 36 21 370.5 filed June 26th, 1986, may be used for controlling the present transporting carriage and is incorporated herein by reference.
In a known device, two handles are disposed on opposite sides of a spinning can to push the can onto the carriage. Such a device is disclosed in German Pat. No. 1,685,629. Then the carriage is manually pushed from the carding machine to the drawing frames. This makes the machine dependent on personnel, i.e. it is not possible to reliably displace the spinning cans and the transporting carriage with this known device. There is the additional drawback that loading and unloading of the cans and their transport cannot be performed with a single device.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an apparatus of the above-mentioned type which avoids the stated drawbacks and which, in particular, permits loading and unloading as well as transporting of the spinning cans in a simple and reliable manner.
The objects of the invention are realized by the present invention which discloses an apparatus for transporting at least one can between a sliver furnishing fiber processing machine and a sliver fed fiber processing machine. The apparatus comprises a transporting carriage and a device associated with the carriage for loading and unloading the at least one can. The device includes a conveying element for moving the at least one can with respect to the transporting carriage.
Preferably, the loading and unloading device is able to accommodate the can within the transporting carriage between the wheels of the carriage. In this way, the can is supported in or near its center of gravity so that high stability of the can position is realized during transport. Moreover, switching of carriages is also facilitated when the can is supported near its center of gravity.
Advisably, the loading and unloading device is a gripper which is able to grip the can. The gripper is rotatable about a horizontal axis and is attached to the transporting carriage. The gripper has at least one pneumatic cylinder with which the can may be pushed or pulled. Preferably, a telescoping cylinder is provided which includes a pressure cylinder and which has a plurality of cylinder pistons to realize a wide range for the gripper. Advantageously, the transporting carriage includes a roller conveyor which is driven and which facilitates displacement of the can. The roller conveyor of the transporting carriage is disposed opposite a stationary pickup station at the carding machine or at the reserve station near the drawing frame. Advantageously, the cans slide on the level floor of the transporting carriage. A retainer for a filled can is provided above the can which presses on sliver material projecting beyond the edge of the can. The retainer may be a lid, a covering sheet, bar or the like and is advisably fastened to the transporting carriage so that only one retainer is required for a plurality of cans. The retainer prevents the sliver material from slipping during transport. The retainer is adjustable in height so it can be adapted to different fill levels in the cans. The retainer may be a conveyor belt which rotates at the speed at which the can is loaded or unloaded.
According to a preferred embodiment, a driving device, e.g. an electric motor, is provided to drive the transporting carriage. This avoids the need for costly and cumbersome manual pushing of the carriage. The transporting carriage may also move automatically on a horizontal path.
The present invention will be described in greater detail below with reference to embodiments that are illustrated in the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic plan view of a spinning preparation device including five carding machines and two drawing frames and employing the can transporting device according to the invention.
FIG. 2 is a front view of the can transporting device with roller conveyor and telescoping cylinder next to a can changer (shown only in part) for a carding machine.
FIG. 3 is a plan view of the can transporting device of FIG. 2 including a gripper and a can disposed in the transporting carriage.
FIG. 4 is a side view of the can transporting device according to FIG. 2.
FIG. 5 shows a top plan view of the transporting device as in FIG. 2 in which the gripper is rotatable about a horizontal axis.
FIG. 6a is a top plan view similar to FIG. 3 but with the can being transported in the direction of arrow E.
FIG. 6b is a top plan view similar to FIG. 3 but with the can being transported in the direction of arrow F.
FIG. 7 is a top plan view in which the can is transported in direction G.
FIG. 8 shows an embodiment of the can transporting device similar to FIG. 4 in which the can is transported on rollers at ground level.
FIG. 9 is a front view of the can transporting device in which the can is transported in the direction of G.
FIGS. 10, 11 and 12 show an embodiment of the transporting device in which a two-sided loading and unloading station is included.
FIG. 11a is an enlarged view of the toothed rod and pinion connection of FIG. 14.
FIGS. 13 to 15 show a can transporting device including a toothed rod displacement device.
FIG. 16 is a perspective view of the transporting device, the carding machine and the can changer according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The spinning preparation device shown in FIG. 1 includes five carding machines 1 to 5 and two drawing frames 6 and 7, which are shown schematically. Each carding machine 1 to 5 has an associated feeding device 1a for feeding the slivers into a spinning can 8a. In addition to feeding device 1a, there is also provided a pickup station 1b where the spinning cans 8b filled with card sliver can be deposited. Feeding device 1a and pickup station 1b may be part of a known can changing device. To transport can 8c between carding machines 1 to 5 and drawing frames 6 and 7, a transporting carriage 9 is provided which transports can 8c to reserve station 6a of drawing frame 6 or to reserve station 7a of drawing frame 7. The six spinning cans (reserve position) marked 8d and 8f, respectively, are disposed at the same level as six further filled spinning cans 8e and 8g, respectively. Spinning cans 8e and 8g are disposed at the inlet of drawing frames 6 and 7, respectively, where the carding machine slivers are removed from them and are fed to the drawing mechanisms of drawing frames 6 and 7, respectively, for multiple filament production and decoration. It is understood that instead of two spinning cans 8e and 8g, a larger or smaller number of spinning cans can be placed simultaneously at the inlet of drawing frames 6 and or 7 if a different type of multifilament design is desired. The reference numeral 27 identifies a reserve station (buffer) for spinning can 8 which is disposed between the carding machine and the drawing frame and is able to accommodate full and/or empty cans, as required. The traveling path of transporting carriage 9 is shown in dashed lines.
FIGS. 2 and 3 show the transporting carriage 9 for each can 8 having a diameter of, for example 1000 mm. The can 8 to be exchanged stands on a roller conveyor 10 whose height above the level floor is, for example, 120 mm. The chassis 11 includes the drives, e.g. an electric motor 26 (see FIG. 3) to drive the carriage, the drives (not shown) for the telescoping cylinders 15 a,b,c and 16 a,b,c (see FIG. 3), energy supply devices and the like. The chassis 11 moves on steered axles 12 and 13 equipped with four wheels 12a, 12b, 13a, 13b, in the direction indicated by arrow A (see FIG. 3). Can 8 is accommodated within transporting carriage 9 between its wheels 12a, 12b and 13a, 13b (see FIG. 3).
A gripper 14 is attached to chassis 11 of transporting carriage 9 as the loading and unloading device for can 8. Gripper 14 has two horizontal telescoping cylinders 15 and 16 which are each composed of cylinder pistons 15a, 15b and 15c and 16a, 16b and 16c, respectively. At the end of cylinder piston 16b, a pressure cylinder 17 is provided (see FIG. 3), at an angle of 90°, to act in the radial direction of can 8 and clamp can 8 against pressure cylinder 15. For adaptation to the circular surface of can 8, bent clamping pieces 19 and 20 are provided.
Above can 8 (see FIG. 2), a retainer 21 is provided for the material 22 filling the can, e.g. the sliver. Referring to FIG. 4, retainer 21 is fastened to chassis 11. Also provided at chassis 11 are blinking warning lights 23, 24 which are activated when transporting carriage 9 is displaced along the traveling path.
According to FIG. 2, transporting carriage 9 is positioned with its longitudinal side next to pickup station 1b of a (schematically shown) can exchanger for a carding machine. Between bottom plate 1c and cover plate 1d, can 8' is shown in dashed lines in the pickup position. Then cylinder pistons 15b, 15c and 16b, 16c (see FIG. 3) move into positions 15b' and 15c' shown in dashed lines or, respectively, into positions 16b' and 16c' (not shown). The cylinder pistons move out simultaneously and then pressure cylinder 17 is actuated so that clamping pieces 19 and 20 take can 8' between them in the manner of a vise. This causes pressure cylinder 17 to clamp can 8' perpendicularly to telescoping cylinders 15 and 16. Then cylinder pistons 15b' and 15c' and 16b' and 16c' are again pulled into cylinder pistons 15a and 16a, respectively. This causes can 8 to be pulled in the direction of arrow B (see FIG. 2) from position 8' into position 8 on the roller conveyor 10 of transporting carriage 9.
Transporting carriage 9 then moves to one of drawing frames 6 or 7. Can 8 is deposited from transporting carriage 9 in the reserve station 6a or 7a of drawing frames 6 or 7, respectively, by actuation of gripper 14 in the reverse sense.
Transporting carriage 9 is able to transport empty cans 8 back from drawing frame 6 or 7 to one of the carding machines 1 to 5 or to a reserve station at the carding machines, for example a can changer. For this purpose, the empty can 8 is pushed in the direction of arrow C (see FIG. 2) from roller conveyor 10 to the reserve station at the carding machine or into the can changer (see FIG. 3).
According to FIG. 3, the transporting carriage moves according to the orientation of its wheels 12a, 12b, 13a, 13b in the direction of arrow A.
According to FIG. 5, gripper 14 is rotatable about a horizontal axis 25 (see arrow D) so that can 8 can be moved from a vertical position into some other position.
According to FIG. 6a, wheels 12a, 12b, 13a, 13b are changed in position by 90° in comparison to the wheels of FIG. 3 about a perpendicular axis by a changing device (not shown) so that transporting carriage 9 moves in the direction of arrow E. According to FIG. 6b, wheels 12a, 12b, 13a, 13b are rotated in such a manner that their horizontal wheel axes intersect at a certain point so that transporting carriage 9 performs a rotary movement, in place, in the direction of arrow F.
FIGS. 7 to 9 show an embodiment in which rollers 28 (see FIG. 8) are disposed in the bottom 8a of can 8, and rollers 28b are disposed on the bottom of transporting carriage 9, with rollers 28, 28b rolling directly on the floor of the fiber processing plant. In FIGS. 7 and 9, arrow G indicates the direction of the loading and unloading device of can 8. In FIG. 7, the transporting carriage 9 has a one-sided loading and unloading opening 9a for can 8. In FIG. 8, arrow H shows the direction of travel of transporting carriage 9 with can 8.
FIGS. 10, 11 and 12 show an embodiment in which a two-sided loading and unloading station is provided for the can. In FIG. 10, the transporting carriage has a two-sided loading and unloading opening 9a, 9b for the can. Can 8 can thus be moved in the direction of arrow I (FIG. 12) and arrow J (FIG. 10) into or out of transporting carriage 9 from two sides. In FIG. 11, arrow K indicates the direction of travel of transporting carriage 9 with can 8. According to FIG. 12, two safety contact plates 29a, 29b are provided on the sides of the lower end of transporting carriage 9.
FIG. 13 shows a transporting carriage 9 with roller conveyor 10 which permits two-sided loading and unloading of can 8 according to arrow L. Arrow M shows the direction of travel of transporting carriage 9. The conveying elements for the movement of can 8 with respect to transporting carriage 9 are two toothed rod displacement devices 30a, 30b. According to FIG. 14, pressure cylinder 17 is fastened to a toothed rod 31 which meshes with a stationary, driven pinion 32. FIG. 11a shows an enlarged drawing of toothed rod 31 which moves in direction N as stationary pinion 32 moves about axis 33. Dotted lines 17', 31' and 8' show pressure cylinder 17' in an extended position. In FIG. 15, arrow L indicates the direction of the loading and unloading station of can 8.
FIG. 16 is a perspective view of transporting carriage 9 in the vicinity of a carding machine 33 and a can changer 34.
According to the invention, an automatically controlled transporting carriage 9 is provided for at least one can 8. Transporting carriage 9 includes a loading and unloading device with which empty or full cans can be loaded and unloaded. The loading and unloading device grips can 8 and pulls it onto transporting carriage 9 or pushes it in front of transporting carriage 9. The loading and unloading of transporting carriage 9 occurs in at least one direction, after the can 8 to be exchanged has been automatically actuated and gripped.
The present invention is described for the example of a carding machine as the sliver delivering fiber processing machine and a drawing frame as the sliver fed fiber processing machine. The invention can be utilized in a similar manner, for example, for a drawing frame or a flyer as the sliver delivery fiber processing machine and a flyer or a spinning machine as the sliver fed fiber processing machine and includes such machines.
Preferably the electric motor 26 (drive motor) of FIG. 3 is connected by wire, for example by way of a current collector, flexible lines and the like, to an energy source. According to a further suitable embodiment, the electric motor is connected to a battery which is fastened to the transporting carriage 9.
Electric motor 26 drives wheels 12a, 12b, 13a, 13b of carriage 9, e.g. by a known power transmission. Gripper 14 and cylinders 15 and 16 are controlled to move into the broken-line positions of FIG. 2 by a control unit, which may be electrically connected with a central control (computer). The cylinders 15, 16 and 17 are activated by a known activating unit.
The present disclosure relates to the subject matter disclosed in FRG Application No. P 35 32 173.3 filed Sept. 10th, 1985, and FRG Application No. P 36 21 370.5 filed June 26th, 1986, the entire specification of which is incorporated herein by reference.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims. | An apparatus for transporting at least one can between a sliver furnishing fiber processing machine, e.g. a carding machine, and a sliver fed fiber processing machine, e.g. a drawing frame, by means of a transporting carriage. In order to improve loading and unloading as well as transport of the spinning cans, a loading and unloading device for the can is associated with the transporting carriage, with the loading and unloading device including conveyor elements for moving the can with respect to the transporting carriage. | 3 |
FIELD OF INVENTION
The present invention relates to a composition and to a process for making a coated polyester yarn with improved bond strength to rubber. The invention provides an adhesive-active polyester fiber which is safe to handle, provides superior adhesion to rubber, utilizes a single-dip process at standard treating conditions, and does not require any special rubber stock for improved adhesion.
BACKGROUND
Polyester plied yarn or cords require application of adhesive systems to obtain good bonding to rubber articles, such as tires, hoses, and belts, etc. Generally, two types of adhesive systems are used, one process is a single-dip process and the other process is a double-dip adhesive system. A double-dip system typically provides good bonding of polyester yarn to rubber articles. However, a single-dip system is preferred, due to economic and practical considerations. A single-dip system generally requires that the polyester yarn or cord have an adhesive-active material on its surface to allow bonding with a latex dip. The resorcinol-formaldehyde latex (RFL) dip generally is a blend of resorcinol, formaldehyde, and styrene-butadiene-vinylpyridine terpolymer latex.
U.S. Pat. No. 3,642,518, to Miki et al., discloses a treatment for polyester materials to increase adhesion to rubber by contacting the polyester material with a treating liquor containing a silane.
U.S. Pat. No. 3,711,321, to Hibbert et al., discloses a process for producing coated articles, and particularly a rapid drying process for coating cellulosic substrates with coating colors containing polyvinyl alcohol as the pigment binder.
U.S. Pat. No. 3,730,892, to Marshall et al., discloses an improved multi-filament polyethylene terephthalate yarn and process for producing said yarn, said yarn being combined with a compatible fiber finish composition of hexadecyl (isocetyl) stearate, coconut oil or mineral oil; glycerol monooleate; decaglycerol tetraoleate; polyoxyethylene tall oil fatty acid; sulfonated glycerol trioleate; polyoxyethylene tallow amine; 4.4'-thiobis (6-tert-butyl-m-cresol); and a silane.
U.S. Pat. No. 4,054,634, to Marshall et al., discloses a process for producing polyethylene terephthalate yarn, particularly for tire cords, wherein a liquid finish is applied to the yarn, said process involving spinning and drawing steps, the improvement comprising (a) first applying to the yarn prior to said drawing step a liquid finish composition consisting essentially of a polyalkylene glycol composition; and then (b) applying to said yarn after said drawing step a liquid finish composition consisting essentially of about 70-95 parts by weight of said mixed polyoxyethylated-polyoxypropylated monoether, about 5 to 30 parts by weight of a silane, and a sufficient amount of water-soluble alkaline catalyst to adjust the pH of the finish composition to 8 to 10.
U.S. Pat. No. 4,348,517, to Chakravarti, discloses a process and finishing composition for producing adhesive-active polyester yarn. The fiber finish composition comprises a triglycidyl ether of glycerol; a low viscosity diglycidyl ether; ethoxylated castor oil; an epoxy silane; and a solvent.
U.S. Pat. No. 4,610,919, to Kent, discloses a fibrous padding in which the fibers are held together by a binder. The fibrous padding disclosed is capable of R.F. sealing with adhesion to loose-weave knit fabrics which are uncoated with adhesive.
SUMMARY OF INVENTION
According to the present invention, a polyester drawn yarn is coated at room temperature with an overcoat finish composition containing a polyfunctional aziridine and the yarn is then formed into cords. The cords are then treated with a resorcinol-formaldehyde latex dip composition at an elevated temperature. The treated cords can then be embedded and cured in rubber compositions. The present invention shows a significant improvement in yarn to rubber adhesion when compared with yarn having no overcoat finish application.
DETAILED DESCRIPTION
The present invention relates to a composition and to a process for production of polyester yarn with improved bond strength to rubber needed for improved reinforced rubber article preparation. Additional advantages of this invention include cost savings and convenience as compared with a two-dip system.
The yarn of the present invention is typically made of polyester. Any suitable polyester known to the art and to the literature can be utilized.
The polyester can generally be any long chain polymer composed of at least 75 percent by weight of an ester and an acid. Such polyesters are formed by the reaction of a glycol containing from about 2 to about 20 carbon atoms and a dicarboxylic acid component containing at least about 75 percent terephthalic acid. The remainder, if any, of the dicarboxylic acid component may be any suitable dicarboxylic acid having from 5 to about 20 carbon atoms such as sebacic acid, adipic acid, isophthalic acid, sulfonyl-4,4'-dibenzoic acid, or 2,8-di-benzofuran-dicarboxylic acid. Examples of linear terephthalate polyesters which can be utilized include poly(ethylene terephthalate) PET, poly(butylene terephthalate),poly(ethyleneterephthalate/5-chloroisophthalate), poly(ethylene terephthalate/5-sodiumsulfoisophthalate), poly(cyclohexane-1,4-dimethylene terephthalate), and poly(cyclohexane-1,4-dimethylene terephthalate/hexahydroterephthlate), with PET being preferred.
In accordance with conventional practice, the polyester yarn is generally made by melt-spinning the polymer and subsequently applying a conventional spin finish composition known to the art as well as to the literature. The amount of the spin finish composition is generally from about 0.4 to about 1.0 percent by weight and preferably from about 0.5 to about 0.8 percent by weight based upon the total weight of the polyester yarn. The spin finish composition can generally be a fatty acid ester based formulation, a polyether based formulation, a mineral oil composition, or any other suitable spin finish formulation heretofore known to the art and to the literature. Subsequent to the application of the spin finish, the yarn is generally drawn.
In accordance with the present invention, an overcoat finish composition, etc. is applied at room temperature, that is from about 60° F. to about 120° F., as a coating to the treated melt-spun yarn. The essential components of the overcoat finish composition include one or more aziridine (also called ethylenimine compounds) compounds known to the art and to the literature, and as dispersing agents a diluent, and a wetting agent. Examples of various aziridine/urea compounds include: bis-polyethylene urea such as ω, ω'-polymethylene bis-polyethylene urea; or aromatic bis-ethylene urea; or triazine ethylene urea (Formula I); and the like, with about 2 to about 3 aziridine groups in the molecule. Other bis-ethylene ureas can be represented by the following general formula II, where R=NH 2 , H, CH 3 O, or C 6 H 5 . ##STR1## Another aziridine compound has the general formula: ##STR2## where R'=CH 3 or OH.
Preferred aziridines include pentaerythritol-tris-(β-(N-Aziridinyl)) propionate and trimethylol propane-tris-(β-(N-Aziridinyl)) propionate. Generally, an amount of 2 to 20 percent by weight of polyfunctional aziridine based upon the total weight of the overcoat finish composition with a desirable amount being from about 4 percent to about 10 percent by weight of the weight of the essential overcoat composition, i.e., the aziridine compound, a diluent, and a wetting agent.
The polyfunctional aziridine is typically dispersed in a diluent. The diluent is desirably a polyether alcohol liquid polymer, known to the art and to the literature, or water, or combinations thereof. Although water can be utilized, it is not preferred due to the short shelf life of the overcoat finish composition. The preferred polyether alcohol can have the general formula: ##STR3## wherein n and m, independently, is from about 2.0 to about 8.0 and preferably from about 2 to about 4, and R is usually a hydrogen atom or an alkyl having from 1 to 8 carbon atoms. The polymer is generally made of ethylene and propylene oxide and is typically linear. The number average molecular weight range of this liquid polymer is generally from about 200 to about 1000, and desirably from about 240 to about 600. The amount of the diluent is generally from about 78 percent to about 96 percent; and desirably from about 80 percent to about 92 percent by weight based upon the total weight of the essential overcoat finish composition.
The third component of the essential overcoat finish composition is a wetting agent. Any wetting agent known to the art and to the literature can be utilized such as phosphate esters, fluoro surfactants, or ethoxylated alcohols. Preferably, the wetting agent is an alkaline metal salt of a sulfated or sulfonated alkyl ester containing a total of from about 8 to about 30 carbon atoms. Hence, specific examples of alkyl esters include the sodium salt of sulfonated succinic acid, and the sodium salt of octyl sulfate. The amount of the wetting agent is generally from about 0.1 percent to about 2 percent by weight and preferably from about 0.5 percent to about 1.5 percent by weight based upon the total weight of the essential overcoat finish composition.
Application of the overcoat finish composition to the yarn can be accomplished by any type of metering device known to the art and to the literature. Specific examples include kiss roll coating a metering finish applicator, spray applicator, and the like. The amount of the overcoat finish composition applied to the yarn is generally from about 2 percent to about 25 percent, desirably from about 4 percent to about 10 percent, and preferably from about 6 percent to about 8 percent (i.e., wet pick-up) based upon the total weight of the yarn. Accordingly, the amount of aziridine level on the yarn is generally between about 0.1 percent and 5.0 percent by weight of yarn, desirably from about 0.2 percent to about 1.0 percent, and preferably from about 0.2 percent to about 0.6 percent by weight of the yarn.
The finish composition can contain other non-essential compounds, however, the pH generally must be alkaline. The range of pH should generally be from about 7.1 to about 11.0, and preferably 8.0 to 9.5.
Once the application of the overcoat finish composition is completed, the yarn is plied or twisted into cords which are then treated with a dip composition. The ply depends on the final application and may be single-ply, 2-ply, 3-ply, or greater. The formation of the cords and the method of plying are well known to the art and to the literature.
The dip composition is generally a latex dip or solution. The dip process allows an adhesive layer to be applied to the overcoat finish composition treated corded yarn to permit bonding to a rubber substrate. Generally, the dip composition is composed of a resorcinol-formaldehyde latex which generally comprises a conventional resorcinol-formaldehyde resin, a base, and water. Conventional resorcinol-formaldehyde resins can be utilized as known to the art and to the literature and the same are described in U.S. Pat. No. 2,128,229; U.S. Pat. No. 2,561,215, etc. and in "Fabric Adhesion and RFL" Adhesive Age, by M. W. Wilson, 4, No. 4, pp. 32-36 (1963), and the same are hereby fully incorporated by reference. The base is generally an inorganic base such as NaOH or NH40H, and the like. For polyester fiber, usually NH4OH is avoided due to ammonolytic degradation of polyester by NH4OH.
The amount of the resorcinol-formaldehyde resin is from about 8 to about 20 percent, desirably from about 12 to about 20 percent, and preferably from about 14 to about 18 percent by weight based upon the total weight of the latex. The amount of the base is generally from about 2 to about 8 percent by weight based upon the total weight of the latex. The RFL dip is desirably aged from about 8 to about 24 hours before application because hydrolysis is slow, and the RFL mixture becomes uniform and provides better adhesion to fiber after this aging period. The molar ratio of the resorcinol to the formaldehyde of the resin can range from about 0.3 to about 2:0, desirably from about 0.3 to about 0.5.
The amount of dip typically applied varies from about 2 percent to about 10 percent by weight, and desirably from about 4 percent to about 6 percent by weight based upon the total weight of the yarn. Once the dip is applied, the plied yarn or cord is subsequently cured in an oven at an elevated temperature, generally between 300° F. to 470° F., desirably between 360° F. to 470° F., and preferably between 460° F. to 465° F.
Subsequent to the dip treatment, the treated plied yarn or cord is embedded in rubber stock in any conventional manner and cured. The material is subjected to vulcanization at temperatures about 300° F. to about 400° F. and generally under pressure of 2,000 to 3,000 kilopascals. The rubber can generally be any type of a rubber with which polyester yarn as in the form of plies or cords are utilized. Such rubbers are generally well known to the art and to the literature and include natural rubber, synthetic rubber such as those made from conjugated dienes containing from 4 to about 12 carbon atoms, rubbers made from copolymers of conjugated dienes containing from 4 to about 12 carbon atoms with vinyl substituted aromatics containing from about 8 to about 12 carbon atoms, various nitrile rubbers, various EPDM rubbers, chloroprene rubber, and the like. Examples of such rubbers containing polyester plies or cords therein include tires, conveyor belts, hoses, or any other shaped, reinforced rubber article.
The adhesion between the cord and rubber article can tested by any conventional testing method used in the art, as for example ASTM (D2138)37, and (D2630)37.
The following examples serve to illustrate the use of the invention, but do not limit it in any way.
EXAMPLE 1
In example of Table III, a polyethylene terephthalate yarn having 25 carboxyl end groups (milli equivalent/Kg) were spun as 1000 denier, 192 filaments. To the yarn was applied a conventional spin finish oil composition which acted as a lubricant. This yarn had only the lubricating spin finish, and did not contain any overcoat finish composition and was thus used as a control.
This yarn was then twisted into a two-ply cord having 12×12 twists per inch. Each cord was then treated with a conventional non-ammoniated resorcinol-formaldehyde latex dip (RFL) containing vinyl pyridine latex, resorcinol, formaldehyde, sodium hydroxide and water, usually at about 4.5 percent solids pick-up based on the weight of the cord. Here, the treating condition 1 was utilized (see Table II). The cords were then embedded unidirectionally in a rubber stock (referred to as Uniroyal-type rubber received from Uniroyal Rubber Co.) for about 15 minutes at 350° F. and at a pressure of about 2300 kilopascals. The peel adhesion force (lbs. pull of the unidirectional fabric peel force) was measured to be only about 13 lbs. (see Table III). This value thus represents the peel force as well as a visual rating of percent rubber coverage for the control sample with no special overcoats.
EXAMPLES 2-4
The procedure of example 1 was repeated in examples 2, 3, and 4 of Table III with the following changes. The overcoat A was applied in example 2, overcoat B was applied in example 3, and overcoat C was applied in example 4, respectively (see Table I for formulation). The percent wet pick-up of overcoat on the yarn in each case was adjusted such that the aziridine level on yarn is preferably from 0.2 percent to 0.5 percent, based on the yarn weight. The results of adhesion testing (strip adhesion-lbs. pull) and percent rubber coverage are shown in Table III.
EXAMPLES 5-8
In example 5 of Table III, the process of example 1 was repeated except that the RFL-treating condition of 2 as described in Table II was used. The adhesion result of example 5 represents another control yarn value without the overcoats of the present invention.
Example 6 was repeated exactly the same way as that of example 5 except that the yarn contained about 5.0 percent to 8.0 percent level of the overcoat C as wet pick-up (see Table I). The aziridine level on yarn was from 0.25 percent to 0.4 percent by weight of the yarn. The strip adhesion testing is also represented in Table III. Likewise, in examples 7 and 8, the process for example 6 was repeated except that overcoats E and F were applied on the yarn, respectively. In each case, the aziridine level on yarn is maintained at about 0.2 percent to 0.4 percent level by the weight of the yarn. The comparative adhesion results are shown in Table III.
EXAMPLES 9-13
The procedure of example I was repeated in example 9, except that the treating conditions 3 of Table II were utilized. Since no overcoat was used in the case of example 9, this represents another control at the treating condition 3, and the adhesion results of example 9 were compared with the others in examples 10-13.
In examples 10-3, the process for example 9 was repeated except that the overcoats C, D, E, and F, respectively, were utilized. Again, the aziridine level on the sample is maintained at about 0.2 percent to 0.4 percent level. Results of adhesion testing are shown in Table III for comparison with the control (example 9).
EXAMPLES 14 AND 15
Polyethylene terephthalate yarn of 1000 denier, 192 filaments, having only 16 carboxyl end groups, was prepared using the same type of spin finish composition as the above examples. The yarn was then twisted into two-ply cord having 12×12 twists per inch. The twisted cord was treated with the same conventional RFL and treating conditions as in example 9. In example 14, no overcoats were used to prepare the yarn, but in example 15, overcoat D was applied on the yarn such that wet pick-up was between 4 percent to 6 percent level, and the aziridine level on the yarn was about 0.4 percent to 0.6 percent based on the yarn weight. RFL treating condition remained the same as that of example 14 (control). Excellent adhesion improvements for example 15 are shown in Table III.
TABLE I______________________________________OVERCOAT FINISH COMPOSITIONS(PERCENT BY WEIGHT) FINISH IDENTIFICATION (PERCENT BY WEIGHT)COMPONENT A B C D E F______________________________________POE (40)/Castor Oil* 21 -- -- -- -- 10UCON 50 HB55.sup.1 -- -- 94 90 94 64UCON 50 HB100.sup.2 -- 84 -- -- -- --Sodium Octysulfate 1 -- 1 0.5 0.5 --**(Desulf SO-LF33)Sodium Dinonyl- -- 1 -- -- -- 1Sulfosuccinate**(Nekal WS25)***XAMA-7 5 -- 5 9.5 5.5 10****XAMA-2 -- 5 -- -- -- --Water 73 10 -- -- -- 15______________________________________ *moles of ethylene oxide per mole of castor oil **Trade names of products from DeForest, Inc. and GAF Corp., respectively ***Trade name for Pentaerythritoltris-((N-Aziridinyl)) Propionate (HoechstCelanese Co.) ****Trade name for Trimethylol propanetris-((N-Aziridinyl)) Propionate (HoechstCelanese Co.) .sup.1 A diluent of formula No. I having a 50:50 mole ratio of ethylene t propylene groups with R being H, and having as ASTM D2270 viscosity index of 97, manufactured by Union Carbide. .sup.2 A diluent of formula No. I having a 50:50 mole ratio of ethylene t propylene groups with R being H, and having an ASTM D2270 viscosity index of 165, manufactured by Union Carbide.
TABLE II__________________________________________________________________________TREATING CONDITIONS WITH SINGLE DIP* SYSTEM DRYING OVEN (ZONE 1) CURING OVEN (ZONE 2) CURING OVEN (ZONE 3) Temp. Exp. Stretch Temp. Exp. Stretch Temp. Exp. StretchCONDITION (°F.) (Sec.) (%) (°F.) (Sec.) (%) (°F.) (Sec.) (%)__________________________________________________________________________1 250° 60 +0.5 275° 60 0 360° 60 02 275° 50 +5.5 465° 40 -2.5 462° 50 03 300° 75 +5.5 460° 45 -2.5 460° 45 0__________________________________________________________________________ *Non-ammoniated resorcinolformaldehyde latex dip containing vinyl pyridin latex, resorcinol, formaldehyde, sodium hydroxide, and water. The percent solids pickup of the dip on the cord could be controlled from 3 percent t 5.5 percent level, preferably at 4.5 percent level, based on the weight o the cord.
TABLE III__________________________________________________________________________STRIP ADHESION RESULTSEXAMPLE OVERCOAT (1) RFL-TREATING (2) COOH-END (3) STRIP ADHESION (4) % RUBBERNO. DESIGNATION CONDITIONS GROUPS PULL-FORCE (W/POUNDS) COVERAGE__________________________________________________________________________1 No Overcoat (Control) 1 25 13 52 A 1 25 36 153 B 1 25 39 154 C 1 25 41 355 No Overcoat (Control) 2 25 20 76 C 2 25 60 607 E 2 25 68 508 F 2 25 38 209 No Overcoat (Control) 3 25 25 1510 C 3 25 80 7511 D 3 25 79 7012 E 3 25 82 8013 F 3 25 46 5014 No Overcoat (Control) 3 16 26 1015 D 3 16 56 80__________________________________________________________________________ F.N. (1) See Table I for overcoat compositions. (2) See Table II for RFL treating conditions. (3) COOH end groups of polyester (in Milli Eq./Kg.). (4) Strip adhesion force, using Uniroyal strip test at room temperature (also referred to as peel adhesion force). Percent rubber coverage are visual ratings where 100 is full coverage, and 0 is no coverage.
As apparent from the Tables, the overcoat finish composition of the present invention resulted in improved rubber coverage, as well as vastly improved strip adhesion.
While in accordance with the Patent Statutes, the best mode and preferred embodiment has been set forth, the scope of the invention is not limited thereto, but rather by the scope of the attached claims. | A composition and a process for producing adhesive-active polyester yarn comprising coating polyester fibers with an overcoat finish composition. The process relates to applying the finish to the yarn, forming the coated yarn into cords, and treating the cords with a conventional resorcinol-formaldehyde latex (RFL) dip and subsequently embedding adhesive-active yarn into a rubber article. The composition comprises an aziridine (also called an ethylenimine compound) compound, a diluent, and a wetting agent. The special finish application allows the formation of a coated yarn with improved bond strength, and in particular improved bond strength to rubber particles. | 8 |
TECHNICAL FIELD
This document relates generally to a surface treatment method for glass bubbles, glass bubbles manufactured by that method and low density sheet molding compound made utilizing glass bubbles manufactured by that method.
BACKGROUND
The government's corporate average fuel economy (CAFE) requirement of 54.5 mpg by 2025 has pushed motor vehicle manufacturers to accelerate the use of lightweight materials in motor vehicles. As a result, it has been proposed to utilize low density sheet molding compounds in the construction of vehicle body panels, such as the hood, instead of standard density sheet molding compounds. More specifically, low density sheet molding compounds have a density of about 1.2 g/cm 3 while standard density sheet molding compounds have a density of about 1.9 g/cm 3 . The key weight reduction in the formulation of low density sheet molding compounds versus standard density sheet molding compounds is replacing the CaCO 3 component of the standard sheet molding compounds with low density glass bubbles.
One of the technical challenges faced in this effort is the low interfacial properties between glass bubbles and resin. More specifically, the smooth/hard surface of the glass bubbles causes weak bonding of the bubbles to the resin matrix which has a tendency to substantially decrease the overall mechanical performance of low density sheet molding compound.
This document relates to a new and improved surface treatment method for glass bubbles which functions to roughen the surface of the glass bubbles so as to allow for better adhesion to the resin.
SUMMARY
In accordance with the purposes and benefits described herein, a method is provided for treating the outer surfaces of a plurality of glass bubbles. That method may be broadly described as comprising the steps of: (a) loading a plurality of glass bubbles into a processing vessel having a roughened lining and (b) displacing the processing vessel so that the plurality of glass bubbles move against the roughened lining and thereby roughen the outer surfaces.
In one possible embodiment, the method includes spinning and rotating the processing vessel. More specifically, the method may include spinning the processing vessel at a speed of between about 60 rpm and about 600 rpm and rotating the processing vessel at a speed of between about 60 rpm and about 600 rmp where the spinning and rotating are provided along two different axes. The method also includes reversing the direction of the spinning and the rotating of the processing vessel. In one possible embodiment, the processing vessel has a spherical shape. In another possible embodiment, the processing vessel has a cylindrical shape.
Still further, the method may include providing the plurality of glass bubbles with an outer surface roughness of about 0.01% to about 0.1% of the diameter of the plurality of glass bubbles. Still further, in one possible embodiment, the method may include subjecting the plurality of glass bubbles to an air plasma treatment. This may be done by moving the plurality of glass bubbles through an air plasma stream using a vibrating conveyor belt, moving the plurality of glass bubbles through an air plasma stream on a slide or dropping the plurality of glass bubbles through an air plasma stream. In any of these embodiments, the method includes subjecting the plurality of glass bubbles to an air plasma temperature of between about 23° C. and about 500° C.
In one possible embodiment, the air plasma treatment is completed after treating the plurality of glass bubbles in the processing vessel. In one possible embodiment, the glass bubbles are only treated mechanically in the processing vessel. In another possible embodiment, the glass bubbles only receive an air plasma treatment.
In accordance with an additional aspect, a method is provided for treating the outer surfaces of a plurality of glass bubbles comprising the step of subjecting the plurality of glass bubbles to an air plasma treatment so as to provide an outer surface roughness of about 0.01% to about 0.1% of the diameter of the plurality of glass bubbles.
In accordance with yet another aspect, a glass bubble is provided wherein that glass bubble comprises a hollow glass body having an outer surface of a diameter of between about 16 μm and about 25 μm and a surface roughness of about 0.01% to about 0.1% of that diameter. Still further, a low density sheet molding compound is provided comprising a resin and a plurality of glass bubbles as set forth and just described.
In the following description, there are shown and described several preferred embodiments of the method and the glass bubble product of the method. As it should be realized, the method and product are capable of other, different embodiments and their several details are capable of modification in various, obvious aspects all without departing from the method and product as set forth and described in the following claims. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The accompanying drawing figures incorporated herein and forming a part of the specification, illustrate several aspects of the method and product of the method and together with the description serve to explain certain principles thereof. In the drawing figures:
FIGS. 1 a and 1 b are schematic representations illustrating a glass bubble with an original smooth surface and the same glass bubble with a roughened surface after undergoing the method of surface treatment described herein.
FIG. 2 a is a schematic illustration of one possible embodiment of a device for subjecting glass bubbles in a spherical container with a roughened inner surface to rotation and spinning along two different axes A 1 , A 2 .
FIG. 2 b is a view similar to FIG. 2 a but showing an alternative embodiment wherein the processing vessel is cylindrical in shape.
FIG. 3 a is a schematic illustration of one possible way to subject a plurality of glass bubbles to an air plasma treatment utilizing a vibrating conveyor belt.
FIG. 3 b is a schematic view illustrating an alternative embodiment wherein the glass bubbles are subjected to air plasma treatment while rolling down a ramp or a slide.
FIG. 3 c is a schematic illustration of another embodiment wherein a plurality of glass bubbles subjected to an air plasma treatment by dropping and falling through a tube.
Reference will now be made in detail to the present preferred embodiments of the method, examples of which are illustrated in the accompanying drawing figures.
DETAILED DESCRIPTION
Reference is now made to FIG. 1 a illustrating a single glass bubble 10 comprising a hollow body 12 and a smooth outer surface 14 . As shown in FIG. 1 b , after being subjected to the method of treating that outer surface, the glass bubble 10 includes a hollow outer body 12 with a roughened outer surface 20 . In one useful embodiment, the treated glass bubble 10 has a diameter of between about 16 μm and about 25 μm and a surface roughness of about 0.01% to about 0.1% of that diameter: that is, a surface roughness of between 160 nm to 2500 nm. A plurality of surface treated glass bubbles 10 as disclosed have a density of about 1.2 g/cm 3 . Further, the roughened outer surface 20 has the desired interfacial interaction with a resin to provide a low density sheet molding compound with desired mechanical properties and performance when used as a motor vehicle panel component.
In order to achieve the desired roughening of the glass bubble surface 20 , the glass bubbles may be subject to roughening in a spinning and rotating processing vessel as illustrated in FIGS. 2 a and 2 b , or air plasma treatment as illustrated in FIGS. 3 a -3 c or both.
FIG. 2 a illustrates one possible embodiment of a device 30 for processing the glass bubbles 10 . The device 30 includes a processing vessel 32 of spherical shape that has a roughened internal lining 34 . The processing vessel 32 is supported at two opposed points by means of the yoke 36 . A drive motor 38 rotates (see action arrow B) the yoke 36 and, therefore, the processing vessel 32 about a first axis A 1 . A second drive motor 40 is carried on the yoke 36 and functions to spin the processing vessel 32 about a second axis A 2 (see action arrow C). In the illustrated embodiment, the first axis A 1 and the second axis A 2 are substantially perpendicular to each other.
A controller 42 connected to the two drive motors 38 , 40 allows the speed of the drive motors to be set and changed as desired during the processing of the glass bubbles 10 . The goal is to ensure that the entire outer surface of the plurality of glass bubbles 10 are roughened consistently throughout so as to provide an outer surface roughness of about 0.01% to about 0.1% of a diameter of the plurality of glass bubbles. Toward this end, the processing vessel 32 may be spun about axis A 1 at a speed of between about 60 rpm and 600 rpm while being rotated about axis A 2 at a speed of between about 60 rpm and 600 rpm. The controller 42 also allows the direction of spinning and the direction of rotating of the processing vessel 32 to be reversed as desired. Thus, for example, the processing vessel 32 may be rotated by the drive motor 38 in a first direction at a speed of between 60 and 600 rpm for a first period of time of, for example, from five to sixty seconds and then rotated in a second direction at a speed of between 60 and 600 rpm for a second period of time of, for example, from five to sixty seconds. Similarly, the processing vessel 32 may be spun by the drive motor 40 in a third direction at a speed of between 60 and 600 rpm for third period of time of, for example, from five to sixty seconds and then spun in a fourth direction at a speed of between 60 and 600 rpm for fourth period of time of, for example, from five to sixty seconds. The rotating and spinning and the periods of time may be sequential or overlapping. The reversing of direction aids in ensuring that the outer surface 20 of the glass bubbles 10 receive consistent overall roughening.
FIG. 2 b illustrates a device 46 similar to the device 30 illustrated in FIG. 2 a . The device 46 includes a processing vessel 48 having a roughened lining 50 , a yoke 52 , a first drive motor 54 , a second drive motor 56 and a controller 58 . The two devices 30 , 46 operate identically, the only difference is the processing vessel 48 in the second device 46 is cylindrical in shape rather than spherical in shape.
Reference is now made to FIGS. 3 a -3 c illustrating three different devices for providing an air plasma treatment to the glass bubbles 10 . In the embodiment illustrated in FIG. 3 a , the glass bubbles 10 are positioned on a face 60 , of a vibrating conveyor belt 62 . Accordingly, the glass bubbles 10 bounce up and down as they move along the vibrating conveyor belt 62 through an air plasma stream 64 emanating from the overlying plasma probe 66 .
As illustrative FIG. 3 b , the glass bubbles 10 roll down an incline, slide or ramp 68 through a plasma stream 70 emanating from the overlying plasma probe 72 .
In the embodiment illustrated in FIG. 3 c , the glass bubbles 10 fall or drop through the tube 74 falling through the air plasma stream 76 emanating from the opposed plasma probes 78 . In any of the air plasma treatment embodiments illustrated in FIGS. 3 a -3 c , the glass bubbles 10 are subjected to air plasma temperatures of between about 23° C. and about 500° C. and undergo an increase in surface energy that enhances their chemical bonding to a resin such as used in the production of a sheet molding compound. This increases the overall mechanical performance of a part made from that low density sheet molding compound thereby making the parts useful as panels such as hoods or the like in a motor vehicle.
With the unique size and shape of glass spheres, the above three treatment processes are specially designed to allow for a full surface treatment. The bouncing, sliding and falling movements ensure that the glass bubbles have full exposure to the plasma stream. A full surface treatment imparts better mechanical properties and performance to the glass bubbles than a partial treatment.
In summary, numerous benefits result from the surface treatment method disclosed in this document whether that method comprises only processing the glass bubbles 10 in the spinning and rotating processing vessels 32 , 48 illustrated in FIGS. 2 a and 2 b , only processing the glass bubbles by means of the air plasma treatments illustrated in FIGS. 3 a -3 c or subjecting the glass bubbles to both rotating and spinning in the processing vessel and air plasma treatment.
By increasing the roughness and/or surface energy of the surface 20 of the treated glass bubbles 10 , chemical bonding between the glass bubbles and any resin used to make low density sheet molding compounds is enhanced thereby providing those sheet molding compounds with superior mechanical properties allowing their use as various panel components of a motor vehicle. This advantageously allows the production of lower weight motor vehicles which are characterized by increased fuel economy. Accordingly, the method disclosed herein and the resulting glass bubbles and low density sheet molding compound products made using the glass bubbles 10 with the roughened surfaces 20 represents a significant advance in the art.
The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Obvious modifications and variations are possible in light of the above teachings. All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. | A method is provided for treating the outer surfaces of a plurality of glass bubbles. That method includes loading a plurality of glass bubbles into a processing vessel having a roughened lining and displacing the processing vessel so that the plurality of glass bubbles move against the roughened lining to thereby roughen the outer surfaces. Alternatively, or in addition, the glass bubbles are subjected to air plasma treatment to increase the surface energy of the glass bubbles. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of U.S. Ser. No. 10/125,447, filed Apr. 18, 2002 now U.S. Pat. No. 6,789,510 which was a continuation-in-part of U.S. Ser. No. 10/021,724 filed Dec. 12, 2001 now U.S. Pat. No. 6,695,054; U.S. Ser. No. 10/079,670, filed Feb. 20, 2002 now U.S. Pat. No. 6,848,510; U.S. Ser. No. 09/981,072, filed Oct. 16, 2001; U.S. Ser. No. 09/973,442, filed Oct. 9, 2001 now U.S. Pat. No. 6,799,637; U.S. Ser. No. 09/732,134, filed Dec. 7, 2000 now U.S. Pat. No. 6,446,729. The present application also is based upon and claims priority to U.S. provisional application Ser. No. 60/432,343, filed Dec. 10, 2002; U.S. Provisional application Ser. No. 60/418,487, filed Oct. 15, 2002; and U.S. provisional application Ser. No. 60/407,078, field Aug. 30, 2002.
BACKGROUND
1. Field of Invention
The present invention relates to the field of well monitoring. More specifically, the invention relates to well equipment and methods utilizing control line systems for monitoring of wells and for well telemetry.
2. Related Art
There is a continuing need to improve the efficiency of producing hydrocarbons and water from wells. One method to improve such efficiency is to provide monitoring of the well so that, for example, adjustments may be made to improve well efficiency. Accordingly, there is a continuing need to provide such systems.
SUMMARY
Embodiments of the present invention provide systems and methods for use in connection with wells. The systems and methods utilize monitoring and telemetry to facilitate various well treatments, data gathering and other well based operations.
BRIEF DESCRIPTION OF THE DRAWINGS
The manner in which these objectives and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
FIG. 1 illustrates a well having a gravel pack completion with a control line therein;
FIG. 2 illustrates a multilateral well having a gravel packed lateral and control lines extending into both laterals;
FIG. 3 illustrates a multilateral well having a plurality of zones in one of the laterals and sand face completions with control lines extending therein;
FIG. 4 is a cross sectional view of a sand screen used in an embodiment of the present invention;
FIG. 5 is a side elevational view of a sand screen showing a helical routing of a control line along the sand screen;
FIGS. 6 through 8 are cross sectional views of a sand screen showing numerous alternative designs;
FIGS. 9 and 10 illustrate wells having expandable tubings and control lines therein;
FIGS. 11 and 12 are cross sectional views of an expandable tubing showing numerous alternative designs;
FIGS. 13 through 15 illustrate alternative embodiments of connectors; and
FIG. 16 illustrates an embodiment of a wet connect.
FIGS. 17A–C illustrate an example of a service tool according to an embodiment of the present invention;
FIGS. 18A–D illustrate another embodiment of the service tool illustrated in FIG. 17 ;
FIGS. 19A–C illustrate an embodiment of a control line system having a wet connect, according to an embodiment of the present invention;
FIG. 20 is a schematic, cross-sectional view of an embodiment of a control line system according to one embodiment of the present invention;
FIG. 21 illustrates an alternate embodiment of the control line system illustrated in FIG. 20 ;
FIG. 22 illustrates another alternate embodiment of the control line system illustrated in FIG. 20 ;
FIG. 23 illustrates another embodiment of the control line system illustrated in FIG. 20 ;
FIG. 24 illustrates another embodiment of the control line system illustrated in FIG. 20 ;
FIG. 25 is a view similar to FIG. 24 with a gravel pack system;
FIG. 26 is an embodiment of a control line system, for use in a plurality of use in wellbore zones;
FIG. 27 is a view similar to FIG. 6 with a single dip tube;
FIG. 28 is another embodiment of the control line system illustrated in FIG. 20 ;
FIG. 29 is a view similar to FIG. 28 with an embodiment of a dip tube mounted on a removable plug;
FIG. 30 is another embodiment of the control line system illustrated in FIG. 20 ;
FIG. 31 is a view similar to FIG. 30 in which an embodiment of a dip tube is mounted on a removable plug;
FIG. 32 illustrates another embodiment of the control line system illustrated in FIG. 20 ;
FIG. 33 is an isometric view of a dip tube pivot joint;
FIG. 34 illustrates an embodiment of a dip tube mounted on a fishable plug;
FIG. 35 is a view similar to FIG. 34 with a mechanism to accommodate full bore flow;
FIG. 36 is a view similar to FIG. 34 illustrating an embodiment of a hydraulic wet connect.
FIG. 37 is a perspective view of an embodiment of a fiber optic engagement system;
FIG. 38 is an expanded view of an embodiment of a course alignment system illustrated in FIG. 37 ;and
FIG. 39 illustrates an embodiment of fiber optic connectors for use with a system, such as the system illustrated in FIG. 37 .
It is to be noted, however, that the appended drawings illustrate only embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION OF THE INVENTION
In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
In this description, the terms “up” and “down”; “upward” and downward”; “upstream” and “downstream”; and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly described some embodiments of the invention. However, when applied to apparatus and methods for use in wells that are deviated or horizontal, such terms may refer to a left to right, right to left, or other relationship as appropriate.
One aspect of the present invention is the use of a sensor, such as a fiber optic distributed temperature sensor, in a well to monitor an operation performed in the well, such as a gravel pack as well as production from the well. Other aspects comprise the routing of control lines and sensor placement in a sand control completion. Referring to the attached drawings, FIG. 1 illustrates a wellbore 10 that has penetrated a subterranean zone 12 that includes a productive formation 14 . The wellbore 10 has a casing 16 that has been cemented in place. The casing 16 has a plurality of perforations 18 which allow fluid communication between the wellbore 10 and the productive formation 14 . A well tool 20 , such as a sand control completion, is positioned within the casing 16 in a position adjacent to the productive formation 14 , which is to be gravel packed.
The present invention can be utilized in both cased wells and open hole completions. For ease of illustration of the relative positions of the producing zones, a cased well having perforations will be shown.
In the illustrated sand control completion, the well tool 20 comprises a tubular member 22 attached to a production packer 24 , a cross-over 26 , and one or more screen elements 28 . The tubular member 22 can also be referred to as a tubing string, coiled tubing, workstring or other terms well known in the art. Blank sections 32 of pipe may be used to properly space the relative positions of each of the components. An annulus area 34 is created between each of the components and the wellbore casing 16 . The combination of the well tool 20 and the tubular string extending from the well tool to the surface can be referred to as the production string. FIG. 1 shows an optional lower packer 30 located below the perforations 18 .
In a gravel pack operation the packer element 24 is set to ensure a seal between the tubular member 22 and the casing 16 . Gravel laden slurry is pumped down the tubular member 22 , exits the tubular member through ports in the cross-over 26 and enters the annulus area 34 . Slurry dehydration occurs when the carrier fluid leaves the slurry. The carrier fluid can leave the slurry by way of the perforations 18 and enter the formation 14 . The carrier fluid can also leave the slurry by way of the screen elements 28 and enter the tubular member 22 . The carrier fluid flows up through the tubular member 22 until the cross-over 26 places it in the annulus area 36 above the production packer 24 where it can leave the wellbore 10 at the surface. Upon slurry dehydration the gravel grains should pack tightly together. The final gravel filled annulus area is referred to as a gravel pack. In this example, an upper zone 38 and a lower zone 40 are each perforated and gravel packed. An isolation packer 42 is set between them.
As used herein, the term “screen” refers to wire wrapped screens, mechanical type screens and other filtering mechanisms typically employed with sand screens. Screens generally have a perforated base pipe with a filter media (e.g., wire wrapping, mesh material, pre-packs, multiple layers, woven mesh, sintered mesh, foil material, wrap-around slotted sheet, wrap-around perforated sheet, MESHRITE manufactured by Schlumberger, or a combination of any of these media to create a composite filter media and the like) disposed thereon to provide the necessary filtering. The filter media may be made in any known manner (e.g., laser cutting, water jet cutting and many other methods). Sand screens have openings small enough to restrict gravel flow, often having gaps in the 60–120 mesh range, but other sizes may be used. The screen element 28 can be referred to as a screen, sand screen, or a gravel pack screen. Many of the common screen types include a spacer that offsets the screen member from a perforated base tubular, or base pipe, that the screen member surrounds. The spacer provides a fluid flow annulus between the screen member and the base tubular. Screens of various types are commonly known to those skilled in the art. Note that other types of screens will be discussed in the following description. Also, it is understood that the use of other types of base pipes, e.g. slotted pipe, remains within the scope of the present invention. In addition, some screens 28 have base pipes that are imperforated along their length or a portion thereof to provide for routing of fluid in various manners and for other reasons.
Note that numerous other types of sand control completions and gravel pack operations are possible and the above described completion and operation are provided for illustration purposes only. As an example, FIG. 2 illustrates one particular application of the present invention in which two lateral wellbores are completed, an upper lateral 48 and a lower lateral 50 . Both lateral wellbores are completed with a gravel pack operation comprising a lateral isolation packer 46 and a sand screen assembly 28 .
Similarly, FIG. 3 shows another exemplary embodiment in which two laterals are completed with a sand control completion and a gravel pack operation. The lower lateral 50 in FIG. 3 has multiple zones isolated from one another by a packer 42 .
In each of the examples shown in FIGS. 1 through 3 , a control line 60 extends into the well and is provided adjacent to the screen 28 . Although shown with the control line 60 outside the screen 28 , other arrangements are possible as disclosed herein. Note that other embodiments discussed herein will also comprise intelligent completions devices 62 in the gravel pack, the screen 28 , or the sand control completion.
Examples of control lines 60 are electrical, hydraulic, fiber optic and combinations of thereof. Note that the communication provided by the control lines 60 may be with downhole controllers rather than with the surface and the telemetry may include wireless devices and other telemetry devices such as inductive couplers and acoustic devices. In addition, the control line itself may comprise an intelligent completions device as in the example of a fiber optic line that provides functionality, such as temperature measurement (as in a distributed temperature system), pressure measurement, sand detection, seismic measurement, and the like.
Examples of intelligent completions devices that may be used in the connection with the present invention are gauges, sensors, valves, sampling devices, a device used in intelligent or smart well completion, temperature sensors, pressure sensors, flow-control devices, flow rate measurement devices, oil/water/gas ratio measurement devices, scale detectors, actuators, locks, release mechanisms, equipment sensors (e.g., vibration sensors), sand detection sensors, water detection sensors, data recorders, viscosity sensors, density sensors, bubble point sensors, pH meters, multiphase flow meters, acoustic sand detectors, solid detectors, composition sensors, resistivity array devices and sensors, acoustic devices and sensors, other telemetry devices, near infrared sensors, gamma ray detectors, H 2 S detectors, CO 2 detectors, downhole memory units, downhole controllers, perforating devices, shape charges, firing heads, locators, and other downhole devices. In addition, the control line itself may comprise an intelligent completions device as mentioned above. In one example, the fiber optic line provides a distributed temperature functionality so that the temperature along the length of the fiber optic line may be determined.
FIG. 4 is a cross sectional view of one embodiment of a screen 28 of the present invention. The sand screen 28 generally comprises a base pipe 70 surrounded by a filter media 72 . To provide for the flow of fluid into the base pipe 70 , it has perforations therethrough. The screen 28 is typical to those used in wells such as those formed of a screen wrap or mesh designed to control the flow of sand therethrough. Surrounding at least a portion of the base pipe 70 and filter media 72 is a perforated shroud 74 . The shroud 74 is attached to the base pipe 70 by, for example, a connecting ring or other connecting member extending therebetween and connected by a known method such as welding. The shroud 74 and the filter media 72 define a space therebetween 76 .
In the embodiment shown in FIG. 4 , the sand screen 28 comprises a plurality of shunt tubes 78 (also known as alternate paths) positioned in the space 76 between the screen 28 and the shroud 74 . The shunt tubes 78 are shown attached to the base pipe 70 by an attachment ring 80 . The methods and devices of attaching the shunt tubes 78 to the base pipe 70 may be replaced by any one of numerous equivalent alternatives, only some of which are disclosed in the specification. The shunt tubes 78 can be used to transport gravel laden slurry during a gravel pack operation, thus reducing the likelihood of gravel bridging and providing improved gravel coverage across the zone to be gravel packed. The shunt tubes 78 can also be used to distribute treating fluids more evenly throughout the producing zone, such as during an acid stimulation treatment.
The shroud 74 comprises at least one channel 82 therein. The channel 82 is an indented area in the shroud 74 that extends along its length linearly, helically, or in other traversing paths. The channel 82 in one alternative embodiment has a depth sufficient to accommodate a control line 60 therein and allow the control line 60 to not extend beyond the outer diameter of the shroud 74 . Other alternative embodiments may allow a portion of the control line 60 to extend from the channel 82 and beyond the outer diameter of the shroud 74 without damaging the control line 60 . In another alternative, the channel 82 includes an outer cover (not shown) that encloses at least a portion of the channel 82 . To protect the control line 60 and maintain it in the channel 82 , the sand screen 28 may comprise one or more cable protectors, or restraining elements, or clips.
FIG. 4 also shows other alternative embodiments for routing of control lines 60 and for placement of intelligent completions devices 62 such as sensors therein. As shown in previous figures, the control line 60 may extend outside of the sand screen 28 . In one alternative embodiment, a control line 60 a extends through one or more of the shunt tubes 78 . In another embodiment, the control line 60 b is placed between the filter media 72 and the shroud 74 in the space 76 . FIG. 4 shows another embodiment in which a sensor 62 a is placed in a shunt tube 78 as well as a sensor 62 b attached to the shroud 74 . Note that an array of such sensors 62 a may be placed along the length of the sand screen 28 . In another alternative embodiment, the base pipe 70 may have a passageway 84 , or groove, therein through which a control line 60 c may extend and in which an intelligent completions device 62 c may be placed. The passageway 84 may be placed internally in the base pipe 70 , on an inner surface of the base pipe 70 , or on an outer surface of the base pipe 70 as shown in FIG. 4 .
The control line 60 may extend the full length of the screen 28 or a portion thereof. Additionally, the control line 60 may extend linearly along the screen 28 or follow an arcuate path. FIG. 5 illustrates a screen 28 having a control line 60 that is routed in a helical path along the screen 28 . In one embodiment, the control line 60 comprises a fiber optic line that is helically wound about the screen 28 (internal or external to the screen 28 ) to increase resolution at the screen. In this embodiment, a fiber optic line comprises a distributed temperature system. Other paths about the screen 28 that increase the length of the fiber optic line per longitudinal unit of length of screen 28 will also serve to increase the resolution of the functionality provided by the fiber optic line.
FIGS. 6 and 7 illustrate a number of alternative embodiments for placement of control lines 60 and intelligent completions device 62 . FIG. 6 shows a sand screen 28 that has a shroud 74 , whereas the embodiment of FIG. 7 does not have a shroud 74 .
In both FIGS. 6 and 7 , the control line 60 may be routed along the base pipe 70 via an internal passageway 84 a , a passageway 84 b formed on an internal surface of the base pipe 70 , or a passageway 84 c formed on an external surface of the base pipe 70 . In one alternative embodiment, the base pipe 70 (or a portion thereof) is formed of a composite material. In other embodiments, the base pipe 70 is formed of a metal material. Similarly, the control line 60 may be routed along the filter media 72 through an internal passageway 84 d , a passageway 84 e formed on an internal surface of the filter media 72 , or a passageway 84 f formed on an external surface of the filter media 72 . Likewise, the control line 60 may be routed along the shroud 74 through an internal passageway 84 g , a passageway 84 h formed on an internal surface of the shroud 74 , or a passageway 84 i formed on an external surface of the shroud 74 . The shroud 74 may be formed of a metal or composite material. In addition, the control line 60 may also extend between the base pipe 70 and the filter media 72 , between the filter media 72 and the shroud 74 , or outside the shroud 74 . In one alternative embodiment, the filter media has an impermeable portion 86 , through which flow is substantially prevented, and the control line 60 is mounted in that portion 86 . Additionally, the control line 60 may be routed through the shunt tubes 78 or along the side of the shunt tubes 78 ( 60 d in FIG. 4 ). Combinations of these control line 60 routes may also be used (e.g., a particular device may have control lines 60 extending through a passageway formed in the base pipe 70 and through a passageway formed in the shroud 74 ). Each position has certain advantages and may be used depending upon the specific application.
Likewise, FIGS. 6 and 7 show a number of alternatives for positioning of an intelligent completions device 62 (e.g., a sensor). In short, the intelligent completions device 62 may be placed within the walls of the various components (e.g., the base pipe 70 , the filter media 72 , the shroud 74 and, the shunt tube 78 ), on an inner surface or outer surface of the components ( 70 , 72 , 74 , 78 ), or between the components ( 70 , 72 , 74 , 78 ). Also, the components may have recesses 89 formed therein to house the intelligent completions device 62 . Each position has certain advantages and may be used depending upon the specific application.
In the alternative embodiment of FIG. 8 , the control line 60 is placed in a recess in one of the components ( 70 , 72 , 74 , 78 ). A material filler 88 is placed in the recess to mold the control line in place. As an example, the material filler 88 may be an epoxy, a gel that sets up, or other similar material. In one embodiment, the control line 60 is a fiber optic line that is molded to, or bonded to, a component ( 70 , 72 , 74 , 78 ) of the screen 28 . In this way, the stress and/or strain applied to the screen 28 may be detected and measured by the fiber optic line. Further, the fiber optic line may provide seismic measurements when molded to the screen 28 (or other downhole component or equipment) in this way.
In addition to conventional sand screen completions, the present invention is also useful in completions that use expandable tubing and expandable sand screens. As used herein an expandable tubing 90 comprises a length of expandable tubing. The expandable tubing 90 may be a solid expandable tubing, a slotted expandable tubing, an expandable sand screen, or any other type of expandable conduit. Examples of expandable tubing are the expandable slotted liner type disclosed in U.S. Pat. No. 5,366,012, issued Nov. 22, 1994 to Lohbeck, the folded tubing types of U.S. Pat. No. 3,489,220, issued Jan. 13, 1970 to Kinley, U.S. Pat. No. 5,337,823, issued Aug. 16, 1994 to Nobileau, U.S. Pat. No. 3,203,451, issued Aug. 31, 1965 to Vincent, the expandable sand screens disclosed in U.S. Pat. No. 5,901,789, issued May 11, 1999 to Donnelly et al., U.S. Pat. No. 6,263,966, issued Jul. 24, 2001 to Haut et al., PCT Application No. WO 01/20125 A1, published Mar. 22, 2001, U.S. Pat. No. 6,263,972, issued Jul. 24, 2001 to Richard et al., as well as the bi-stable cell type expandable tubing disclosed in U.S. patent application Ser. No. 09/973,442, filed Oct. 9, 2001. Each length of expandable tubing may be a single joint or multiple joints.
Referring to FIG. 9 , a well 10 has a casing 16 extending to an open-hole portion. At the upper end of the expandable tubing 90 is a hanger 92 connecting the expandable tubing 90 to a lower end of the casing 16 . A crossover section 94 connects the expandable tubing 90 to the hanger 92 . However, other known methods of connecting an expandable tubing 90 to a casing 16 may be used, or the expandable tubing 90 may remain disconnected from the casing 16 . FIG. 9 is but one illustrative embodiment. In one embodiment, the expandable tubing 90 (connected to the crossover section 94 ) is connected to another expandable tubing 90 by an unexpanded, or solid, tubing 96 . The unexpanded tubing is provided for purposes of illustration only and other completions may omit the unexpanded tubing 96 . A control line 60 extends from the surface and through the expandable tubing completion. FIG. 9 shows the control line 60 on the outside of the expandable tubing 90 although it could run through the wall of the expandable tubing 90 or internal to the expandable tubing 90 . In one embodiment, the control line 60 is a fiber optic line that is bonded to the expandable tubing 90 and used to monitor the expansion of the expandable tubing 90 . For example, the fiber optic line could measure the temperature, the stress, and/or the strain applied to the expandable tubing 90 during expansion. Such a system would also apply to a multilateral junction that is expanded. If it is determined, for example, that the expansion of the expandable tubing 90 or a portion thereof is insufficient (e.g., not fully expanded), a remedial action may be taken. For example, the portion that is not fully expanded may be further expanded in a subsequent expansion attempt, also referred to as reexpanded.
In addition, the control line 60 or intelligent completions device 62 provided in the expandable tubing may be used to measure well treatments (e.g., gravel pack, chemical injection, cementing) provided through or around the expandable tubing 90 .
FIG. 10 illustrates an alternative embodiment of the present invention in which a plurality of expandable tubings 90 are separated by unexpanded tubing sections 96 . As in the embodiment of FIG. 9 , the expandable tubing 90 is connected to the casing 16 of the well 10 by a hanger 92 (which may be a packer). The expandable tubing sections 90 are aligned with separate perforated zones and expanded. Each of the unexpanded tubing sections 96 has an external casing packer 98 (also referred to generally herein as a “seal”) thereon that provides zonal isolation between the expandable tubing sections 90 and associated zones. Note that the external casing packer 98 may be replaced by other seals 28 such as an inflate packer, a formation packer, and or a special elastomer or resin. A special elastomer or resin refers to an elastomer or resin that undergoes a change when exposed to the wellbore environment or some other chemical to cause the device to seal. For example, the elastomer may absorb oil to increase in size or react with some injected chemical to form a seal with the formation. The elastomer or resin may react to heat, water, or any method of chemical intervention.
In one embodiment the expandable tubing sections 90 are expandable sand screens and the expandable completion provides a sand face completion with zonal isolation. The expandable tubing sections and the unexpanded tubing sections may be referred to generally as an outer conduit or outer completion. In the embodiment of FIG. 10 , the zonal isolation is completed by an inner completion inserted into the expandable completion. The inner completion comprises a production tubing 100 extending into the expandable completion. Packers 42 positioned between each of the zones to isolate the production of each zone and allow separate control and monitoring. It should be noted that the packers 42 may be replaced by seal bores and seal assemblies or other devices capable of creating zonal isolation between the zones (all of which are also referred to generally herein as a “seal”). In the embodiment shown, a valve 102 in the inner completion provides for control of fluid flow from the associated formation into the production tubing 100 . The valve 102 may be controlled from the surface or a downhole controller by a control line 60 .
Note that the control line 60 may comprise a fiber optic line that provides functionality and facilitates measurement of flow and monitoring of treatment and production. Although shown as extending between the inner and outer completions, the control line 60 may extend outside the outer completions or internal to the components of the completions equipment.
As one example of an expandable screen 90 , FIG. 11 illustrates a screen 28 that has an expandable base pipe 104 , an expandable shroud 106 , and a series of scaled filter sheets 108 therebetween providing the filter media 104 . Some of the filter sheets are connected to a protective member 110 which is connected to the expandable base pipe 104 . The figure shows, for illustration purposes, a number of control lines 60 and an intelligent completions device 62 attached to the screen 28 .
FIG. 12 illustrates another embodiment of the present invention in which an expandable tubing 90 has a relatively wider unexpanding portion (e.g., a relatively wider thick strut in a bistable cell). One or more grooves 112 extend the length of the expandable tubing 90 . A control line 60 or intelligent completions device 62 may be placed in the groove 112 or other area of the expandable tubing. Additionally, the expandable tubing 90 may form a longitudinal passageway 114 therethrough that may comprise or in which a control line 60 or intelligent completions device 62 may be placed.
In addition to the primary screens 28 and expandable tubing 90 , the control lines 60 also pass through connectors 120 for these components. For expandable tubing 90 , the connector 120 may be formed similar to the tubing itself in that the control line may be routed in a manner as described above.
One difficulty in routing control lines through adjacent components involves achieving proper alignment of the portions of the control lines 60 . For example, if the adjacent components are threaded it is difficult to ensure that the passageway through one components will align with the passageway in the adjacent component. One manner of accomplishing proper alignment is to use a timed thread on the components that will stop at a predetermined alignment and ensure alignment of the passageways. Another method of ensuring alignment is to form the passageways after the components have been connected. For example, the control line 60 may be clamped to the outside of the components. However, such an arrangement does not provide for the use of passageways or grooves formed in the components themselves and may require a greater time and cost for installation. Another embodiment that does allow for incorporation of passageways in the components uses some form of non-rotating connection.
One type of non-rotating connector 120 is shown in FIGS. 13 and 14 . The connector 120 has a set of internal ratchet teeth 122 that mate with external ratchet teeth 124 formed on the components to be connected. For example, adjacent screens 28 may be connected using the connector 120 . Seals 126 between the connector 120 and components provide a sealed system. The connector 120 has passageways 128 extending therethrough that may be readily aligned with passageways in the connected equipment. Although shown as a separate connector 120 , the ratchets may be formed on the ends of the components themselves to achieve the same resultant non-rotating connection.
Another type of non-rotating connection is a snap fit connection 130 . As best seen in FIG. 15 , the pin end 132 of the first component 134 has a reduced diameter portion at its upper end, and an annular exterior groove 136 is formed in the reduced diameter portion above an O-ring sealing member externally carried thereon. A split locking ring member 138 , having a ramped and grooved outer side surface profile as indicated, is captively retained in the groove 136 and lockingly snaps into a complementarily configured interior side surface groove 140 in the box end 142 of the second component 135 when the pin end 132 is axially inserted into the box end 142 with the passageway 128 of the pin end 132 in circumferential alignment that of the box end 142 . Although shown as formed on the ends of the components themselves the snap fit connectors 130 may be employed in an intermediate connector 120 to achieve the same resultant non-rotating connection.
In one embodiment, a control line passageway is defined in the well. Using one of the routing techniques and equipment previously described. A fiber optic line is subsequently deployed through the passageway (e.g., as shown in U.S. Pat. No. 5,804,713). Thus, in an example in which the non-rotating couplings 120 are used, the fiber optic line is blown through the aligned passageways formed by the non-rotating connections. Timed threads may be used in the place of the non-rotating connector.
Often, a connection must be made downhole. For a conventional type control line 60 , the connection may be made by stabbing an upper control line connector portion into a lower control line connector portion. However, in the case of a fiber optic line that is “blown” into the well through a passageway, such a connection is not possible. Thus, in one embodiment (shown in FIG. 16 ), a hydraulic wet connect 144 is made downhole to place a lower passageway 146 into fluid communication with an upper passageway 148 . A seal 150 between the upper and lower components provides a sealed passageway system. The fiber optic line 60 is subsequently deployed into the completed passageway.
In one exemplary operation, a completion having a fiber optic control line 60 is placed in the well. The fiber optic line extends through the region to be gravel packed (e.g., through a portion of the screen 28 as shown in the figures). A service tool is run into the well and a gravel pack slurry is injected into the well using a standard gravel pack procedure as previously described. The temperature is monitored using the fiber optic line during the gravel pack operation to determine the placement of the gravel in the well. Note that in one embodiment, the gravel is maintained at a first temperature (e.g., ambient surface temperature) before injection into the well. The temperature in the well where the gravel is to be placed is at a second temperature that is higher than the first temperature. The gravel slurry is then injected into the well at a sufficient rate that it reaches the gravel pack area before its temperature rises to the second temperature. The temperature measurements provided by the fiber optic line are thus able to demonstrate the placement of the gravel in the well.
If it is determined that a proper pack has not been achieved, remedial action may be taken. In one embodiment, the gravel packed zone has an isolation sleeve, intelligent completions valve, or isolation valve therein that allows the zone to be isolated from production. Thus, if a proper gravel pack is not achieved, the remedial action may be to isolate the zone from production. Other remedial action may comprise injecting more material into the well.
In an alternative embodiment, sensors are used to measure the temperature. In yet another alternative embodiment, the fiber optic line or sensors are used to measure the pressure, flow rate, or sand detection. For example, if sand is detected during production, the operator may take remedial action (e.g., isolating or shutting in the zone producing the sand). In another embodiment, the sensors or fiber optic line measure the stress and/or strain on the completion equipment (e.g., the sand screen 28 ) as described above. The stress and strain measurements are then used to determine the compaction of the gravel pack. If the gravel pack is not sufficient, remedial action may be taken.
In another embodiment, a completion having a fiber optic line 60 (or one or more sensors) is placed in a well. A proppant is heated prior to injection into the well. While the proppant is injected into the well, the temperature is measured to determine the placement of the proppant. In an alternative embodiment the proppant has an initial temperature that is lower than the well temperature.
Similarly, the fiber optic line 60 or sensors 62 may be used to determine the placement of a fracturing treatment, chemical treatment, cement, or other well treatment by measuring the temperature or other well characteristic during the injection of the fluid into the well. The temperature may be measured during a strip rate test in like manner. In each case remedial action may be taken if the desired results are not achieved (e.g., injecting additional material into the well, performing an additional operation). It should be noted that in one embodiment, a surface pump communicates with a source of material to be placed in the well. The pump pumps the material from the source into the well. Further, the intelligent completions device (e.g., sensor, fiber optic line) in the well may be connected to a controller that receives the data from the intelligent completions device and provides an indication of the placement position using that data. In one example, the indication may be a display of the temperature at various positions in the well.
Referring now to FIGS. 17A and 17B , a service string 160 is shown disposed within the production tubing 162 and connected to a service tool 164 . The service string 160 may be any type of string known to those of skill in the art, including but not limited to jointed tubing, coiled tubing, etc. Likewise, although shown as a thru-tubing service tool, the present invention may employ any type of service tool and service string. For example, the service tool 164 may be of the type that is manipulated by movement of the service tool 164 relative to the upper packer 166 . A gravel pack operation is performed by manipulating the service tool 164 to provide for the various pumping positions/operations (e.g., circulating position, squeeze position, and reversing position) and pumping the gravel slurry.
As shown in the figures, a control line 60 extends along the outside of the completion. Note that other control line routing may be used as previously described. In addition, a control line 60 or intelligent completions device 62 is positioned in the service tool 164 . In one embodiment, the service tool 164 comprises a fiber optic line 60 extending along at least a portion of the length of the service tool 164 . As with the routing of the control line 60 in a screen 28 , the control line 60 may extend along a helical or other non-linear path along the service tool 164 . FIG. 17C illustrates an exemplary cross section of the service tool 164 showing a control line 60 provided in a passageway of a wall thereof. The figure also shows an alternative embodiment in which the service tool 164 has a sensor 62 therein. Note that the control line 60 or sensor 62 may be placed in other positions within the service tool 164 .
In one embodiment the fiber optic line in the service tool 164 is used to measure the temperature during the gravel packing operation. As an example, this measurement may be compared to a measurement of a fiber optic line 60 positioned in the completion to better determine the placement of the gravel pack. The fiber optic lines 60 may comprise or be replaced by one or more sensors 62 . For example, the service tool 164 may have a temperature sensor at the outlet 168 that provides a temperature reading of the gravel slurry as it exits the service tool. Other types of service tools (e.g., a service tool for fracturing, delivering a proppant, delivering a chemical treatment, cement, etc.) may also employ a fiber optic line or sensor therein as described in connection with the gravel pack service tool 164 .
In each of the monitoring embodiments above, a controller may be used to monitor the measurements and provide an interpretation or display of the results.
FIGS. 18A–D disclose yet another embodiment of the present invention comprising a service tool 164 that provides a fiber optic line therein. In the embodiment illustrated, the fiber optic line 60 is run along a washpipe 170 and to a position above a setting tool 172 to a special wet connect sub 174 . This sub 174 allows for a “slick-line” conveyed (or otherwise conveyed) plug 176 to be set therein. The “slick-line” encapsulates a fiber optic line. This can use a control line or other line (e.g., tubing encapsulated line or line in a coiled tubing) or sensor, or it can be a wound wire or wireline with fiber optic encased therein.
Once the plug 176 is in the wet connect sub 174 , the operative connection between the fiber optic line 60 extending to the washpipe and the fiber optic line 60 extending to the surface is made, and real-time temperature data can be monitored through the fiber optic line 60 . As shown in FIG. 18A , the washpipe 170 has a control line 60 mounted, either temporarily or permanently along the outside of the washpipe or mounted in some other manner that allows the fiber optic line in the control line to be exposed to the temperatures both internal of and external of the washpipe as desired. In this example, the washpipe is connected to the sand control service tool 164 with an integral fiber optic conduit. A fiber optic crossover tool (FOCT) 178 and the attached setting tool 172 have a fiber optic line routed therethrough. The wet connect sub is attached to the assembly above the setting tool 172 .
In one embodiment, the wet connect sub 174 has an inside diameter that is sufficiently large that packer setting balls may pass through. It also has a profile in which the plug 176 may located (although he locating function may be spaced from the fiber optic wet connect function). In addition, at the time plug 176 is located, bypass area is allowed in this sub so as not to prevent the flow of fluids down the workstring, past the sub 174 , and through the FOCT 178 . The wet connect sub 174 also contains one half of a wet connection. The second half of the wet connection is incorporated in the plug 176 .
The plug is transported in the well on a conveyance device such as a slickline, wireline, or tubing, that provides a fiber optic line. This fiber optic line is connected to the plug which has a fiber optic conduit connecting the fiber optic line to the second half of the wet connect. When the plug is landed in the sub 174 profile, a fiber optic connection is made and allows the measurement of the temperature (or other well parameters) with the entire fiber optic line, through the wet connect sub, through the FOCT and along the fiber optic placed in and/or along the washpipe. The temperature data, for example, is gathered and used in real time to monitor the flow of fluid during the gravel pack and to thereby allow real time adjustments to the gravel pack operation.
Referring generally to FIGS. 19A and 19B , another embodiment of a wet connect system is illustrated. The wet connect system facilitates the connection of a control line or control lines, e.g., control line 60 . The system provides a wet connect tool 180 that may be run on a production string 182 for interfacing with a mating connect component 184 placed below a packer 186 . The mating connect component 184 is, for example, part of a liner 188 that may have various control lines coupled to liner components below the packer 186 .
After placing liner 188 in the wellbore, the wet connect tool 180 is run into the well, as illustrated in FIG. 19A . As the “run in” is continued, wet connect tool 180 is moved through packer 186 and into engagement with mating connect component 184 . By way of example, wet connect tool 180 may comprise a spring loaded dog 190 that is biased into a corresponding receptacle 192 when the wet connect is completed, as illustrated in FIG. 19B . As production string 182 is landed, the fiber optic lines may be positioned using a passageway or passageways 193 , e.g. gun drilled ports, through a seal assembly 194 , as illustrated in FIG. 19B . Seal assembly 194 seals in the packer bore of packer 186 . The fiber optic line or other control line 60 passes through passageway 193 . As described above, multiple control lines can be used, and multiple passageways 193 may be formed longitudinally through seal assembly 194 . The control line, e.g. control line 60 , may comprise hydraulic control lines for actuation of components or delivery of wellbore chemicals, fiber optic lines, electrical control lines or other types of internal control lines depending on the particular application.
In an alternate embodiment, as illustrated in FIG. 19C , the gun drilled seal assembly is replaced with a multiport packer 195 used for sealing and anchoring. Multiport packer 195 is disposed above packer 186 , which may be a gravel pack packer. In this system, a fluted locator 196 may be used within the packer bore without a seal. However, the fluted locator extends downwardly via, for example, a tube 197 for connection to other components.
In one exemplary application, a lower completion having a fiber optic instrumented sand screen, a packer, a service tool and a polished bore receptacle is run in hole. A fiber optic cable is terminated in the receptacle which contains one side of a fiber optic wet mateable connector. A dry-mate fiber optic connection may be utilized on an opposite end of the wet-mate connector.
Once the lower completion is in place, normal gravel packing operations can be performed beginning with setting of the packer and the service tool. Once the packer is tested, the service tool is released from the packer and shifted to another position to enable pumping of the gravel. Upon pumping of sufficient gravel, a screen out may be observed, and the service tool is shifted to another position to reverse out excess gravel. The service tool may then be pulled out of the wellbore. It should be noted that the service string carrying the service tool also can have a fiber optic line and/or plugable connector as well. This would allow use of the fiber optic line during the gravel pack or other service operation.
Subsequently, a dip tube is run in hole on the bottom of a production tubing with a fiber optic cable attached. The dip tube contains the other mating portion of the fiber optic wet-mate connection. It also may use a dry-mate connection on an opposite end to join with the fiber optic cable segment extending to the surface. The dip tube lands in the receptacle, and production seals are stabbed into a seal bore in the receptacle. The hardware containing the fiber wet-mate connector may be aligned by alignment systems as the connector portions are mated. During the last few inches of the mating stroke, a snap latch may be mated, and the fiber optic connection may be completed in a sealed, clean, oil environment. This is one example of an intelligent control line system that may be connected and implemented at a down hole location. Other embodiments of down hole control line systems are described below.
Referring generally to FIG. 20 , a well system 200 comprises a control line system 201 and is illustrated according to an embodiment of the present invention. System 200 is deployed within a wellbore and comprises a lower completion 202 , an upper completion 204 and a stinger or a dip tube 206 .
Lower completion 202 may comprise a variety of components. For example, the lower completion may comprise a packer 208 , a formation isolation valve 210 and a screen 211 , such as a base pipe screen. Formation isolation valve 210 may be selectively closed and opened by pressure pulses, electrical control signals or other types of control inputs. By way of example, valve 210 may be selectively closed to set packer 208 via pressurization of the system. In some applications, formation isolation valve 210 may be designed to close automatically after gravel packing. However, the valve 210 is subsequently opened to enable the insertion of dip tube 206 .
In the embodiment illustrated, upper completion 204 includes a packer 212 and a side pocket sub 214 , which may comprise a connection feature 216 , such as a wet connect. Packer 212 and side pocket sub 214 may be mounted on tubing 218 . Additionally, the lower completion 202 and upper completion 204 may be designed with a gap 220 therebetween such that there is no fixed point connection. By utilizing gap 220 between the lower and upper completions, a “space out” trip into the well to measure tubing 218 is not necessary. As a result, the time and cost of the operation is substantially reduced by eliminating the extra out trip down hole.
Upon placement of lower completion 202 and upper completion 204 , dip tube 206 is run through tubing 218 on, for example, coiled tubing or a wireline. Dip tube 206 comprises a corresponding connection feature 222 , such as a wet connect mandrel 224 that engages connection feature 216 .
In the embodiment illustrated, engagement of connection feature 216 and corresponding connection feature 222 forms a wet connect by which a lower control line 226 , disposed in dip tube 206 , is coupled with an upper control line 228 , disposed on upper completion 204 , to form an overall control line 230 . Control line 230 may be a single control line or multiple control lines. Additionally, control line 230 may comprise tubing for conducting hydraulic control signals or chemicals, an electrical control line, fiber optic control line or other types of control lines. The overall control line system 201 is particularly amenable to use with control lines such as fiber optic control lines that may incorporate or be combined with sensors such as distributed temperature sensors 232 . In some embodiments, connection feature 216 and corresponding connection feature 222 of system 200 comprise a hydraulic wet connect. With a hydraulic wet connect, system 200 may further comprise a fiber optic or other signal carrier that is subsequently inserted through the tubing by, for example, blowing the signal conductor through the tubing.
In another embodiment illustrated in FIG. 21 , the upper completion 204 comprises a plurality of side pocket subs 214 arranged in a stacked configuration. At least one dip tube 206 is connected to connection feature 216 via a corresponding connection feature, e.g. a wet connect mandrel 224 . The connection features 216 may be located at different angular positions to accommodate insertion of dip tubes 206 through upper packer 212 and lower packer 208 .
Another embodiment of system 200 is illustrated in FIG. 22 . In this embodiment, side pocket sub 214 comprises an upper connection feature 234 to which dip tube 206 is coupled in a “lock-up” position rather than a “lock-down” position, as in the embodiments illustrated in FIGS. 20 and 21 . In other words, a connection, such as a wet connect, is formed by moving a corresponding connecting feature 236 of dip tube 206 upwardly into engagement with upper connection feature 234 of side pocket sub 214 . As described with previous embodiments, the connection may be a wet connect in which corresponding connection feature 236 is formed on a wet connect mandrel 238 sized to fit within the side pocket 240 of side pocket sub 214 . As previously discussed, control line 230 may comprise a variety of control lines, but one example is a fiber optic control line that forms a fiber optic wet connect across upper connection 234 and corresponding connection feature 236 .
Referring generally to FIG. 23 , another embodiment of system 200 is illustrated. In this embodiment, the lower completion 202 having, for example, packer 208 , formation isolation valve 210 and screen 211 is coupled to upper completion 204 by an expansion joint 242 . In the example illustrated, expansion joint 242 comprises a telescopic joint that compensates for deviation in the gap or distance between lower completion 202 and upper completion 204 . Also, upper completion 204 may have a tubing isolation valve 243 to, for example, facilitate setting of packer 212 .
In this embodiment, the control line 230 comprises a coiled section 244 to reduce or eliminate stress on control line 230 during expansion or contraction of joint 242 . Control line 230 may comprise a variety of control lines, including hydraulic lines, chemical injection lines, electrical lines, fiber optic control lines, etc. In the example illustrated, control line 230 comprises a fiber optic control line having an upper section 246 coupled to coiled section 244 by a fiber optic splice 248 . Coiled section 244 is connected to a lower control line section 250 by a connector 252 , such as a fiber optic wet connect 254 and latch 256 . Thus, the overall control line 230 is formed when upper completion 204 , including expansion joint 242 and coiled section 244 , is coupled to lower completion 202 . As illustrated, lower control line section 250 may be deployed externally to screen 211 and may deploy a variety of sensors, e.g., a distributed temperature sensor.
Another embodiment of system 200 is illustrated in FIG. 24 . In this embodiment, an entire completion 258 comprising lower completion 202 and upper completion 204 can be run in hole in a single trip. Accordingly, it is not necessary to form wet connects along control line 230 . Although completion 238 may comprise a variety of embodiments, in the embodiment illustrated, packer 212 and packer 208 are mounted on tubing 218 . Between packer 208 and 212 , a valve 260 , such as a ball valve, is mounted. Additionally, a circulating valve 262 may be mounted above valve 260 . Below packer 208 , screen 211 comprises an expandable screen section 264 along which or through which control line 230 extends.
In operation, the entire completion 258 along with control line 230 is run into the wellbore in a single trip. The system is landed out on a tubing hanger “not shown”, and a control signal, such as a pressure pulse, is sent to close ball valve 260 . Subsequently, the interior of tubing 218 is pressurized sufficiently to set the screen hanger packer, packer 208 , via a separate control line 266 . Next, a screen expander tool is run through tubing 218 on a work string. Valve 260 is then opened by, for example, a pressure pulse or other command signal or by running a shifting tool at the end of the screen expander tool. The screen expander is then moved through screen 211 to transition the screen to its expanded state, illustrated in FIG. 24 as expanded screen 264 .
Upon expansion of the screen, the expanding tool is pulled out of the wellbore, and the valve 260 is closed with, for example, a shifting tool at the end of the screen expander. Once the expander tool is removed from the wellbore, a pressure pulse or other appropriate command signal is sent down hole to open circulating valve 262 via, for example, a sliding sleeve 268 . The fluid in tubing 218 is then displaced with a completion fluid, such as a lighter fluid or a thermal insulation fluid. Subsequently, the valve is closed to permit pressure buildup within tubing 218 . The pressure is increased sufficiently to set upper packer 212 . Then, a pressure pulse or other appropriate command signal is sent down hole to open valve 260 . At this stage, the entire completion 258 is set at a desired location within the wellbore along with control line 230 . Furthermore, the entire procedure only involved a single trip down hole.
An embodiment similar to that of FIG. 24 is illustrated in FIG. 25 . In this embodiment, the expandable sand screen is replaced with a gravel pack system 270 . By way of example, gravel pack system 270 may comprise a gravel pack port closure sleeve 272 and a base pipe sand screen 274 . The control line 230 may be deployed externally of the base pipe sand screen 274 . In operation, the same single trip procedure as discussed with respect to FIG. 24 may be utilized. However, instead of performing the act of expanding the sand screen, a gravel pack is run. It also should be noted that. the systems illustrated generally in FIGS. 24 and 25 can be utilized with multi-zoned intelligent completions.
Another embodiment of system 200 is illustrated in FIG. 26 . In this embodiment, a multiple completion 276 is illustrated for use in at least two wellbore zones 278 , 280 . Wellbore zone 280 is isolated by a packer 282 to which an expandable sand screen 284 is connected. A tubing 286 extends through packer 282 and into communication with expandable sand screen 284 . Tubing 286 may utilize a polished bore receptable 287 above packer 282 to facilitate construction of multiple completion 276 . Additionally, a formation isolation valve 288 may be deployed between packer 282 and sand screen 284 .
Above packer 282 , a larger tubing 290 encircles tubing 286 and is coupled to a screen, such as a base pipe screen 292 . Screen 292 allows fluid from wellbore zone 278 to enter the annulus between tubing 286 and larger tubing 290 . Larger tubing 290 extends to a packer 294 deployed generally at an upper region of wellbore zone 278 to isolate wellbore zone 278 . Additionally, a port closure sleeve 296 and a flow isolation valve 298 may be deployed between screen 292 and packer 294 .
A dip tube 300 incorporating a control line extends into wellbore zone 278 intermediate tubing 286 and larger tubing 290 . An additional dip tube 302 having, for example, a fiber optic control line, is deployed through tubing 286 into the lower wellbore zone 280 . Each of the dip tubes 300 and 302 may be deployed according to methods described above with respect to FIGS. 20–23 . For example, a control line 304 associated with dip tube 300 may be connected though a wet connect/snap latch mechanism 306 disposed above a packer 308 located up hole from packer 294 . As described with reference to FIG. 23 , an expansion joint 310 may be utilized to facilitate the connection of wet connect and snap latch 306 when an upper completion is moved into location within the wellbore above packer 308 . Furthermore, dip tube 302 and its associated control line 312 may be moved through the center of tubing 286 and into connection with the upper portion of control line 312 via a wet connect 314 disposed in a side pocket sub 316 . It should be noted that in at least some applications, a plug 318 may be utilized in cooperation with side pocket sub 316 to selectively block flow through tubing 286 while the tubing is pressurized to set upper packer 320 disposed above side pocket sub 316 . Accordingly, by sequentially moving completion sections to appropriate wellbore locations, a multiple completion can be constructed with separate control lines isolated in separate wellbore zones. Also, individual dip tubes in combination with, for example, a fiber optic line may be used to sense parameters from more than one zone. Center dip tube 302 and an inner fiber optic line can be used to measure temperature in zones 278 and 280 without direct contact with fluid from both zones.
In FIG. 27 , for example, another embodiment of multiple completion 276 is illustrated. In this embodiment, fluid is produced from multiple wellbore zones, e.g. wellbore zone 278 and wellbore zone 280 , but the outlying dip tube 300 has been eliminated. Accordingly, expansion joint 310 also is no longer necessary in this particular application. As illustrated, the single dip tube 302 extends through tubing 286 into the interior of expandable sand screen 284 . As with previous embodiments, the dip tube 302 can be utilized for a variety of applications, including chemical injection, sensing and other control line related functions. For example, dip tube 302 may be perforated to expose an internal fiber optic distributed temperature sensor.
Another embodiment of a system 200 is illustrated in FIG. 28 . In this embodiment, the control line 230 is combined with an embodiment of upper completion 204 that may be deployed in a single trip. By way of example, lower completion 202 comprises a packer 322 , such as a screen hangar packer, and sand screen 324 , such as an expandable sand screen, suspended from packer 322 . Additionally, a latch member 326 may be deployed above packer 322 to receive upper completion 204 .
Initially, packer 322 and expandable sand screen 324 are positioned in the wellbore, and sand screen 324 is expanded. Subsequently, upper completion 204 along with one or more control lines 230 is run in hole and latched to latch member 326 . In this embodiment, upper completion 204 may comprise a snap latch assembly 328 for coupling to latch member 326 . Additionally, upper completion 204 comprises a formation isolation valve 330 , a control line coiled section 332 , a space out contraction/expansion joint 334 , a tubing isolation valve 336 and an upper packer 338 all mounted to tubing 340 .
The control line or lines 230 extend through upper packer 338 to coil section, 332 where the control lines are coiled to accommodate lineal contraction or expansion of joint 334 . From coil section 332 , the control line or lines 230 extend around formation isolation valve 330 and through snap latch assembly 328 to a dip tube 342 extending into sand screen 324 .
With this design, the formation isolation valve 330 may be in a closed position subsequent to latching upper completion 204 to lower completion 202 . This allows for deployment of control lines 230 and dip tube 342 prior to, for example, changing fluid in tubing 340 , a procedure that requires closure of formation isolation valve 330 . The upper tubing isolation valve 336 enables the selective setting of upper packer 338 prior to opening tubing 340 . Thus, the entire upper completion and control line 230 along with dip tube 342 can be deployed in a single trip without the formation of any control line wet connects.
In FIG. 29 , a similar design to that of FIG. 28 is illustrated but with a removable stinger/dip tube 342 . In this embodiment, the dip tube 342 is coupled to a retrievable plug 344 . The control line or lines 230 are routed through plug 344 and into or along dip tube 342 . However, the retrievable plug allows the dip tube 342 to be retrieved through tubing 340 without pulling upper completion 204 . In the embodiment illustrated, there is no wet connect between retrievable plug 344 and the remainder of upper completion 204 . Accordingly, if plug 344 and dip tube 342 are retrieved, the control line 230 is cut or otherwise severed.
Referring generally to FIG. 30 , another configuration of control line system 200 is illustrated. In this embodiment, a sand screen such as an expandable sand screen 346 , along with a screen hangar packer 348 are initially run into the wellbore. Subsequently, an anchor packer 350 along with a formation isolation valve 352 , a wet connect member 354 and a lower section 356 of control line 230 are run in hole and positioned within the wellbore. In this embodiment, a dip tube 358 is provided to receive at least a portion of control line lower section 356 , and dip tube 358 is positioned to extend through screen hangar packer 348 into expandable sand screen 346 .
Upon placement of anchor packer 350 , the upper section of the completion may be run in hole. The upper completion is connected to a tubing 360 and comprises a packer 362 . A tubing isolation valve 364 is position below packer 362 , and a space out contraction/expansion joint 366 is located below valve 364 . Control line 230 is coupled to a control line coil section 368 and terminates at a corresponding wet connect member 370 . The corresponding wet connect member 370 is designed and positioned to pluggably engage connector member 354 to form a wet connect.
A similar embodiment is illustrated in FIG. 31 . However, in this embodiment, dip tube 358 is coupled to a removable plug 372 . As described above with reference to FIG. 29 , removable plug 372 enables the removal of dip tube 358 through tubing 360 without removal of the completion or segments of the completion.
Referring generally to FIG. 32 , another embodiment of system 200 is illustrated. In this embodiment, one example of a lower completion 374 comprises a screen 376 , such as a base pipe screen, a formation isolation valve 378 , a port closure sleeve 380 and a packer 382 . However, a variety of other components can be added or interchanged in the construction of lower completion 374 . A space out gap is disposed between lower completion 374 and an upper completion 386 . By way of example, upper completion 386 comprises an upper packer 388 mounted to tubing 390 . A tubing isolation valve 392 is disposed below packer 388 in cooperation with tubing 390 . A slotted pup 394 is disposed below tubing isolation valve 392 to permit inwardly directed fluid flow from an outer fluid flow path 396 . The outer fluid flow path 396 flows around a control line side step plug 398 to which a dip tube 400 is mounted at an offset location to permit a generally centralized fluid flow along a fluid flow path 402 . Thus, fluid may flow to tubing 390 via outer or inner flow paths. The side step plug 398 may be designed to receive fiber optic lines or other types of control lines therethrough. The control line can be connected through a wet connect 404 proximate side step plug 398 , or a dry connect may be utilized.
Many intelligent completion systems may benefit from a moveable dip tube. For example, when running into deviated wells, a pivotable dip tube design may be utilized, as illustrated in FIG. 33 . In this example, a dip tube 406 which may embody many of the dip tubes described above, is coupled to a subject system by a pivot joint 408 . By way of example, pivot joint 408 may be constructed by forming a ball 410 at the base of dip tube 406 . The ball 410 is sized for receipt in a corresponding receptacle 412 for pivotable movement. The pivot joint 408 enables movement of dip tube 406 as it is run into a given wellbore. The ability to pivot can facilitate movement past obstructions or into deviated wellbores. In deviated wells, the control line also can be strapped externally to a perforated pipe, or friction reducing members, e.g., rollers, can be coupled to the dip tube.
Referring generally to FIGS. 34 through 36 , alternate dip tube embodiments are illustrated. In each of these embodiments, a dip tube 414 is deployed at a desired wellbore location. As illustrated in FIG. 34 , dip tube 414 and a connector 416 are mounted to a retrievable plug 418 having a fishing feature 420 . Fishing feature 420 may be an internal or external feature configured for engagement with a fishing tool (not shown) to permit retrieval and potentially insertion of dip tube 414 through production tubing 422 .
Although fishing feature 420 and dip tube 414 may be utilized in a variety of applications, an exemplary application utilizes a flow shroud 424 connected between tubing 422 and a lower segment tubing or sand screen 426 . A completion packer 428 is disposed about tubing 426 , and dip tube 414 extends into tubing 426 through completion packer 428 . In this embodiment, fluid flow typically moves upwardly through tubing 426 into the annulus between flow shroud 424 and in internal mounting mechanism 430 to which retrievable plug 418 is mounted. Mounting mechanism 430 comprises an opening 432 through which dip tube 414 passes and a plurality of flow ports 434 that communicate between the surrounding annulus and the interior of tubing 422 . Thus, retrievable plug 418 and dip tube 414 can readily be retrieved through tubing 422 without obstructing fluid flow from tubing 426 to tubing 422 .
Furthermore, connector 416 may comprise a variety of connectors, depending on the particular application. For example, the connector may comprise a hydraulic connector for the connection of tubing, or the connector may comprise a fiber optic wet connect or other control line wet connect. These and other types of connectors can be utilized depending on the specific application of the system.
With reference to FIG. 35 , a base 436 of mounting mechanism 430 may be formed as a removable component. For example, the base 436 may be coupled to a side wall 438 of mounting mechanism 430 by a sheer pin or other coupling mechanism 440 . Thus, the base 436 can be released or broken free from the remainder mounting mechanism 430 to provide a substantially uninhibited axial flow from tubing 426 through mounting mechanism 430 and into tubing 422 . By way of example, the fishable dip tube 414 can be retrieved from the completion, and base 436 may be knocked down hole to provide a full bore flow.
A variety of connection features may be incorporated into the overall design depending on the particular application. For example, a hydraulic wet connection feature 442 may be pivotably mounted within retrievable plug 418 . In this particular embodiment, the hydraulic wet connection feature 442 is connected to a lower section 444 of control line 230 , and the connection feature 442 is pivotably mounted within retrievable plug 418 for pivotable outward motion upon reaching a desired location. For example, when retrievable plug 418 is fully inserted into mounting mechanism 430 , as illustrated in FIG. 36 , the hydraulic wet connection feature 442 pivots outwardly for engagement with an upper section 446 of control line 230 . As described above, the control line 230 may comprise a variety of control lines including tubes, wire, fiber optics and other control lines through which various materials or signals flow. It should also be noted that a variety of other types of connectors can be utilized with the various control line systems illustrated.
Referring generally to FIGS. 37 through 39 , a system 450 for connecting a fiber optic line in a wellbore is illustrated. By way of example, system 450 may comprise a lower completion 452 , an upper completion 454 and an alignment system 456 . In the embodiment illustrated, lower completion 452 comprises a receptacle assembly 458 having a polished bore receptacle 460 , an open receiving end 462 and a receptacle latch 464 generally opposite open receiving end 462 .
In this embodiment, upper completion 454 comprises a stinger 466 having a stinger collet 468 at a lead end. A fiber optic cable accumulator 470 is deployed at an end of stinger 466 generally opposite stinger collet 468 . In this design, stinger 466 is rotatably coupled to fiber optic accumulator 470 . In one embodiment, stinger 466 is rotationally locked with respect to fiber optic cable accumulator as the upper completion is moved downhole, but upon entry of stinger 466 into open receiving end 462 , a release lever 472 (see FIG. 38 ) is actuated to rotationally release stinger 466 with respect to fiber optic cable accumulator 470 . Thus, alignment system 456 can rotate stinger 466 to properly align the fiber optic cable segments in lower completion 452 and upper completion 454 , enabling a downhole wet connect.
By way of specific example, alignment system 456 may comprise a helical cut 474 formed on open receiving end 462 . An alignment key 476 is coupled to stinger 466 , and is guided along helical cut 474 and into an internal groove 478 formed along the interior of receptacle assembly 458 . Internal groove 478 guides alignment key 476 and stinger 466 as the upper completion 454 and lower completion 452 are moved towards full engagement.
As the insertion of stinger 466 continues towards completion, a fine alignment system 480 moves fiber optic connectors into engagement, as best illustrated in FIG. 39 . As illustrated, at least one and often a plurality of fiber optic cable segments 482 extend longitudinally along or through upper completion 454 and terminate at wet plugable connector ends 484 . Similarly, fiber optic cable segments 486 extend along or through lower completion 452 to corresponding fiber optic connector ends 488 . In this embodiment, a plurality of fine tuning keys 490 are connected to the interior of receptacle assembly 458 , as shown schematically in FIG. 39 . The fine tuning keys 490 have tapered lead ends 492 that are slidably received in corresponding grooves 494 formed in the exterior of stinger 466 . As tapered ends 492 move into grooves 494 , the fine tuning keys 490 are able to rotationally adjust stinger 466 for precise plugable connection of connector ends 484 with corresponding connector ends 488 to establish a wet connect between one or more fiber optic cables. It should be noted that the upper and lower completions can utilize a variety of other components, and the arrangement of alignment keys, helical cuts, internal grooves and other features can be interchanged between the upper completion and the lower completion.
Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Thus, although a nail and a screw may not be structural equivalents in that a nail employs a cylindrical surface to secure wooden parts together, whereas a screw employs a helical surface, in the environment of fastening wooden parts, a nail and a screw may be equivalent structures. 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. | A well system utilizes a control line system. The control line system is implemented with a completion of the type deployed in a wellbore. The control line system facilitates transmission of monitoring, command or other types of control and telemetry. It is emphasized that 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. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. 37 CFR 1.72(b). | 4 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to and the benefit of Korean Patent Application No. 2006-94172, filed Sep. 27, 2006, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND
1. Field of the Invention
The present invention relates to a method for optical connection between an optical transmitter and an optical receivers and a structure for optical connection fabricated using the same. More particularly, the present invention relates to an optical connection method and structure for connecting an optical transmitter with an optical receiver using flexible optical connection/transmission media, e.g. plastic optical fibers or flexible optical waveguides.
In addition, the present invention relates to an optical connection structure and method for connecting an optical transmitter and an optical receiver on a printed circuit board (PCB) of an optical transmission system to solve the problem of an electromagnetic field generated by signal transfer in a conventional electrical circuit.
2. Discussion of Related Art
Ongoing development in the field of integrated circuit (IC) technology is pushing the limits of operating speed and integration density, resulting in the rapid development of new high-performance microprocessors and high-capacity memory chips. In order to effectively apply cutting-edge IC technology to a next-generation information and communication system capable of switching at more than a terabit per second (Tb/s) and transmitting mass amounts of information at high speed, improvement in signal processing capability is prerequisite. Simply put, this translates into need for higher signal transfer speed and higher line density.
However, as information is usually transferred by means of an electrical signal over a relatively short distance such as between two boards or between two chips, there is a limit to increasing signal transfer speed and line density. This limit arises from the inevitable problems of signal delay due to the resistance of the line itself and electromagnetic interference (EMI) generated as signal transfer and line density increase. Thus, there is need for an alternative strategy for realizing a high-speed system.
In order to solve these problems, a variety of connection methods are being suggested that apply optical interconnection technology using polymer and glass fibers. As an example, an optical PCB (OPCB) made Lip of a PCB into vehicle an optical waveguide is inserted has been devised. The optical waveguide and a glass substrate guide optical signals to perform high-speed data communication, and a copper trace pattern is formed in the same board to convert the optical signals into electrical signals for data storing/signal processing in a device.
A method for manufacturing a 3-dimensional optical interconnection block is disclosed in Korean Laid-Open Patent No. 10-2005-0074417. The method comprises the steps of: inserting at least one optical fiber array into an opening of at least one optical connector to connect them with each other; inserting the structure of the optical connector connected through the optical fiber array into a guide groove of a sustaining block to combine them with each other; inserting a solid body into the combined sustaining block to fix the optical fiber array connected with the optical connector in the sustaining block; and cutting the optical connector to separate the sustaining block from the optical connector along X, Y and Z-axes to form an optical connection block to which the optical fiber array is fixed by the solid body.
However, when optical fibers are connected by forming an optical connection block as described above, a device and apparatus for optical coupling, such as an optical connection block, should be devised. The optical coupling device is both expensive to build and difficult to precisely attach.
In addition, as optical transmission-connection media for connecting optical devices with each other, optical fibers and optical waveguides are frequently used. In general, single-mode glass optical fibers are used for long-distance transmission, multimode glass optical fibers are used for short (300 m or less) and very short (1 nm or less) distances, and optical waveguides mainly using polymer are frequently used for chip-scale optical transmission. However, when an optical fiber does not have a jacket, it lacks flexibility. Also, finishing of a cut end is not easy and requires a dedicated cutting machine.
SUMMARY OF THE INVENTION
The present invention is directed to a structure and method for optical connection between an optical transmitter and an optical receiver, which simplify a fabrication process, can be easily applied regardless of various device modifications, and can reduce time taken to assemble an optical connection structure.
The present invention is also directed to a structure and method for optical connection applying a general electrical circuit chip packaging technique to package an optical transmitter and an optical receiver.
One aspect of the present invention provides a method for optical connection between an optical transmitter and an optical receiver, comprising the steps of: (a) forming on a substrate a light source device, an optical detection device, an optical transmission unit electrically connected with the light source device, and an optical detection unit electrically connected with the optical detection device; (b) preparing a flexible optical transmission connection medium to optically connect the light source device formed on the substrate with the optical detection device; (c) cutting the prepared optical transmission-connection medium and surface-finishing it; and (d) directly connecting one end of the surface-finished optical transmission-connection medium with the light source device and the other end with the optical detection device.
Step (c) of surface-finishing the optical transmission-connection medium may comprise the steps of: cutting the optical transmission-connection medium using a cutting machine, and thermally annealing the cut end of the optical transmission-connection medium using a soldering iron. Step (d) of connecting the optical transmission-connection medium with the light source device and the optical detection device may comprise the steps of: applying an adhesive to regions of the light source device and the optical detection device; connecting ends of the optical transmission-connection medium, to which the adhesive is applied, to the region of the light source device and the optical detection device; and irradiating the regions of the light source device and the optical detection device to which the optical transmission-connection medium is connected with ultraviolet light.
The method may further comprise the step of, when one end of the optical transmission-connection medium is connected to the region of the light source device or the optical detection device, connecting an optical power meter to the other end of the optical transmission-connection medium and checking whether or not the light source device or the optical detection device is properly connected with the optical transmission-connection medium. The method may further comprise the step of, when one end of the optical transmission-connection medium is connected with the light source device or the optical detection device after the other end of the optical transmission-connection medium is connected to the light source device or the optical detection device, driving the optical transmission unit or the optical detection unit and checking whether or not the light source device or the optical detection device is properly connected with the optical transmission-connection medium.
The optical transmission-connection medium may be a plastic optical fiber or a flexible optical waveguide. The flexible optical waveguide may take the form of a two-dimensional sheet with a polyimide film attached to it.
Another aspect of the present invention provides a structure for optical connection between an optical transmitter and an optical receivers comprising: an optical transmission unit for transmitting a signal applied through an electrical signal line formed on a substrate; a light source device electrically connected with the optical transmission unit, converting the applied signal into light and emitting it; an optical detection device optically connected with the light source device and detecting the light converted and emitted by the light source device; an optical detection unit electrically connected with the optical detection device and converting the light received at the optical detection device into an electrical signal; and a flexible optical transmission-connection medium whose one end is connected with the light source device and whose other end is directly connected with the optical detection device.
The flexible optical transmission-connection medium may be a plastic optical fiber or a flexible optical waveguide. The plastic optical fiber or the flexible optical waveguide may be used in a single mode for long-distance transmission of an optical signal, and used in a multimode for short-distance transmission or very-short-distance transmission of an optical signal. The substrate may be a printed circuit board (PCB) or an optical bench.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, features and advantages of the present invention will become more apparent to those of ordinary skill in the art by describing in detail exemplary embodiments thereof with reference to the attached drawings in which:
FIG. 1 is a perspective view of an optical connection system according to an exemplary embodiment of the present invention;
FIGS. 2A to 2G are diagrams illustrating processes in a method of connecting a light source device and an optical detection device according to an exemplary embodiment of the present invention;
FIG. 3 is a perspective view showing an optical connection structure connecting a light source device with an optical detection device through flexible optical waveguides according to an exemplary embodiment of the present invention; and
FIG. 4 is a side cross-sectional view of an optical connection system including an optical connection structure according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Hereinafter, exemplary embodiments of the present invention will be described in detail. However, the present invention is not limited to the embodiments disclosed below, but can be implemented in various forms. The following embodiments are described to make this disclosure sufficiently detailed and comprehensive to enable one of ordinary skill in the art to embody and practice the invention.
FIG. 1 is a schematic perspective view of a structure for optical connection between an optical transmitter and an optical receiver according to an exemplary embodiment of the present invention. The illustrated structure is used for high-speed signal transfer over a very short distance, such as between general chips.
Referring to FIG. 1 , an optical connection structure 100 comprises an optical transmission unit 102 and an optical detection unit 103 formed on a substrate 101 , a light source device 104 and an optical detection device 105 , optical transmission-connection media 106 optically connecting the light source device 104 with the optical detection device 105 , and first electrical signal lines 109 receiving a signal from outside and second electrical signal lines 110 providing a signal to outside.
More specifically, an optical printed circuit board (OPCB) or silicon optical bench that neither causes nor is susceptible to electromagnetic interference (EMI) is used for the substrate 101 . The light source device 104 and the optical detection device 105 optically connected with the light source device 104 and detecting light emitted from the light source device 104 are formed on the substrate 101 implemented by an OPCB or a silicon optical bench.
In order to transfer the optical signal from the light source device 104 to the optical detection device 105 without loss, the optical transmission-connection media 106 are formed between the light source device 104 and the optical detection device 105 . Plastic optical fibers or flexible optical waveguides may be used as the optical transmission-connection media 106 because they are easier to cut and bard-face the cut ends than conventional glass optical fibers or polymer optical waveguides. Other types of optical fibers and waveguides may also be used according to transmission distance.
Plastic optical fibers have never been used as inter-chip optical transmission-connection media such as the optical transmission-connection media 106 . Currently, plastic optical fibers have a minimum core diameter of about 500 μm and are used in lighting and display technology, and as jump cables of a few high-performance audio systems. Plastic optical fibers used in the present invention may have a core (not shown in the drawings) diameter reduced to 8 to 62.5 μm, and may have a rectangular core. Multimode plastic optical fibers having a core diameter of 50 to 62.5 μm may be used for short-distance (300 m or less) and very short-distance (1 m or less) transmission, and single-mode optical fibers having a core diameter of 7 to 8 μm may be used for long-distance transmission. When flexible optical waveguides are used, cores of the optical waveguides take the form of a 2-dimensional sheet, and a polyimide film is attached to the coverings to protect the sheet.
The light source device 104 is electrically connected with the optical transmission unit 102 by wires 107 a , and the optical detection device 105 is electrically connected with the optical detection unit 103 by wires 108 a . On the substrate 101 , the first electrical signal lines 109 electrically connected with the optical transmission unit 102 and the second electrical signal lines 110 electrically connected with the optical detection unit 103 are formed. The optical transmission unit 102 is connected with the first electrical signal lines 109 by wires 107 b , and the optical detection unit 103 is connected with the second electrical signal lines 110 by wires 108 b.
In the optical connection structure 100 constituted as described above, a high-speed data signal for inter-device transmission passes through the optical transmission unit 102 along the first electrical signal lines 109 and arrives at the light source device 104 , which converts the signal applied from the first electrical signal lines 109 into light. As the light source device 104 , a surface emitting laser or a general laser may be used. The size of the optical transmission-connection media 106 handling transmission of the optical signal is determined according to the type of light source. The optical signal emitted for the light source device 104 passes through the optical transmission-connection media 106 and arrives at the optical detection device 105 . Here, the optical transmission-connection media 106 are directly connected to the surface of the optical detection device 105 . The optical signal (light) arriving at the optical detection device 105 is converted by the optical detection unit 103 into an electrical signal (current) and transmitted to the second electrical signal lines 110 , thereby completing connection between two points in close proximity. With this connection method, there is almost no loss, and the specifications of all components, such as a chip, a PCB, packaging, etc., can be flexibly adjusted for packaging. Thus, it is possible to reduce the cost of optical packaging to the cost of electrical device packaging by reducing the overall cost of packaging.
FIGS. 2A to 2G are diagrams illustrating processes in a method of connecting the light source device and the optical detection device according to an exemplary embodiment of the present invention. Parts of the drawings may be drawn out of proportion for better visibility.
First, in order to connect a light source device 104 and an optical detection device 105 , i.e., to perform optical link packaging, optical transmission-connection media 106 must be prepared and cut to a proper size using an appropriate tool, and then the cut end must be surface-finished. In this embodiment, plastic optical fibers are used as the optical transmission-connection media 106 . More specifically, referring to FIG. 2A , the plastic optical fibers 106 prepared for optical link packaging are cut using cutting scissors 210 . The plastic optical fibers 106 may be prepared in a bundle.
In the next step, referring to FIG. 2B , the cut ends of the cut plastic optical fibers 106 are thermally annealed. In the thermal annealing process, the cut ends of the cut plastic optical fibers 106 may be easily hard-faced using a soldering iron 220 , and so on. Once the prepared plastic optical fibers 106 are cut and the cut end surface-finishing is completed, a post process of inserting the cut portions of the plastic optical fibers 106 into openings 201 formed on the light source device 104 is performed.
Referring to FIG. 2 C( a ), the cut plastic optical fibers 106 are inserted into the openings 201 of the light source device 104 , and an adhesive 203 is used to fix them therein. An ultraviolet (UV) epoxy, a UV hardening resin or so on may be used as the adhesive 203 . An injector 205 , a pipette, or so on may be used to precisely drop the adhesive 203 into the openings 201 of the light source device 104 . Alternatively, referring to FIG. 2 C( b ), the cut ends of the plastic optical fibers 106 are dipped in a vessel 202 containing the adhesive 203 and taken out after a predetermined time period, so that the adhesive 203 may be applied to the cut ends of the plastic optical fibers 106 . In the step of applying the adhesive, one of the methods illustrated in FIGS. 2 C( a ) and ( b ) may be selected and used.
FIG. 2D illustrates a process of inserting the plastic optical fibers 106 into the openings 201 of the light source device 104 and then irradiating them with UV light using a UV irradiation device 230 . Before UV irradiation, precise optical connection between the light source device 104 and the plastic optical fibers 106 must be confirmed. This includes the steps of driving the optical transmission unit 102 to cause an optical signal to be emitted from the light source device 104 , connecting the other ends, i.e., connectors (e.g., subscriber connectors (SCs)), of the plastic optical fibers 106 with an optical power meter 240 , and measuring the optical power.
In the next step, referring to FIGS. 2E and 2F , the other ends of the plastic optical fibers 106 inserted and fixed in the openings 201 of the light source device 104 are cut off and surface-finished. As illustrated in FIGS. 2A and 2B , the other ends are cut using the cutting device 210 and then surface-finished using the heat of the soldering iron 220 .
As illustrated in FIG. 2Q , the other ends of the plastic optical fibers 106 connected with the light source device 104 are inserted and fixed into openings 204 formed on the optical detection device 105 . Here, the other ends of the plastic optical fibers 106 are connected with the openings 204 of the optical detection device 105 in the same way their one ends are connected with the openings 201 of the light source device 104 . In order to connect the cut and surface-finished plastic optical fibers 106 with the optical detection device 105 , the adhesive 203 is inserted into the openings 204 of the optical detection device 105 and then irradiated and fixed by UV light. Here, in order to confirm precise optical connection, it is preferable to connect the optical transmission unit 102 and the light source device 104 with the optical detection unit 103 and the optical detection device 105 during operation. As the UV hardening operation is performed while the intensity of the light source is metered to check optical connection of the light source device 104 , optical connection of the optical detection device 105 can be checked using an amount of current proportional to the optical signal received from the light source device 104 .
A method of checking whether the light source device 104 and the light detection device 105 are properly connected with the optical transmission-connection media 106 by driving the optical transmission unit 102 and the optical detection unit 103 is described above. However, another checking method for precise optical connection is to connect the optical transmission unit 102 with the optical detection unit 103 and observe the system under a microscope (not shown in the drawings).
FIG. 3 is a perspective view showing an optical connection structure connecting a light source device with an optical detection device through flexible optical waveguides according to an exemplary embodiment of the present invention. In this embodiment, flexible optical waveguides 310 instead of plastic optical fibers are used as the optical transmission-connection media 106 for optical links. The flexible optical waveguides 310 may be fabricated by a molding method using a master and must be flexible. Like the plastic optical fibers 106 , the flexible optical waveguides 310 are connected with a light source device 104 and an optical detection device 105 using an adhesive (a UV epoxy, etc.). A magnified portion of FIG. 3 shows the optical waveguides 310 as integrated into a single body having a flat rectangular shape. In order to connect the flexible optical waveguide 310 with the light source device 104 and the optical detection device 105 , openings (not shown in the drawing) corresponding to both ends of the optical waveguides 310 must be formed on the respective devices 104 and 105 .
FIG. 4 is a schematic side cross-sectional view of an optical connection system including an optical connection structure according to an exemplary embodiment of the present invention. Referring to FIG. 4 , the optical connection system can be used as an interface between chips requiring high-speed signal processing, and more particularly, for connection between a high-speed central processing unit (CPU) 401 and a control chip 402 . Recent drastic increase in the sheer quantity of information being handled has generated demand for high-speed communication circuits capable of transferring signals between chips at rates of several GHz or more. The required speed of signal transfer will continue to increase into the future, as will transmission capacity per channel between chips or even within a chip. To continue this trend, it is expected that system on chip (SOC) and system in package (SIP) technology will be developed into system on package (SOP) technology, wherein easy signal connection between chips and signal integrity will be of paramount importance. Referring to FIG. 4 , the various control chips 402 , a complementary metal-oxide semiconductor (CMOS)/SOC chip (not shown in the drawing), and the CPU 401 are disposed on a multilayer PCB 403 , and high-speed signal transfer is required between them.
Here, a light source device 104 , such as a vertical cavity surface emitting laser (VCSEL) or a laser diode (LD), and a driving unit 102 driving the light source device 104 are required. In addition, after an electrical signal is converted into light by the light source device 104 , optical transmission-connection media 106 are required to transmit the light (optical signal) to another chip. Here, the transmitted signal is converted back into an electrical signal and transmitted to a desired chip by an optical detection device 105 , e.g., a photodetector (PD). When an optical link is established by the method suggested in the present invention, an optical module can be easily packaged. In the future, optical device driving units 102 and 103 will be embedded in the CPU, 401 and the control chips 402 by a CMOS process.
In the above-described exemplary embodiment, the optical link is easily established by converting a high-speed signal into light. And in the future, even the light source device 104 and the optical detection device 105 may be embedded in a CMOS chip.
As described above, the present invention can be applied to an interface between chips requiring high-speed signal processing, and has the effects of speeding-up the transfer of a high-speed signal and increasing transmission capacity per channel between the chips or within a chip.
In addition, unlike conventional optical connection methods, since no separate optical connection device or apparatus is required and packaging can be completed in a short time at low cost, the present invention call be easily applied to all optical devices and productivity can be improved. Even an optical device chip can be embedded in a CMOS chip by the optical link technology of the present invention, thus opening the door to the optical packaging era.
While the invention has been shown and described with reference to certain exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. | Provided are a method and structure for optical connection between an optical transmitter and an optical receiver. The method includes the steps of: forming on a substrate a light source device, an optical detection device, an optical transmission unit electrically connected with the light source device, and an optical detection unit electrically connected with the optical detection device; preparing a flexible optical transmission-connection medium to optically connect the light source device with the optical detection device; cutting the prepared optical transmission-connection medium and surface-finishing it; and connecting one end of the surface-finished optical transmission-connection medium with the light source device and the other end with the optical detection device. Fabrication of an optical package having a 3-dimensional structure is facilitated and fabrication time is reduced, thus improving productivity. In addition, since the optical transmission-connection medium is directly connected with the light source device and the optical detection device, a polishing operation or additional connection block is not required, thus facilitating mass production. | 7 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a divisional application of U.S. patent application Ser. No. 11/143,013 which was filed on Jun. 1, 2005, which is a continuation of U.S. patent application Ser. No. 10/759,758, which was filed on Jan. 14, 2004, now U.S. Pat. No. 6,901,718, which is a divisional of U.S. patent application Ser. No. 10/202,554, which was filed on Jul. 23, 2002, now U.S. Pat. No. 6,732,492, the entirety of all of which is are incorporated by reference herein.
TECHNICAL FIELD
[0002] The invention pertains to methods of packaging paper products, and in particular applications pertains to methods of packaging facial tissue in a dispenser.
BACKGROUND OF THE INVENTION
[0003] A method of packaging paper products, such as facial tissue, which has gained acceptance in the marketplace is to fold a stack of paper product sheets about a central axis and then provide the sheets within a boutique-type box. The box has a perforation extending therethrough to the central region of the folded sheets, and such allows a consumer to withdraw the sheets from the box. The packaging can have an advantage in that the box of folded paper product can have a smaller footprint that would a box of non-folded paper product. Also, in many cases consumers associate a box of folded paper product with a premium line of product, rather than with lower-tier product. Examples of facial tissue products marketed in boutique-type boxes are ALBERTSON'S™ “WHISPER SOFT IMAGES”™; HYVEE™ “SOFT ESSENTIALS TREASURES”™; and KLEENEX™ “ULTRA SOFT DOUX”™.
[0004] The box having the folded tissue therein is a dispenser. Ideally, the tissue will be dispensed one-at-a-time through the perforation which extends into the box. However, it is frequently found that the first several sheets do not dispense smoothly in a one-at-a-time manner. Instead the sheets bind within the box and either tear as they are being pulled from the box, or come out as a clump of four or five tissues. Since the tissues within a boutique-type dispenser are associated with premium product, there can be heightened consumer dissatisfaction with the poor dispensing of the first few sheets than would occur with packaging not associated with premium product.
[0005] The problem of having the first few sheets dispensed poorly from a boutique-type dispenser has existed for years, and to date there has not been a satisfactory solution to the problem. A recent study by Potlatch Corporation has shown that there are times when at least sixty percent of the boutique-type dispensers produced for a line of premium paper product will fail to appropriately dispense the first sheet of product, and there can even be times when eighty percent or more of the packages fail to appropriately dispense the first sheet of tissue product.
[0006] FIGS. 1-3 illustrate an exemplary process for providing facial tissue within a boutique-type box. Referring initially to FIG. 1 , an arrangement 8 is shown comprising a clip 10 of facial product folded around a ski 14 . The clip comprises a plurality of individual tissue sheets 12 (only some of which are labeled). The term “clip” is known in the art to refer to a stacked plurality of sheets which have been appropriately sized to be provided within a package.
[0007] The ski 14 has an edge 16 , and opposing lateral surfaces 18 extending upwardly from the edge. The clip 10 comprises a central region 20 proximate the edge 16 of ski 14 . Clip 10 further comprises peripheral regions 22 and 24 on opposing sides of central region 20 , with the peripheral regions extending along lateral edges 18 of ski 14 in the shown folded configuration of the clip.
[0008] Clip 10 would be folded about ski 14 utilizing an apparatus (not shown) which forces peripheral regions 22 and 24 upwardly relative to central region 20 of the clip.
[0009] FIGS. 2 and 3 illustrate an apparatus 30 comprising the clip and ski arrangement 8 , and further comprising a holder 32 configured to retain a package 34 thereon. Package 34 can correspond to a boutique-type dispenser. In the shown configuration, a perforation (not visible in FIGS. 2-4 ) would be at a bottom surface 36 of dispenser 34 , and ultimately a consumer would remove tissue of clip 10 from dispenser 34 through the perforation. Dispenser 34 has a series of flaps 38 , 40 and 42 associated therewith, and such flaps surround an opening (not visible in the views of FIGS. 2 and 3 ).
[0010] The ski 14 of FIGS. 2 and 3 extends along a longitudinal direction 15 , and comprises a length 17 . In operation, the folded clip 10 is slid along a portion of length 17 of ski 14 , and ultimately is slid off from ski 14 and along an axis 44 into the opening within dispenser 34 . FIG. 2 shows the clip at a processing stage at which the clip is along the ski, and FIG. 3 shows the clip at a processing stage after it has been slid off from the ski and into the dispenser. The clip 10 of FIG. 3 is shown in phantom view to indicate that the clip is within dispenser 34 . It is noted that clip 10 is generally moved from the ski to the dispenser by a conveying mechanism (not shown) such as a block or plurality of fingers configured to engage a surface of the clip and push the clip along the axis 44 .
[0011] FIG. 3 illustrates that the flaps 38 , 40 and 42 ( FIG. 2 ) have been folded over to retain clip 10 within package 34 .
SUMMARY OF THE INVENTION
[0012] In one aspect, the invention encompasses a method of packaging paper products in a dispenser. A clip comprising a stacked plurality of paper products is provided. Also, a ski is provided. The ski comprises a first surface extending longitudinally along the first direction, and has a pair of second surfaces extending transversely from the first surface. The clip is folded around the ski. The folded clip has a central region along the first surface of the ski, and has a pair of opposing peripheral regions separated from one another by the central region. The folded clip is slid off from the ski and subsequently the peripheral regions of the folded clip are pressed toward one another to compress the peripheral regions. After the peripheral regions are compressed, the folded clip is transferred into the dispenser. The peripheral regions can be subjected to at least about 1 pound per square inch gauge (psig) of pressure during the pressing.
[0013] In further aspects, the invention encompasses methods of packaging facial tissue:
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
[0015] FIG. 1 is a diagrammatic end-view of a prior art arrangement comprising a clip of paper product sheets folded around a ski.
[0016] FIG. 2 is a diagrammatic side view of a prior art apparatus utilized for inserting a folded clip of paper product into a package.
[0017] FIG. 3 is a view of the prior art apparatus of FIG. 2 shown at a processing stage subsequent to that of FIG. 2 .
[0018] FIG. 4 is a diagrammatic side view of an apparatus utilized for inserting a folded clip of paper product into a package in accordance with an aspect of the present invention.
[0019] FIG. 5 is a diagrammatic end-view of an arrangement comprising a folded clip of paper product in accordance with an exemplary method of the present invention.
[0020] FIG. 6 is a diagrammatic end-view of an arrangement comprising a folded clip of paper product around a ski in accordance with an exemplary method of the present invention.
[0021] FIG. 7 is a diagrammatic side view of an exemplary ski which can be utilized in methodology of the present invention.
[0022] FIG. 8 is a diagrammatic end view of the FIG. 7 ski, along the line 8 of FIG. 7 .
[0023] FIG. 9 is a black and white photograph showing a prior art assembly comprising a boutique-type package having a folded clip retained therein.
[0024] FIG. 10 is a black and white photograph of an assembly comprising a folded clip within a boutique-type package and formed in accordance with an aspect of the present invention.
[0025] FIG. 11 is black and white photograph of an assembly comprising a folded clip retained within a boutique-type package and formed in accordance with another aspect of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0026] One aspect of the invention is a recognition that a reason the first few sheets of tissues are difficult to remove from a boutique-type box can be that the first few sheets are tightly pushed against the interior sides of the boutique-type box, and accordingly friction makes it difficult to withdraw the first few sheets. Once the first few sheets have been removed, the remaining sheets can be more easily withdrawn because the pressure between the remaining sheets of the clip and the interior sidewall of the box decreases as sheets are removed and the bulk of the remaining clip is thereby reduced.
[0027] Various methods have been investigated for reducing the overall bulk of a folded clip within a boutique-type box in an effort to reduce the friction of the outermost sheets of the clip relative to an interior surface of the box. Among such methods are to increase the dimensions of the box, or decrease the number of sheets in a clip. Neither method is considered satisfactory. If the dimensions of the box are increased, then the footprint of the box will increase which means that less boxes can be included on the same amount of shelf space as are presently being provided. Also, an increase in the dimensions of a boutique-type box would create complications in the transport and distribution of the boxes. A reduction in the total number of sheets contained within a box can create problems with consumer perception of the quality of the package. Specifically, each box of tissue is generally prominently labeled with the number of sheets in the box. Consumers would likely be dissatisfied if the number of sheets in boxes of premium tissue were suddenly reduced, even if such translated into better dispensing of the first of the remaining sheets from the box.
[0028] FIG. 4 shows an apparatus 50 which can be utilized in various aspects of the present invention. Similar numbering will be utilized in referring to FIG. 4 as was used above in referring to FIGS. 2 and 3 , where appropriate. The apparatus of FIG. 4 is similar to that of FIGS. 2 and 3 , except that a compression unit 52 is provided between ski 14 and dispenser 34 . In operation, folded clip 10 is slid off from ski 14 and into the compression unit, squeezed by the compression unit, and then transferred into dispenser 34 . The squeezing of clip 10 by the compression unit prior to insertion of the clip into the dispenser is found to reduce friction of peripheral edges of the clip relative to internal sidewalls of the dispenser, and to thus improve dispensing of the first few sheets of the clip from the dispenser.
[0029] FIG. 5 illustrates operation of the compression unit 52 for reducing the bulk associated with a folded clip prior. More specifically, FIG. 5 shows an arrangement 100 comprising the clip 10 folded and compressed within compression unit 52 . Clip 10 comprises a stacked plurality of paper products 106 (only some of the individual paper products are labeled). The paper products can correspond to, for example, facial tissue.
[0030] Clip 10 comprises a central region 120 and comprises a pair of opposing peripheral regions 122 separated from one another by the central region. In the shown aspect of the invention, clip 10 is folded approximately in half. Accordingly, peripheral regions 122 correspond to folded regions separated from one another by the fold and each comprising about one-half of the total clip.
[0031] Compression unit 52 comprises a pair of plates 130 which press against the peripheral regions 122 of clip 10 . A compressive force applied to plates 130 is illustrated diagrammatically by arrows 132 and 134 . The force against the plates can be generated utilizing, for example, one or more of electric, hydraulic or pneumatic power sources.
[0032] Preferably, peripheral regions 122 are subjected to at least about 1 pound per square inch gauge (psig) of pressure during the compression of the peripheral regions with plates 130 . In particular applications, the pressure can be at least about 5 psig, and least about 10 psig, and at least about 15 psig. In some applications, the pressure can be greater than or equal to about 15 psig, and less than or equal to about 400 psig.
[0033] It is found that if too much pressure is applied, desirable qualities of the individual sheets can be compromised, and even lost. Also, it is found that if too little pressure is applied, the bulk of the peripheral regions of the clip is not sufficiently reduced to avoid the problems associated with drawal of the first few sheets of the clips that were discussed above with reference to the prior art. It can be desired to apply from at least about 10 psig of pressure to less than or equal to about 100 psig of pressure to peripheral regions 122 , and even more desired to apply from at least about 20 psig of pressure to less than or equal to about 80 psig of pressure to peripheral regions 122 . In exemplary applications, about 50 psig of pressure is applied to peripheral regions 122 , and in other applications about 80 psig of pressure is applied to peripheral regions 122 .
[0034] The pressure at peripheral regions 122 can be applied for a time of less than or equal to about 10 seconds (such as a time of from about 1 second to about 10 seconds, or a time of less than or equal to about 5 seconds), and can be applied at typical operating temperatures utilized in paper production factories, such as, for example, temperature of from greater than 0° C. to less than or equal to about 40° C.
[0035] After the compression described with reference to FIG. 5 , the clip 10 can be slid into a package utilizing processing analogous to that described above with reference to prior art FIGS. 2 and 3 . Specifically, plates 130 are withdrawn from peripheral surfaces 122 of clip 10 , and the clip is subsequently slid into a package.
[0036] Although the clip is typically slid off from the ski prior to the compression of the peripheral regions of the clip, the ski shape can still influence physical properties of the compressed clip. It is found that it can be advantageous to utilize a narrow ski, rather than a wide ski, in various methods of the present invention. However, a problem which can occur when a narrow ski is utilized is that the clip can rotate relative to the ski so that the clip is skewed in its ultimate orientation within a package. Such is illustrated in FIGS. 9 and 10 . Specifically, FIG. 9 shows a prior art package comprising a folded clip of facial tissue within a boutique-type box. A side of the box has been opened so that the clip can be seen in its ultimate orientation within the box. A perforation (not clearly visible in the view of FIG. 9 ) is at the top of the box, and in operation a consumer would reach through the perforation to pull a sheet of facial tissue from the folded clip. Ideally, the folded clip would be oriented in the box such that a highest point of the clip is directly under the perforation at the top of the box, and so that each of the peripheral sides of the clip would have approximately the same pressure against an interior side of the box as one another. The shown prior art clip of FIG. 9 is slightly skewed in the box, but the orientation is reasonable in that both sides of the clip have about the same amount of overlap with interior sides of the box. It is noted that the folded clip of FIG. 9 has a relatively wide hole in the middle, evidencing that the ski utilized to insert the clip into the package was relatively wide.
[0037] FIG. 10 illustrates a clip formed around a narrow ski prior to being inserted into the package. Note that the central region of the clip does not have the wide gap of the FIG. 9 clip, which evidences that the FIG. 10 folded clip came off of a narrower ski than did the FIG. 9 folded clip. The FIG. 10 clip is skewed significantly more than the FIG. 9 clip, as evidenced by the fact that the shown left side of the clip rubs against an interior side of the package whereas the shown right side of the clip does not even contact the interior right side of the box. The excessive skew of the FIG. 10 clip is undesired. The excessive skew can cause tissue to pull unevenly from the clip due to the significantly increased friction along the left side of the clip relative to the right side. As the tissue pulls unevenly from the clip, clumping of remaining tissue within the FIG. 10 package can occur, which can lead to tearing of the sheets as a consumer attempts to withdraw the clump, and/or to multiple sheets coming out simultaneously.
[0038] FIG. 11 illustrates a folded clip that has been formed around a narrow ski and subsequently inserted into a package in a desired configuration. Specifically, a top surface of the clip is directly under a perforation (not visible in the view of FIG. 11 ) at the top of the package, and the clip is symmetric so that the left and right sides of the clip rub about equally on interior sidewalls of the package.
[0039] It is desired to increase the number of packages having the desired configuration of FIG. 11 relative to the packages having the undesired configuration of FIG. 10 . The FIG. 10 problems and FIG. 11 advantages can occur regardless of whether the compression unit 52 of FIGS. 4 and 5 is present. If the compression unit is not present and the clip is transferred directly from the ski into the dispenser, poor orientation of the clip from the ski will typically be directly translated into a poor orientation of the clip in the dispenser. If the clip is transferred from the ski to the compression unit, poor orientation of the clip from the ski can lead to compression of the clip along an undesired axis and a resulting poor fold orientation. The poor fold orientation can then translate into a poor orientation of the clip in the dispenser.
[0040] FIG. 6 illustrates one method for enhancing control of the orientation of a clip as it is slid off from a ski. In referring to FIG. 6 , similar number will be utilized as was used above in describing FIGS. 2-5 , where appropriate. FIG. 6 illustrates an assembly 200 comprising clip 10 folded around a ski 220 . Ski 220 has a different shape than conventional skis. Ski 220 comprises an edge 224 between a pair of laterally-extending surfaces 226 . A notch (or cavity) 228 extends into edge 224 . Notch 228 can extend, for example, at least about ¼ inch or at least about ½ inch into the edge. In the shown embodiment, edge 224 comprises a width “W”, and notch 228 is approximately centered relative to the width. Ski 220 typically extends longitudinally analogously to the ski 14 of FIG. 2 . Further, ski 220 wilt comprise a longitudinal length, analogous to the length 17 of prior art ski 14 . In particular embodiments, notch 228 can extend along at least a portion of length of the ski. In some aspects the notch can extend along at least a fourth of the length of the ski and in further aspects can extend along an entirety of the length of the ski.
[0041] Notch 228 can assist in retaining clip 104 in a particular orientation relative to ski 220 . Specifically, notch 228 provides additional surfaces for retaining clip 104 as the clip is slid off from ski 220 and into a package. Accordingly, notch 228 can assist in reproducibly and consistently orienting clips of stacked tissue in a desired configuration within a dispenser. Such can enable the desired FIG. 9 configuration of a package, for example, to be reproducibly obtained.
[0042] FIGS. 7 and 8 illustrate an exemplary ski 302 that can be utilized in methodology of the present invention. Ski 302 comprises a first (or bottom) surface 308 extending longitudinally along a first direction (with the longitudinal direction of the ski being analogous to the direction 15 of FIG. 2 ). Ski 302 further comprises a pair of second surfaces 310 which extend upwardly relative to first surface 308 . In particular applications, surface 308 can be referred to as an edge, and surfaces 310 can be referred to as opposing lateral surfaces extending from the edge. Ski 302 can be referred to generically as a bar.
[0043] Ski 302 can have an edge width of less than or equal to about one inch, less than or equal to about ¾ inch, and in particular applications can have a width of less than or equal to about one-half inch.
[0044] The edge 308 of ski 302 is illustrated as being curved upwardly between lateral surfaces 310 to form a cavity 320 . Cavity 320 can have a depth of about ⅛ inch. Corners 322 are formed where edge 308 joins surfaces 310 , and such corners can aid in retaining and orienting a clip folded around the lower portion of ski 302 .
[0045] Ski 302 has a ramped portion 330 of the lower surface, which can extend at, for example, about a 9° angle relative to the non-ramped portion of the lower surface. The ramped portion can aid in releasing a folded clip from the ski.
[0046] In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and described, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents. | The invention includes a method of packaging paper products (such as facial tissue) in a dispenser. A clip of paper product is folded. The folded clip has a central region and a pair of opposing peripheral regions separated from one another by the central region. The peripheral regions of the folded clip are pressed toward one another to compress the peripheral regions. After the peripheral regions are compressed, the folded clip is transferred into the dispenser. | 1 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to making a bunter of the type used to imprint indicia on ammunition cartridge cases. Specifically, this invention relates to methods and blanks for making such bunters.
BACKGROUND OF THE INVENTION
[0002] The base of an ammunition cartridge case commonly has a “headstamp,” which comprises recessed lettering or other recessed indicia showing who manufactured the case. The headstamp may also indicate the caliber and year of manufacture. As is well known, the base typically also has a primer pocket. The headstamp, primer pocket, or both can be formed in the base using a hardened metal plug called a “bunter.”
[0003] The bunter has raised lettering around its face. Thus, when the face of the bunter is pressed against the base of the case, the raised lettering on the bunter forms corresponding recessed letters in the base.
[0004] The raised letters on bunters have been formed on the bunter's face by EDM or engraving. Unfortunately, both of these techniques leave the bunter's face with considerable surface roughness, and this roughness is transferred to the cartridge case when the bunter is used to stamp the headstamp on the case. Moreover, the EDM and engraving techniques require a substantial amount of time. Further, when using EDM or engraving, the bunter is not workhardened during the forming process.
[0005] It would be desirable to provide a fast, efficient process for forming raised indicia on the face of a bunter. It would be particularly desirable to provide a process that leaves the face of the bunter with a smooth, workhardened surface. It would also be desirable to provide a bunter blank configuration that facilitates such a process.
SUMMARY OF THE INVENTION
[0006] Certain embodiments of the present invention provide a method of producing a bunter that is configured to stamp recessed headstamp indicia into a base of an ammunition cartridge case. In the present embodiments, the method involves providing a bunter blank having a generally ring-shaped working face from which projects a radial center protrusion. The radial center protrusion is configured for receipt in a primer pocket of the cartridge case's base during stamping of the recessed headstamp indicia. The bunter blank's generally ring-shaped working face surrounds the radial center protrusion and has an outwardly rounded configuration. The method comprises providing a hub having a generally ring-shaped contact face that defines indicia recesses. The generally ring-shaped contact face of the hub surrounds a central pocket. The method includes assembling the generally ring-shaped working face of the bunter blank against the generally ring-shaped contact face of the hub such that the bunter blank's radial center protrusion is received in the hub's central pocket and applying enough force to the thus assembled bunter blank and hub that material defining the outwardly rounded configuration of the bunter blank's working face is deformed into the hub's indicia recesses so as to form raised indicia on the working face.
[0007] Other embodiments provide a bunter blank to be machined into a bunter for stamping recessed headstamp indicia into a base of an ammunition cartridge case. In the present embodiments, the bunter blank preferably comprises metal and includes both a base and a generally ring-shaped working face from which projects a radial center protrusion. The radial center protrusion preferably has a cylindrical shape and is configured for receipt in a primer pocket of the cartridge case's base during stamping of the recessed headstamp indicia. In the present embodiments, the bunter blank's generally ring-shaped working face has a hump that encircles the radial center protrusion, and this hump has an aspect ratio of greater than 7. Preferably, the hump is located radially outside of an inwardly radiused section adjacent to a base portion of the radial center protrusion.
[0008] In certain embodiments, the invention provides a method of producing a bunter that is configured to stamp recessed headstamp indicia into a base of an ammunition cartridge case. The method involves providing a bunter blank having a working face from which projects a radial center protrusion. The radial center protrusion is configured for receipt in a primer pocket of the cartridge case's base during stamping of the recessed headstamp indicia. In the present embodiments, the bunter blank's working face has a hump that encircles the radial center protrusion. The method includes providing a hub having a contact face that defines indicia recesses. The contact face of the hub surrounds a central pocket. The present method embodiments comprise assembling the working face of the bunter blank against the contact face of the hub, such that a peak of the hump is aligned with the indicia recesses and such that the radial center protrusion is received in the central pocket, and applying enough force to the thus assembled bunter blank and hub that material defining the hump is deformed into the indicia recesses so as to form raised indicia on said working face.
[0009] Some embodiments of the invention provide a method of producing a bunter that is configured to stamp recessed headstamp indicia into a base of an ammunition cartridge case. In the present embodiments, the method comprises providing a bunter blank having a working face with a hump defined by a generally toroidal surface (in the present embodiments, the radial center protrusion is optional and may be omitted). The method involves providing a hub having a contact face that defines indicia recesses (the contact face of the hub is not required to have a central pocket, though, it is preferred). The method comprises assembling the working face of the bunter blank against the contact face of the hub, such that a peak of the hump is aligned with the indicia recesses, and applying enough force to the thus assembled bunter blank and hub that material defining the hump is deformed into the indicia recesses so as to form raised indicia on the working face.
[0010] Certain embodiments provide a bunter blank to be machined into a bunter for stamping recessed headstamp indicia into a base of an ammunition cartridge case. In the present embodiments, the bunter blank preferably comprises metal and includes both a base and a working face (in the present embodiments, the radial center protrusion is optional and may be omitted). Preferably, the bunter blank's working face has a hump defined by a generally toroidal surface. In the present embodiments, the hump has an aspect ratio of greater than 3.5, greater than 5, or even greater than 7. Preferably, the hump is located radially inside of (e.g., is encircled by) a planar perimeter surface (or “flat”).
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1A is a side view of a conventional ammunition casing.
[0012] FIG. 1B is a bottom view of the casing of FIG. 1A .
[0013] FIG. 2A is a front view of a bunter produced in accordance with certain embodiments of the invention.
[0014] FIG. 2B is a cross-sectional side view of the bunter of FIG. 2A , the cross section being taken along lines B-B of FIG. 2A .
[0015] FIG. 3A is a side view of a bunter blank in accordance with certain embodiments of the invention.
[0016] FIG. 3B is a cross-sectional view of a leading end region of the bunter blank of FIG. 3A , the cross section being taken along lines C-C of FIG. 3A .
[0017] FIG. 3C is a detail view of the leading end region shown in FIG. 3B .
[0018] FIG. 4A is a perspective view of a hub used in forming raised indicia on the working face of a bunter in accordance with certain embodiments of the invention.
[0019] FIG. 4B is a front view of the hub of FIG. 4A .
[0020] FIG. 4C is a side view of the hub of FIG. 4A .
[0021] FIG. 4D is a front view of another hub used in forming raised indicia on the working face of a bunter in accordance with certain embodiments of the invention.
[0022] FIG. 4E is a cross-sectional view of the hub of FIG. 4D , the cross section being taken along lines A-A of FIG. 4D .
[0023] FIG. 5 is a broken away cross-sectional side view showing a leading end region of a bunter blank in engagement with a working end of a hub in accordance with certain embodiments of the invention.
[0024] FIG. 6A is a perspective view of a fixture mounted on a press with a ram of the press spaced above the fixture in accordance with certain embodiments of the invention.
[0025] FIG. 6B is a perspective view of the fixture mounted on the press of FIG. 6A , with the ram of the press engaging stops on the fixture in accordance with certain embodiments of the invention.
[0026] FIG. 7A is a cross sectional side view of a bunter blank assembled together with a hub inside a retainer in accordance with certain embodiments of the invention, the assembly being shown prior to cold forming.
[0027] FIG. 7B is a cross sectional side view of the assembly of FIG. 7A , the assembly being shown after cold forming.
[0028] FIG. 8 is a cross sectional view of the cold forming system of FIG. 6B , the ram of the press being shown in engagement with both of the illustrated retainers.
[0029] FIG. 9 is a partially broken-away schematic cross-sectional view of a bunter in accordance with certain embodiments of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0030] The following detailed description is to be read with reference to the drawings, in which like elements in different drawings have like reference numerals. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. Skilled artisans will recognize that the given examples have many useful alternatives, which fall within the scope of the invention.
[0031] The invention provides a cold forming process for producing a bunter configured to stamp recessed headstamp indicia into a base of an ammunition cartridge case. The invention also provides a bunter blank configuration that facilitates this process.
[0032] The present cold forming process forms raised indicia on the working face of a bunter. The process starts with a bunter blank having a working face with a special outwardly rounded configuration. FIGS. 3A-3C depict an exemplary bunter blank 10 B in accordance with certain embodiments of the invention. Here, the bunter blank 10 B has a working face 15 from which projects a radial center protrusion 17 . The illustrated working face 15 is generally ring shaped, although this is not strictly required. The radial center protrusion 17 is configured for receipt in a primer pocket PP of the cartridge case's base 100 B (see FIGS. 1A and 1B ) during stamping of the recessed headstamp indicia 100 HS. The bunter blank's working face 15 surrounds the radial center protrusion 17 and has an outwardly rounded configuration 19 . In the embodiment illustrated, the working face 15 is generally ring shaped and encircles the radial center protrusion 17 . While this will typically be preferred, the working face 15 can be provided in different shapes.
[0033] Applicants have discovered that by providing the working face 15 of the bunter blank 10 B with an outwardly rounded configuration 19 having a high aspect ratio, particularly good results can be obtained. For example, it is possible to obtain fully formed letters (and/or other indicia) on the working face of the resulting bunter without objectionable distortion. In contrast, when the working face of the bunter blank is flat, the flat geometry does not allow the desired raised indicia to readily form into the recesses of the hub. Moreover, when the working face of the bunter blank is flat, the high tonnage required to get any forming of the desired indicia can deform the fixture. Further, when the working face of the bunter blank has a raised non-rounded rectangular or square projection, an outline of the desired raised indicia may be formed, but ridges will commonly be left in the working face of the resulting bunter.
[0034] FIG. 3C shows one exemplary shape for the outwardly rounded configuration (or “hump”) 19 on the working face 15 of the bunter blank 10 B. Here, the outwardly rounded configuration 19 has a width HW that is greater than its height HH. Thus, the illustrated hump 19 has a high aspect ratio. The aspect ratio is defined as the width HW of the hump 19 divided by its height HH. Preferably, the aspect ratio is greater than 3.5, greater than 5, greater than 7, or even greater than 9. In one exemplary embodiment, the aspect ratio is about 9.3.
[0035] When the aspect ratio of the hump 19 is within the noted ranges, the cold forming process can provide particularly good results in terms of creating fully formed raised indicia on the working face of the bunter while minimizing distortion of the bunter blank during the cold forming process.
[0036] In one group of embodiments, the hump 19 has a height of between 0.005 inch and 0.015 inch. However, this is not required. For example, when the bunter is intended to form headstamps in larger caliber cases, the desired height of the hump may be larger. Similarly, when the bunter is intended to form headstamps in smaller caliber cases, the desired height of the hump may be smaller. When the hump 19 has a height within the noted range, it preferably has an aspect ratio within one or more of the ranges taught above. For the noted height range, for example, the width HW of the hump 19 preferably is between about 0.017 inch and about 0.053 inch, between about 0.025 inch and about 0.075 inch, between about 0.035 inch and about 0.105 inch, or between about 0.045 inch and about 0.135 inch, such as between about 0.046 inch and about 0.140.
[0037] In some cases, the height HH of the hump 19 is between 0.006 inch and 0.013 inch, such as from 0.007 inch to 0.010 inch. These exemplary ranges, however, are by no means required. When the hump's height HH is within one or both of these ranges, the hump's width HW can optionally be within any one or more of the ranges that are obtained by multiplying the noted top and bottom ends of the height range by 3.5, 5, 7, or 9.
[0038] In the embodiment of FIGS. 3A-3C , the outwardly rounded configuration 19 of the bunter blank's working face 15 is defined by a generally toroidal surface. Preferably, this toroidal surface is defined by a single hump 19 encircling the radial center protrusion 17 . Particularly good results can be obtained when using a single hump of this nature. For example, the resulting raised letters (and/or other indicia) can be well defined on both their inner and outer sides, and the tops of the letters can be flat.
[0039] As best seen in FIG. 3C , the working face 15 of the illustrated bunter blank 10 B defines a planar surface (or “flat”) 11 that surrounds the generally toroidal surface defining the hump 19 . While this planar surface 11 is not strictly required, it can provide particular advantages. For example, having a small perimeter flat (which can optionally border an outer edge 14 of the working face 15 ) can make it possible to use a smaller radius hump. This can reduce the overall tonnage needed to form the desired indicia. It can also increase the formability of the hump without impacting the finished product. The illustrated perimeter surface 11 is generally ring shaped and encircles the hump 19 , although this too is optional.
[0040] In the illustrated embodiment, the bunter blank's radial center protrusion 17 has a cylindrical configuration. While this will typically be preferred, it is not strictly required. The radial center protrusion 17 preferably is an integral projection of (e.g., is defined by the same body as) the bunter blank's working face 15 .
[0041] In certain preferred embodiments, the outwardly rounded configuration 19 of the bunter blank's working face 15 is located radially outside of an inwardly radiused section 13 adjacent to a base portion BP of the radial center protrusion 17 . Reference is made to FIG. 3C . Here, the inwardly radiused section 13 comprises a surface that defines an interior radius located between (e.g., extending between) the hump 19 and a side surface 17 S of the radial center protrusion 17 . In other words, the illustrated inwardly radiused section 13 is located where the working face 15 comes together with the side 17 S of the radial center protrusion 17 . When provided, this interior radius is advantageous in that it can form a finished radius that is tangent between the working face 15 and surface 17 S.
[0042] Thus, one group of preferred embodiments provides a bunter blank 10 B to be machined into a bunter 10 for stamping recessed headstamp indicia 100 HS into a base 100 B of an ammunition cartridge case 100 . Preferably, the bunter blank 10 B comprises metal and includes both a base 100 B and a generally ring-shaped working face 15 from which projects a radial center protrusion 17 . In the present embodiments, the radial center protrusion 17 has a cylindrical shape and is configured for receipt in a primer pocket PP of the cartridge case's base 100 B during stamping of the recessed headstamp indicia 100 HS. In these embodiments, the bunter blank's generally ring-shaped working face 15 has a hump 19 (preferably a single hump) that encircles the radial center protrusion 17 , and this hump preferably has an aspect ratio of greater than 3.5, greater than 5, greater than 7, or even greater than 9. The hump 19 in these embodiments is located radially outside of an inwardly radiused section 13 adjacent to a base portion BP of the radial center protrusion 17 . Optionally, these embodiments can include a planar perimeter surface 11 encircling the hump 19 .
[0043] In the bunter blank embodiments of the invention, the bunter blank 10 B preferably is formed of metal (e.g., steel) and its base BA preferably has a generally cylindrical configuration. The base BA can alternatively have other configurations. However, a cylindrical base configuration will generally be convenient for the present cold forming process.
[0044] In one particular non-limiting example, the height HH of the hump 19 is about 0.009 inch and the width HW of the hump is about 0.084 inch. In this example, the bunter blank's radial center protrusion 17 is a cylinder projecting from the bunter blank's working face 15 and having a diameter of about 0.175 inch. In the present example, the bunter blank 10 B has the configuration shown in FIGS. 3A-3C . Here, the height of the radial center protrusion 17 is about 0.125 inch, and the width of the working face 15 is about 0.060 inch. The planar surface 11 encircling the hump 19 has a width of about 0.015 inch. The bunter blank 10 B is formed of annealed CPMM4 and its base has a diameter of about 0.508 inch. Finally, an interior radius of about 0.015 inch is provided where the working face 15 meets the side 17 S of the radial center protrusion 17 . These details, however, are merely exemplary; they are by no means limiting to the invention.
[0045] Exemplary methods for fabricating the bunter blank will now be described. In one method, the bunter blank is formed of annealed tool steel, such as CPMM4 material, although other suitable materials can be used, including high speed steel. Another exemplary method for fabricating the bunter blank involves the blank being derived from cold work tool steel formed by powder metallurgy processing. The bunter blank is machined using a lathe turning center from a solid billet to the geometry shown in FIGS. 3A and 3C . The details of these fabrication methods, however, are not limiting to the invention.
[0046] For the cold work, powder metallurgy-derived steels, from which bunter blanks of the invention can be manufactured, in certain embodiments, the tool steel is formed so as to contain not greater than about 4% tungsten by weight, and preferably not greater than about 2% tungsten by weight. For heavy duty stamping operations, in certain embodiments, the cold work tool steel is formed to contain from about 0.2 to about 4% (and preferably from about 0.5% to about 2%) of tungsten by weight and, preferably, contains from about 5% to about 10% (and most preferably from about 7% to about 9%) of chromium by weight. In a preferred embodiment, the invention provides a durable, wear-resistant bunter blank derived from cold work tool steel formed by powder metallurgy processing and containing tungsten in an amount not greater than about 2% by weight, at least about 7% (and preferably at least about 7.3%) chromium by weight, and not over about 2% of molybdenum by weight.
[0047] In addition to the foregoing bunter blank 10 B embodiments, the invention provides cold forming methods for forming raised indicia 25 on the working face 15 of a bunter 10 . The method involves providing a hub 50 having a contact face 55 (optionally a generally ring-shaped contact face) that defines indicia recesses 52 . The contact face 55 of the hub 50 surrounds a central pocket PP. FIGS. 4A-4E depict two exemplary hub configurations. The present methods involve assembling the working face 15 of a bunter blank 10 B against the contact face 55 of the hub 50 such that the bunter blank's radial center protrusion 17 is received in the hub's central pocket 58 . Sufficient force is applied to the thus assembled bunter blank and hub that material defining the outwardly rounded configuration 19 of the bunter blank's working face 15 deforms into the hub's indicia recesses 52 so as to form raised indicia 25 on the working face 15 of the resulting bunter 10 .
[0048] The force applied in this cold forming process preferably is supplied by a press (e.g., a cold forge press). This forming of the raised indicia on the working face preferably is initiated while the bunter blank 10 B is at room temperature. The method may involve operating the press such that a force of at least 12 tons is applied to the assembled bunter blank and hub. The amount of force used will, of course, vary depending upon a number of factors, including the desired height of the raised indicia 25 , the material from which the bunter blank 10 B is formed, and the press used.
[0049] During this forming of the raised indicia 25 on the working face, the outwardly rounded configuration 19 is generally flattened. In more detail, after the cold forming process, the working face 15 of the bunter 10 has a plurality of raised letters, numbers, and/or other indicia, but it preferably is otherwise generally planar. Reference is made to FIG. 2B .
[0050] The height of the raised indicia 25 on the bunter's working face 15 will depend upon the depth desired for the recessed headstamp indicia 100 HS. In certain embodiments, the height of the raised indicia 25 formed on the bunters working face 15 is between about 0.002 inch and about 0.003 inch. This, however, is merely an exemplary range. Larger or smaller caliber cases may require a different height for the raised indicia 25 .
[0051] The present cold forming process is advantageous in that it can create a particularly smooth surface on the working face of the resulting bunter. For example, after forming the raised indicia 25 , the working face can have an average surface roughness R a of less than 50 microinches, less than 25 microinches, or even less than 10 microinches. The surface is measured using a stylus moving a radial motion from the center side of the working face 15 to the outer edge 14 of the working face. The measurement excludes the raised indicia 25 . The measurement is taken by a CNC surface roughness measurement machine having a resolution of less than 0.1 microinch.
[0052] Since the invention involves a cold forming process rather than an EDM process, the working face 15 of the resulting bunter 10 does not have a so-called white layer (or “recast layer”). When EDM is used, the processed surface is left with a white layer, which has a different metallurgical structure (e.g., contains considerably more carbon) than the base material. This surface layer (which extends from the surface to a certain depth below the surface) can be more brittle than the base material. Thus, when the working face of a bunter blank is fabricated by EDM, the working face of the resulting bunter (including the raised indicia on the working face) has a white layer, which can cause the raised indicia to be more brittle than the base material. The present cold forming process is advantageous in that it produces a working face devoid of such a white layer.
[0053] Thus, in certain embodiments, the bunter blank 10 B comprises a steel base material (the bunter blank 10 B can optionally consist essentially of the steel base material), and after forming the raised indicia 25 on the working face 15 , a surface region SUR (see FIG. 9 ) of the working face does not have a carbon-enriched surface layer (e.g., contains substantially the same amount of carbon as the steel base material).
[0054] The present cold forming process is perhaps best understood with reference to FIGS. 5 , 6 A, and 6 B. FIGS. 6A and 6B depict embodiments in which a fixture FX is provided on a lower table LT of a press. Here, the fixture FX has two stops STP configured to limit the downward movement of the ram RA (which occurs during the cold forming process). The number and type of stops used can, of course, be varied. The illustrated fixture FX includes a cold forming mount HM and a removal mount SE. The cold forming mount HM is configured to stably secure a retainer 80 in a cold forming position. The retainer 80 has an interior opening in which the bunter blank 10 B and hub 50 can be positioned. Preferably, the bunter blank 10 B and hub 50 are assembled together inside the retainer 80 in the manner depicted in FIG. 5 . Here, the working face 15 of the bunter blank 10 B is positioned against the contact face 55 of the hub 50 such that the bunter blank's radial center protrusion 17 is received in the hub's center pocket 58 . In the embodiment illustrated, a peak of the hump 19 is aligned with the hub's indicia recesses 52 when the bunter blank and hub are so assembled within the retainer 80 . Preferably, the peak of the hump 19 extends in a circle, the hub's indicia recesses 52 are arranged in a circle, and both of these circles have substantially the same radius, such that when the working face 15 of the bunter blank 10 B is properly positioned against the hub's contact face 55 (as shown in FIG. 5 ), the peak of the hump is aligned with the hub's indicia recesses. The ram RA of the press is used to apply enough force to the thus assembled bunter blank 10 B and hub 50 that material defining the hump 19 is deformed into the indicia recesses 52 of the hub so as to form raised indicia 25 on the working face 15 . In the embodiment illustrated, force is applied so as to press the hub 50 against the bunter blank 10 B; the bunter blank is mounted such that it does not move substantially in response to this application of force other than by having material forming its hump 19 deform into the hub's indicia recesses 52 . In the present method, the hub 50 moves slightly (during pressing) as the hump 19 on the bunter blank 10 B is generally flattened. If desired, the positioning of the hub 50 and the bunter blank 10 B could be reversed (using a different retention system) such that force from the ram is applied so as to press the bunter blank against the hub.
[0055] In FIG. 6A , an end surface 59 S of the hub's base 59 is spaced upwardly from the uppermost surface 81 of the first retainer 80 . As a result, when the ram RA descends, it contacts the base 59 of the hub 50 , thereby pressing the hub downwardly against the bunter blank 10 B. This causes the hump 19 on the bunter blank's working face 15 to be generally flattened while some of the material from the hump deforms into the hub's indicia recesses 52 . Thus, the working face 15 of the resulting bunter 10 defines raised indicia 25 but is otherwise generally flat. The descent of the ram RA is stopped at the appropriate position when the ram contacts the stop surfaces TP of the stops STP.
[0056] The fixture FX shown in FIGS. 6A and 6B is advantageous in that it enables a single stroke of the ram RA to accomplish two operations. Specifically, it accomplishes the cold forming of a bunter blank in a first retainer while simultaneously removing a completed bunter from a second retainer. As shown in FIG. 6A , the second retainer 80 has a plunger PL that is engaged by the downwardly moving ram RA and is thereby moved forcibly in a downward direction, such that once a bottom end of this plunger contacts the base BA of the completed bunter 10 in the second retainer, this bunter is forced downwardly and out of its retainer along with the hub 50 in that retainer. FIG. 6B shows a bunter 10 and hub 50 dropping out of the second retainer 80 . The present cold forming process is by no means limited to use of such a dual-purpose fixture. However, it is currently preferred.
[0057] The retainer 80 preferably is formed of A8 material, although other suitable materials include tool steel or high speed steel. The hub 50 preferably is formed of tool steel, such as CPMM4 material, although other suitable materials include high speed steel. In certain preferred embodiments, the hub 50 has a Rockwell C hardness of at least 56. Preferably, the hub 50 is heat treated to at least this minimum hardness. The hub 50 can optionally also include a surface treatment, such as a CVD, PVD, or diffusion type coating.
[0058] Exemplary methods for fabricating the hub 50 will now be described. In one method, the hub 50 is formed of tool steel, such as CPMM4 material, although other suitable materials can be used, as noted above. Another exemplary method for fabricating the hub 50 involves the hub 50 being derived from cold work tool steel formed by powder metallurgy processing, similar to that already described herein with respect to the bunter blank. The hub 50 is machined in a lathe turning center to near net finish diameter of 0.750 inch, with a depth of 0.175 inch for pocket 58 , and a diameter of 0.875 inch for the base 59 . The recessed indicia 52 are then hard milled using a milling center to a depth of 0.0025 inch. Then the hub 50 is heat treated to a minimum hardness of 56 Rockwell C. The hub is then turned in a lathe turning center to the finish diameter of 0.750 inch and the base 59 to a diameter of 0.875 inch. The final step is to break the edges of the recessed indicia using polishing technology. These exemplary details are by no means limiting to the invention.
[0059] One exemplary method for fabricating the retainer 80 will now be described. In the present method, the retainer 80 is formed of A8 material, although other suitable materials can be used. The retainer 80 is turned out of an A8 material blank on lathe and most of the features are added and some material is left for finishing. Then, an air release nip is added in a mill. 0.094 inch dia. 0.015 inch deep. Next, the part is sent to heat treat and the part is drawback to RC 52-54. After heat treat, the part is put on a grinder and the outside diameter is ground to 1.525 inches and there is a clean-up grind on the ends to square the part up. The retainer then goes to a jig grinder and the two inside diameters are ground out to 0.750 inch and 0.508 inch and the bottom of the holes are cleaned up. Finally, the ends of the retainer are ground so there is 0.500 inch from bottom of 0.508 hole and bottom of retainer and the overall length is ground to 3.362 inches. Here again, the noted exemplary details are not limiting to the invention.
[0060] One exemplary method for fabricating the fixture FX will now be described. In the present method, the fixture FX is formed of A2 material, although many other suitable materials can be used. The fixture FX is made out of an A2 material block. The block is put in a mill squared up and all the desired features are added. It is then heat treated and the two counter bores are jig ground to size. The fixture is 6.5 inches wide, 6 inches deep, and 3.25 inches high. There are two tapped holes to hold the stops STP. There is a 1.530 inch diameter by 0.485 inch deep counter bore with a 1.015 inch diameter through-hole in the center of the fixture FX. Feature SE has a 1.530 inch diameter counter bore that is 0.880 inch deep and 1.000 inch cut out of the side of the part. Again, the details given here are not limiting to the invention.
[0061] In one exemplary embodiment, the bunter 10 is designed for use with 5.56 mm caliber ammunition cases, the bunter blank 10 B is of the nature described above in the non-limiting example, the hub 50 is fabricated in the manner described above, the retainer 80 is fabricated in the manner described above, the fixture FX is fabricated in the manner just described, and a hydraulic or mechanical cold forge press is used for the cold forming process. In the present embodiment, the cold forming process happens when the ram RA is moved down vertically and comes into contact with surface 59 S of the hub 50 . The contacting surface CS of the ram RA continues moving downward vertically until it comes into contact with surfaces TP of the stops STP. Once surfaces CS and TP are flush, the cold forming process is complete, and the ram RA is moved upward vertically to its home position.
[0062] The raised indicia 25 on the working face 15 can comprise letters, numbers, and/or other indicia. Commonly, the raised indicia 25 will include manufacturer indicia (i.e., indicia identifying the company that manufactured the case 100 ). In some cases, the raised indicia 25 will also include year indicia (i.e., indicia identifying the year in which the case 100 was manufactured), caliber indicia (i.e., indicia identifying the caliber or gauge of the case 100 ), or both.
[0063] The raised indicia 25 on the bunter's working face 15 preferably define raised surfaces (i.e., surfaces spaced forwardly of the generally flattened part of the working face) that are planar and generally parallel to the flattened part of the working face. In many cases, the indicia 25 will include a plurality of individual (e.g., separate or “discrete”) raised letters, numbers, or both. In such cases, the raised surfaces of the different letters and/or numbers preferably are substantially flush to one another. If desired, the raised surfaces of the indicia 25 can be substantially parallel to a planar leading surface 17 L of the radial center protrusion 17 . This, however, is not required.
[0064] The bunter 10 can optionally have a groove SL formed in, and extending entirely around, the base BA of the bunter. Reference is made to FIG. 2B . Here, the illustrated bunter 10 is defined by a single integral body. However, this is not required. For example, the bunter 10 can alternatively comprise multiple bodies. This can be appreciated by referring to FIG. 3A , which depicts an embodiment in which the bunter is to be formed by two generally cylindrical bodies BA 1 , BA 2 joined together in an end-to-end fashion. Other variants of this nature are also possible.
[0065] In the illustrated embodiments, the working face 15 of the bunter blank 10 has a generally ring-shaped configuration, the contact face 55 of the hub 50 has a generally ring-shaped configuration, and the bunter blank's radial center protrusion 17 has a cylindrical configuration. While these configurations will commonly be most convenient, they are not strictly required. For example, the contact face of the hub could be square, hexagonal, or various other shapes. The same is true of the working face of the bunter blank. In most cases, though, the noted configurations will be used.
[0066] In some embodiments, the working face 15 of the bunter 10 is provided with a coating 1300 . One exemplary embodiment is shown in FIG. 9 . When provided, the coating 1300 can optionally be over the entire working face 15 of the bunter 15 . In FIG. 9 , the coating 1300 is over the working face 15 , including the raised indicia 25 , and it is also over the radial center protrusion 17 . If desired, the coating 1300 can be over the entire bunter 10 . Thus, in some method embodiments, after the formation of the raised indicia 25 , the method further includes forming a coating 1300 on the working face 15 of the bunter 10 .
[0067] The coating 1300 can optionally be a dry lubricant coating. For example, the coating 1300 can comprise nickel (e.g., nickel alloy) and/or a low friction polymer. In some cases, the coated surface has one or more of the following features: (i) a coefficient of static friction below 0.35, below 0.3, or even below 0.2; (ii) a coefficient of dynamic friction below 0.3, below 0.25, below 0.18, or even below 0.1. Useful dry lubricant coatings are available commercially from, for example, General Magnaplate Corporation (Linden, N.J., USA) and Poeton Industries, Ltd. (Gloucester, England). As one example, the coating can be a NEDOX® coating.
[0068] In certain embodiments, the coating 1300 comprises a nitride and/or a carbide. One commercially available nitride coating is the Nitrex® coating, which is a high endurance surface enhancement available commercially from Nitrex, Inc. (Aurora, Ill., USA). Particularly useful nitriding and nitrocarburizing enhancements are described in U.S. Pat. No. 6,327,884, the salient teachings of which are incorporated herein by reference.
[0069] Nitriding and nitrocarburizing processes are known in the field and need not be described in great detail. Reference is made to U.S. Pat. Nos. 4,790,888 and 4,268,323, the teachings of which regarding such enhancements are incorporated herein by reference. The latter patent refers to the use of a fused salt bath to enable nitrogen and carbon to diffuse into the surface of a steel piece suspended in the bath to form a carbonitride case. Reference is made also to U.S. Pat. No. 5,234,721 (referring to methods of forming carbonitride coatings), the teachings of which regarding such coatings are incorporated herein by reference.
[0070] Nitriding processes, both plasma (ion) nitriding and liquid nitriding, are described in detail in the ASM Handbook prepared under the direction of the ASM International Handbook Committee, Revised vol. 4 : Heat Treating , pp. 410-424 (1994), the teachings of which concerning nitriding enhancements are incorporated herein by reference. Plasma or ion nitriding involves the use of glow discharge technology to provide nascent nitrogen to the surface of a heated steel part. Here, the part is subjected to a nitrogen plasma in a vacuum chamber. Nascent nitrogen diffuses into the surface of the part to form an outer “compound” zone containing γ (Fe 4 N) and ε (Fe 2,3 N) intermetallics, and an inner “diffusion” zone which may be described as the original core microstructure with some solid solution and precipitation strengthening. Liquid nitriding involves immersing a steel part in a molten, nitrogen-containing fused salt bath containing cyanides or cyanates, e.g., NaCN or NaCNO. Steel components can be enhanced by liquid nitriding through a wide variety of commercial coating manufacturers, such as Metal Treaters Inc. of St. Paul, Minn., USA. As used herein, the term coating includes discrete coatings on the surface of a part, diffusion of material into the part so as to enhance its surface, etc.
[0071] While the coating 1300 may be advantageous in some embodiments, it is by no means required. Thus, the bunter 10 need not have any coating(s). While a preferred embodiment of the present invention has been described, it should be understood that various changes, adaptations and modifications may be made therein without departing from the spirit of the invention and the scope of the appended claims. | The invention provides methods for making bunters used to form headstamp indicia into ammunition cases. The invention also provides bunter blanks that are specially configured to yield high quality bunters. | 1 |
[0001] This application is a Continuation-In-Part application of co-pending U.S. patent application Ser. No. 11/271,619 filed on Nov. 9, 2005 which was based on provisional patent application Ser. No. 60/626,668 filed on Nov. 10, 2004.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to an expandable furniture system and, more particularly, to a self-contained plug-and-play furniture system that is expandable and encloseable and ready to host state-of-the-art technology in a movable, autonomous, acoustically balanced and climate controlled environment.
[0004] 2. Discussion of the Related Art
[0005] For centuries, people have had the need for a suitable space to think, create, study or just be alone to gather their thoughts in a calm, peaceful environment. These needs have evolved in modern times to include information processing and time management in order to be productive and generate wealth. The use of state-of-the-art technology, including computers and telecommunications equipment, has become essential in today's society. Likewise, the need for peaceful and inspiring surroundings remains as an essential element of efficiency.
[0006] In the past, others have proposed various prefabricated fixed or mobile modular systems to build work stations, enclosed rooms or small building structures. Notwithstanding, the numerous proposed systems and structures do not fully meet the emerging needs of a personal home office or commercial work space (e.g. warehouse, factory, etc.). More specifically, the prior art fails to provide a self-contained, movable, and expandable plug-and-play furniture system that is ready to host state-of-the-art technology.
[0007] Examples of enclosed workspace systems and enclosed modular office systems are disclosed in the U.S. patents to Ando et al., U.S. Pat. No. 6,701,682; and Koby-Olsen, U.S. Pat. No. 5,897,325 and in U.S. Patent application Pub. No. US 2004/0003545 to Gillespie. The modular office systems disclosed in these related art references require the detailed assembly of hundreds of parts, with each part being uniquely designed for the fixed sized assembly at a specific location within the overall assembly. Gillespie, in particular, appears to require the assembly of at least several hundred individual parts, each being uniquely designed for their intended purpose, similar to the manufacturing assembly of an automobile or recreational vehicle. The need to manufacture and assemble many individual and unique parts makes these prior art modular office systems extremely expensive. Moreover, the modular office systems in the related art fail to provide for ease of expansion to accommodate the needs and budget of the consumer. Furthermore, the workspace systems disclosed in the related art fail to provide for flexibility in materials and, particularly, the ability to easily switch materials to accommodate the needs of the user such as providing resistance to fire, bullets, moisture, mold, sounds, heat, or insects. The systems in the related art also fail to provide for flexibility in transparency and visual control. More specifically, the systems in the related arts fail to allow for easy installation of transparent panels, such as panes of glass, at any location around the vertical wall structure and ceiling structure in order to provide desirable visibility, light, and to eliminate a claustrophobic feeling when inside the enclosed environment.
[0008] Telecommuting, or the ability to work from home, is a new social dynamic or segment of the marketplace that is poised for rapid growth. The term “telecommuter” has been known for more than 20 years, and in that time the category of people it describes has exploded. It is estimated that the number of workers whose only office is at home has doubled over the last three years. Clearly, given the present social issues with spiraling fuel prices, traffic congestion issues, parents needing to be in the home to care for children or elderly, and other factors, telecommuting will continue to become integrated into society. With the emergence of advanced telecommunication services into the home, spaces are now being established within the employee's residence which effectively creates a virtual office environment. Accordingly, telecommuting and the ability to work from places other than the traditional office environment is an emerging concept poised for rapid growth.
[0009] Future telecommuting market growth will depend not only on the emergence of user friendly and robust, low cost, easy to install home equipment, but also on providing the end user with a sensible, affordable, easily assembled, sound and ambience controlled private space. This space should be specifically designed to satisfy the consumer's needs for working and spending leisure time by providing a comfortable, easily managed and partitioned environment, free from noise and distractions, and which allows people to easily connect into their employer offices and communicate with the world while working from their residence. Given the paradigm shift to the telecommuter or “at-home” worker, technology being targeted for this space must be viewed as a consumer grade service. As such, any design goals must consider the “technology challenged” consumer and require functionality that is inexpensive, simple to construct, and use. In the case of an in-home spatial enclosure suitable for telecommuting, the consumer expectation is that the technology functions properly and requires little more than plugging a cable into the home's power and telecommunication sources to make it permanently ready to work or play.
[0010] Success in the consumer market requires that a home office be reasonably priced, easy to install, easy to use, and that it provides all the required surfaces, spaces, shelves, drawers, electrical power, lighting, climate control, power outlets, voice and data outlets all designed and ready to host computer equipment, telecommunications equipment and other supplies and equipment required for an “at-home” work environment. Additionally, a home office furniture system should provide for ease of expanding, both vertically and horizontally, to accommodate the existing budget and personal needs of the consumer. Moreover, the design should also provide a comfortable environment where one is free to “get away from it all.” An environment to support these objectives is ideally provided in a “plug-and-play” self-contained and expandable furniture system of the present invention.
Objects and Advantages of the Invention
[0011] Considering the shortcomings of the prior art, and the definite need to combine an informed person and high-tech equipment within inspiring surroundings in order to improve their effectiveness and efficiency, it is a primary object of the present invention to provide a self-contained, plug-and-play furniture system that allows for the progressive vertical assembly of prefabricated pieces of the furniture system, in “slices,” as the individual consumers budget allows, thereby making it possible to use one or several reduced cost partially assembled sections as customers develop the ideal level of expansion to suit their needs.
[0012] It is a further object of the present invention to provide a self-contained, plug-and-play furniture system that permits the progressive addition of horizontal prefabricated sections to the furniture system, in layers, in accordance with the customer's budget, thereby making it possible to use one or several reduced cost partial sections as customers develop the ideal level of expansion of the furniture system to suit their needs.
[0013] It is still a further object of the present invention to provide a self-contained, plug-and-play furniture system that allows for the progressive assembly over a period of time while enabling the customer to fully utilize installed or newly added prefabricated partial sections as they are needed, developing the system in either or both horizontal or vertical directions and ultimately allowing the customer to enclose the assembly in order to provide a private, peaceful and fully functional indoor work environment.
[0014] It is yet a further object of the present invention to provide a self-contained furniture system that allows for adaptability to suit the customer's needs, including the ability to mix and swap various materials to accommodate such things as wind resistance, fir resistance, bullet resistance, moisture and mold resistance, sound resistance, heat resistance and insect resistance.
[0015] It is still a further object of the present invention to provide a self-contained furniture system, as described above, and wherein the furniture system provides for portability, allowing one or more fully assembled furniture systems of the present invention to be easily transported to any location in the world, and further wherein the self-contained furniture system can be quickly and easily set up for use at any location, even remote locations, for connection to landline or wireless telecommunication services and internet services.
[0016] It is still a further object of the present invention to provide a self-contained furniture system, as described above, and provides for any degree of desired transparency by switching out opaque wall panels for transparent wall and ceiling panels, as desired, and thereby allowing the user to customize their interior work environment to enhance visibility of the outdoor environment, light input from outside sources and elimination of a claustrophobic feeling when in the interior environment of the furniture system.
[0017] It is a further object of the present invention to provide a self-contained furniture system, as described above, which allows for maximum organization and efficient placement of equipment and items for storage.
[0018] It is a further object of the present invention to provide a self-contained, plug-and-play furniture system in a movable enclosure that includes work surfaces, shelves, lighting, electrical power with outlets, voice and data outlets and switches and which is ready to host state-of-the-art computer and telecommunication equipment, as well as all other supplies and equipment needed to work, play and communicate in a peaceful and highly efficient environment.
[0019] It is still a further object of the present invention to provide a self-contained furniture system as described above, and which is adapted to be quickly and easily assembled at the point of use to provide a fully enclosed plug-and-play system that is ready to host today's high-tech computer and telecommunications equipment without the need to acquire special building permits.
[0020] It is still a further object of the present invention to provide a self-contained, movable and autonomous furniture system as described above, which is adapted to be placed within an existing home or commercial building without the need for remodeling the existing home or building structure.
[0021] It is still a further object of the present invention to provide a self-contained furniture system that solves the missing connection between a person and today's high-tech equipment, by providing the person with privacy and total control of their surrounding environment, thus uniquely enhancing their productivity in a calm, relaxed atmosphere.
[0022] It is still a further object of the present invention to provide a self-contained, movable and autonomous furniture system which provides multiple levels of interior and exterior shelves to accommodate all necessary equipment and supplies needed for a person to function with maximum efficiency within a compact, highly organized area.
[0023] It is still a further object of the present invention to provide a self-contained, movable and autonomous furniture system which is constructed entirely with conventional materials.
[0024] It is still a further object of the present invention to provide a self-contained, movable and autonomous furniture system as described above, and which includes an electrical system that connects to an existing power supply source via UL rated plug-and-play extension cords, thus eliminating the need for a licensed electrician for assembly and use.
[0025] It is still a further object of the present invention to provide a self-contained, movable and autonomous furniture system, as described above, which provides the further advantages of:
indirect lighting to avoid glare and discomfort, remote control air-conditioning for climate control, a heat cube for cold weather, a fire extinguisher kit (includes a smoke detector) Sound and weather insulation, a noise absorbing acoustic ceiling, easy to clean laminate finishes that can be upgraded to plastic, metal or wood finishes,
[0033] These and other objects and advantages of the present invention are more readily apparent with reference to the following detailed description and accompanying drawings.
SUMMARY OF THE INVENTION
[0034] The present invention is directed to a self-contained plug-and-play furniture system that is ready to host state-of-the-art technology within a portable, autonomous and expandable structure so that a person may work, play and communicate at optimum efficiency. The assembly of the system begins with a primary unit including a desk work station. The primary unit is fully equipped for electric power, voice and data connection and includes multiple power outlets, as well as data and voice outlets. The primary unit is expandable both vertically and horizontally by attaching prefabricated sections, as needed, including a sliding door section that completes assembly of an interior environment of the furniture system. Insulated wall, ceiling and floor panels fit within openings of the exterior frame structures of the primary unit and prefabricated sections to provide privacy and, when fully assembled, to enclose the interior environment. An air conditioner unit with remote control mounts on top of the ceiling for controlling the climate of the enclosed interior environment. Wheels on the primary unit and the base of attached prefabricated sections promote portability.
BRIEF DESCRIPTION OF THE DRAWINGS
[0035] For a fuller understanding of the nature of the present invention, reference should be made to the following detailed description taken in conjunction with the accompanying drawings in which:
[0036] FIG. 1 is a front, top perspective view of the frame structure of the furniture system of the present invention shown partially exploded to demonstrate the ability to add to the furniture systems in slices and stacks for expanding both vertically and horizontally, eventually to a completed, anchored unit structure;
[0037] FIG. 2 is a perspective view of a primary unit of the furniture system shown assembled with a work surface, an upper shelf and a lower shelf and including a fully integrated plug-and-play power, voice and data outlet system for hosting computer equipment, telecommunication equipment, lighting, and other supplies and equipment required for a fully functional work environment;
[0038] FIG. 3 is a front, top perspective view showing the exterior of the fully assembled furniture system as an enclosed structure;
[0039] FIG. 4 is an isolated perspective view, shown in cut-away, illustrating the manner of connection of the frame members, using screws and U-shaped clips, in the assembly of the frame structure of prefabricated sections;
[0040] FIG. 5 is a side elevational view of the fully assembled enclosed furniture system, shown in partial cross-section, showing the frame structure, interior shelves and air-conditioning housing with an air-conditioning unit;
[0041] FIG. 6 is an isolated view, shown in cross-section, illustrating the wall panel construction and installation to the frame structure;
[0042] FIG. 7 is an isolated view, shown in cross-section, illustrating the shelve support structure of the frame assembly;
[0043] FIG. 8 is a perspective view showing a primary unit of the furniture system with additional “stacks” of prefabricated expansion sections attached to add shelves and vertical height to the furniture system for fully functional use without the assembly of additional expansion sections;
[0044] FIG. 9 is a perspective view, shown partially in phantom lines, showing the entire furniture system fully assembled and illustrating the interior construction and arrangement of shelves, work surfaces, an executive chair, equipment and supplies, and further illustrating the assembly of slices and stacks of prefabricated expansion sections that allow for the vertical and horizontal expansion of the overall furniture system;
[0045] FIG. 10 is a general schematic of the electrical system; and
[0046] FIG. 11 is a chart showing an example of various items of equipment connected to the several circuits of the electrical system.
[0047] Like reference numerals refer to like parts throughout the several views of the drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0048] The self-contained plug-and-play furniture system is described hereinafter and is referred to generally as 10 throughout the several views of the drawings. The furniture system 10 includes prefabricated sections that are adapted to be attached in order to selectively expand the size of the system both vertically and horizontally.
[0049] The prefabricated sections of the furniture system 10 have an external skeletal frame structure 12 . The prefabricated sections include a primary unit 16 , a front section 14 with a sliding door 40 and various horizontal and vertical expansion sections to selectively expand the furniture system.
[0050] The exterior skeletal frame structure 12 , including the frame structure of the front section 14 , the primary unit 16 and all prefabricated expansion sections, has various sized square and/or rectangular openings for receiving wall panels and/or clear (window) panels. In a preferred embodiment, the access door 40 on the front section 14 is a double sliding glass door (one fixed glass door and sliding glass door) with a lock. A remainder of the skeletal frame structure 12 is defined by perpendicularly arranged frame members 30 , extending vertically in the exterior walls and an A.C. ceiling structure, as well as horizontally in the vertical planes of the walls and in the horizontal planes of the ceiling sections. The interconnected arrangement of frame members 30 form the rectangular and square openings on the four vertical sides, the ceiling and the base. In a preferred embodiment, the frame members 30 consist of square aluminum tubing. The bottom horizontal frame members may be larger in dimension to provide a base frame structure 30 a that supports plywood floor planks. Additionally, the front wall frame structure, surrounding the sliding glass door 40 , including the header rail 42 , base rail 44 and side rails 46 , is of an increased width to accommodate the width of the sliding glass door and track structure. It should be noted that the choice of particular materials may vary and is not limited to aluminum tubing. Moreover, the dimensions of the numerous structural components may vary and are not intended to be limited to those set forth herein.
[0051] The openings on the vertical sides, top and base of the skeletal frame structure, formed by the interconnected frame members 30 , are of pre-determined size to accommodate correspondingly sized and configured wall panels 50 .
[0052] The top or ceiling frame structure 60 , as seen in FIGS. 1 and 5 , is formed to define openings between the frame members. The center opening of the prefabricated expansion ceiling sections accommodate an air-conditioning housing 70 and unit 72 (see FIG. 5 ), as described more fully hereinafter.
[0053] As previously noted, the frame members 30 a forming the base frame structure are preferably slightly larger in cross-sectional configuration for supporting plywood planks 35 . In a preferred embodiment, the plywood planks are sized to rest on the base frame structure, within the interior, and are supported around their perimeter by the top surface of the base frame members. Once the floor panels are dropped into supported position on the base frame structure, a flooring material, such as carpet can be installed to cover the plywood planks 35 .
[0054] The wall panels 50 are preferably formed of a sandwich construction. More particularly, the wall, ceiling and floor panels (all generally referred to as 50 ) consist of an insulation core 52 that is sandwiched between outer 54 and inner 56 panel boards, as seen in FIG. 6 . This sandwiched construction is surrounded by an aluminum frame 58 which holds the inner 56 and outer 54 panel boards against the insulation core 52 . The frame of the wall, ceiling and floor panel construction further includes a flanged lip 59 that mates against an outer facing surface of the frame members 30 surrounding the openings of the skeletal frame structure. The wall panels 50 are specifically sized and configured for congruent receipt within the predetermined sized openings of the frame structure to close the openings and form an insulated wall structure. Likewise, the ceiling panels fit within the top openings of the frame structure and the floor panels fit within the base frame openings, below the plywood floor planks. In a preferred embodiment, the flanged lip 59 of the wall panel frame is provided with a double-faced adhesive for mating attachment to the outer spacing surface of the frame members, thereby holding the wall panels on the frame structure in fitted position within the pre-determined sized openings of the skeletal frame structure. The flanged lip 59 and double-faced adhesive arrangement also allows for ease of removal of any one or more wall panels and replacement of a new insulated wall panel 50 or, alternatively, a plexiglass, glass or other transparent material to provide one or more transparent windows 50 a (see FIG. 5 ). The wall and ceiling panels may also be made to be resistant to high winds, fire, bullets, moisture, mold, sound, heat and/or insects.
[0055] The primary unit 16 is adapted to be fully functional as a work station and can be expanded, at a later date, to eventually become an enclosed environment as shown in FIGS. 1 and 3 . The primary unit 16 provides the user with a fully operational office that can be paced inside of a vehicle, such as a minivan, van or truck. The primary unit 16 can then be upgraded by expansion, to include a back tower, and then eventually into the interior enclosed work space. When used in a vehicle, the assembly, as well as the drawers and equipment, are held in place with hook and loop fasteners or other securing means to prevent items from shifting and falling while the vehicle is moving. The primary unit 16 provides all required surfaces, spaces, shelves, drawers, electrical power, lighting, power outlets, voice and data outlets and other items for hosting computer equipment, telecommunications equipment and other supplies and equipment required for a fully functional office environment. In the embodiment shown in FIG. 2 , the primary unit relies on the climate control system of the surrounding indoor space of either a home or building structure, or a vehicle.
[0056] As seen in FIGS. 3 , 5 and 9 , an air-conditioning housing 70 is affixed on the ceiling above the center openings of the prefabricated expansion ceiling sections. The air-conditioning housing 70 is formed by tube frame members 74 that are essentially the same as those used in the construction of the skeletal frame structure. The frame members 74 form a generally rectangular box configuration that accommodates air-conditioning unit 72 and an airflow duct 76 . Insulated panels of the same type used in the construction of the side walls and ceiling of the system 10 are used to enclose the air-conditioning housing. The size of the insulated panels on the air-conditioning housing 70 may be different from those used on the walls. In one embodiment, the panels used on the sides of the housing 70 are different in size from the walls and ceiling. This allows for and ease of panel identification.
[0057] As seen in FIG. 5 , the air-conditioning unit 72 may be supported on the top of the ceiling frame structure 60 . In a preferred embodiment, the air-conditioning unit 70 includes a remote control, allowing the user to activate the AC unit and increase or decrease the desired temperature without the need of reaching up into the air duct to access the air-conditioning unit. A plastic egg crate 75 is fitted within the center ceiling opening just below the air duct 76 .
[0058] Initial assembly of the skeletal frame structure for each prefabricated section is preferably performed at the manufacturing site. Specifically, the frame structure of the front section 14 , including the sliding glass door 40 , as well as the primary unit 16 is performed at the manufacturing site. At that time, wheel casters 90 are attached to the base of the frame structure of the front section 14 and the primary unit 16 . Preferably, the front section 14 and primary unit 16 are each provided with at least four wheel casters 90 , on the bottom corners of the base frame 30 a of each unit.
[0059] As seen in FIGS. 5 , 8 , and 9 , the interior of the system 10 , and particularly the primary unit 16 , is constructed to include a plurality of shelves 102 , 104 , 106 , in addition to a desk top or work surface 100 that is provided in the primary unit 16 . In a preferred embodiment, the shelves and work surface extend across the entire width of the primary unit 16 , as seen in FIG. 8 . It is preferable that the shelves and work surface extend further along the right side wall, as seen in FIG. 9 , in an L-shape that partially surrounds the user when seated in the executive chair shown in FIG. 9 . This allows for maximum storage capacity to host a full array of computer equipment, telecommunications equipment and other equipment needed by a person to fully function in an optimal manner. The multiple level of shelves also allow for storage and organization of office supplies, files, a small refrigerator and all other equipment needed by the user. The work surface 100 and shelves are supported on a lip 31 that extends from the frame members 30 b , as seen in FIG. 7 .
[0060] As seen in FIG. 5 , the shelf assembly includes a lower shelf 102 that is below the desk top or work surface 100 . A first upper shelf 104 is provided above the work surface and is ideally suited for supporting a printer/fax/scanner/copier machine, speakers and other electronic equipment. The uppermost shelf 106 extends out about the same width as the lowest shelf and is ideally suited for holding files, paper and various stationery supplies. The lowest shelf 102 , below the work surface 100 , may be used to support a computer (i.e. CPU), a paper shredder, a subwoofer component of the speaker system, a small refrigerator and/or other equipment and supplies. The main desktop or work surface accommodates a computer keyboard, monitor, and other items and equipment commonly found on one's desk. The continuation of the work surface and shelves along the right side wall, in a general L configuration, allows for additional work surface and storage capabilities so that the floor remains clear of any clutter.
[0061] FIG. 10 illustrates a general schematic of the electric system and voice/data connections. In a preferred embodiment, the main disconnect is a UL approved extension cord which plugs into a standard power outlet of a home or building that provides the main power supply. The power is then directed to three circuits, namely Circuit A, Circuit B and Circuit C. Circuits A and B provide outlets arranged under the shelves and behind a hinged access door 94 , providing a power source for the electronic components to plug into, including the user's computer, fax/copier/scanner, telephone and other equipment. Circuit B provides power to outlets and lighting within the interior. It should be noted that the lighting is all indirect and under-mounted below the shelves to avoid glare and discomfort. Circuit C provides power to the air-conditioning unit 72 .
[0062] The voice/data jacks provide up to 5 connections including at least one voice connection, a DSL line connection, a fax connection and at least two spare jacks.
[0063] FIG. 11 shows a chart with examples of various equipment and components that are powered by each of the three circuits A, B and C of the electrical system.
[0064] The structure, function and method of assembly of the furniture system 10 of the present invention provides numerous advantages and benefits over the several modular office structures in the related art, including those prior art references mentioned above. In particular, the furniture system 10 of the present invention provides the following novel features of construction and assembly:
[0065] 1. —Slice-ability (Gradual Vertical Assembly) permits the progressive vertical assembly of available prefabricated pieces to the primary unit at will, like slices on a loaf of bread, as personal budget allows (see FIGS. 1 and 9 ). This makes possible using one or several reduced cost partial solutions available, as customers develop the ideal level of expansion. Each “slice” constitutes a component of the whole unit and has its own features, all contributing to make the furniture system 10 easy to assemble and advantageous over the prior art. Progressive assembly is a new construction technique allowing customers to fully utilize installed or newly added partial sections as they are added, developing a unit in the vertical directions at will. Assembly may be stopped at any point with no crisis to the user, indeed an innovative engineering and technical novelty.
[0066] 2. —Stack-ability (Gradual Horizontal Assembly) permits the progressive addition of available horizontal prefabricated pieces to the primary unit and base layer at will, like stacking pancakes, as personal budget allows (see FIGS. 1 , 8 and 9 ). This makes possible using one or several reduced-cost partial solutions available, as customers develop the ideal level of expansion. Each “stack” constitutes a component of the whole unit and has its own features, all contributing to make the furniture system 10 easy to assemble and advantageous over the prior art.
[0067] 3. —Sustainability: Friendly on the environment, every structural element and component of the furniture system 10 has been thought of as contributing elements to make it a green solution, striving to meet today's LEED or other pertaining green certification requirements.
[0068] In addition to the “green” requirements, such as a minimum recycled content for the fabrication of the structural system, insulation, floor/wall panel finishes, and a two bin recycle/trash method, the reduced footprint is cooled or heated at a very low cost with a high efficiency AC or HVAC unit, as well as lit by ultra efficient low profile LED—or similar—energy-saving lighting fixtures. A high capacity rechargeable UPS (Uninterrupted Power Supply system) to be plugged to an available external energy source, such as solar panels, a wind generator, a hybrid car, for example, will allow necessary equipment and a few appliances to run for an ample period of time without utilizing public energy.
[0069] 4. —Adaptability: The furniture structure is strong (see FIGS. 1 , 3 and 4 ). A solid aluminum (metal, wood, plastic) structure can withstand heavy loads in all directions, but it can be further strengthened to withstand strong winds by means of 4 guy-wires easily installed from each one of 4 preinstalled corner hooks to a set of 4 concrete pilasters buried in the ground, and held tight by tension. The structure was also conceived and designed so its modular members can be expanded as required.
[0070] Wall panels can again be switched occasionally, or permanently, to standard heavy duty wind resisting panels. Switching may be done to fire, bullet, moisture, mold, sound, heat, or bug resistant regular panels, as required.
[0071] The extreme flexibility provided by the abovementioned features further provide the furniture system 10 with an unparalleled custom ability that makes it the only answer offering not just one fixed design but many unique possibilities while proposing to develop a private and workable space starting from the first basic part, or slice, and gradually adding to it until it becomes a complete private and enclosed space ready to be plug-and-played, and used many ways and in various activities, so as to fully meet each person's needs.
[0072] The furniture system 10 of the present invention is designed to become a superb individual space, with all logical things a person needs at hand, able to be rolled-in to their premises with every previously selected equipment in place. The main basic unit, or slice, includes all electrical connections and any ordered equipment perfectly interconnected to avoid the hardship of complicated interconnection between systems for the end user. Once the end users feel the necessity to add-on more features and space, they can start ordering the rest of the slices to complete the whole enclosed furniture system module.
[0073] The prior art modular offices require the AC or its parts to be connected to an existing AC supply duct. The furniture system 10 of the present invention includes the whole system in a quickly screwed-on preassembled unit that fits on top and, once plugged, starts running the AC or HVAC system without requiring any adaptation, another original functional feature.
[0074] 5. —Communications ready: Even the most basic primary unit slice comes with the required wire connections to cable, data, voice and digital, plus conduits for required antennas/dishes. Independent satellite connections for voice, data and cable are optional, and were conceived from the beginning to allow customers locate the furniture system 10 away from civilization and still be connected via satellite. This allows the furniture system to be detached from any particular fixed address and roam around wherever the end user requires.
[0075] 6. —Real Portability: The furniture system 10 has been designed for ultimate portability. This includes, among others, overall dimensions to fit in the most cost-effective transportation system available, meaning the container. By design, six fully assembled furniture systems can be rolled into a container thus offering immediate plug and play capacity upon delivery anywhere in the world, with a factory warranty just like automobiles. The furniture system can also be sent partially disassembled, if required, occupying a fraction of the shipping volume.
[0076] 7. —Transparency:
[0077] A-Visual control: The furniture system 10 can accommodate 360° of unobstructed visibility and transparency in any direction via single panes of glass ergonomically designed to offer perfect view/control at seated eye level or at full height to eliminate the claustrophobic feeling when you are inside.
[0078] B-Display-ability: The furniture system can accommodate single pane windows so arranged as to make available perfect display ability to show just about anything at trade shows, malls, anywhere, perfectly matching any needs.
[0079] 8. —Electrical systems designed with specific usage ability:
[0080] Power, Voice/Data: The electrical system of the furniture system 10 of the present invention is unlike previous art in that it is precisely conceived to allow calculated systems make the furniture system an immediate “plug-and-play” solution, while meeting standard electrical codes and safety requirements. It is composed of a series of standard UL rated commercial grade extension chords technically selected and interconnected via a vertical shaft and an easily accessible but out of view horizontal cable tray with three final outside terminals for electrical/AC/voice-data systems to be connected to the source to immediately make all systems ready to go. This prebuilt function eliminates the need to have a licensed electrician finishing up connections and making the system work. This original feature, with its particular amperage requirement calculations ( FIG. 11 ), is in place in any slice of the furniture system that requires it and has been attached to our original patent. Additionally the electrical layout includes a redundant fuse system, one in the main disconnect and one on each circuit. Although this is small electrical system, it is carefully divided into 3 separate circuits, each with its own circuit breaker; one for the AC unit, one for electronic equipment and one for lighting/extra courtesy outlets. The furniture system further differentiates from pervious solutions by its manner of placing: the manner in which every piece of equipment is placed to make the best possible use of space, and ergonomically arranged to achieve optimal reach-and-get benefits. The furniture system of the present invention takes this objective to the point of considering even small details as the direction every piece faces. An example is the low profile LED energy-saving lighting fixtures, placed so as to illuminate the workspace and shelf areas indirectly in order to avoid glare while avoiding use of the inefficient ceiling mounted spotlights that, in this case, illuminate empty space and create shadows or glare. The furniture system lighting system provides comfortable and relaxing illumination that delivers proper intensity levels precisely where they are needed.
[0000] AC: The electrical circuitry diagram on FIG. 10 shows the three main circuits into which the electrical system is laid out.
[0081] 9. —Organize-ability: The furniture system 10 has an advanced storage system with a place for every logical office need in order to keep the work/play surface uncluttered, freeing it so the user may do what he/she feels like: a place for everything to keep users organized, while saving them time.
[0082] While the invention has been shown and described in accordance with a preferred and practical embodiment thereof, it is recognized that departures from the instant disclosure are fully contemplated within the spirit and scope of the present invention and is not to be limited, except as defined in the following claims as interpreted under the doctrine of equivalence. | A self-contained plug-and-play furniture system is ready to host state-of-the-art technology within a portable, autonomous and expandable structure so that a person may work, play and communicate at optimum efficiency. The assembly of the system begins with a primary unit including a desk work station. The primary unit is fully equipped for electric power, voice and data connection and includes multiple power outlets, as well as data and voice outlets. The primary unit is expandable both vertically and horizontally by attaching prefabricated sections, as needed, including a sliding door section that completes assembly of an interior environment of the furniture system. Insulated wall, ceiling and floor panels fit within openings of the exterior frame structures of the primary unit and prefabricated sections to provide privacy and, when fully assembled, to enclose the interior environment. An air conditioner unit with remote control mounts on top of the ceiling for controlling the climate of the enclosed interior environment. Wheels on the primary unit and the base of attached prefabricated sections promote portability. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to a process of deinking cellulosic materials and in particular to a process of deinking a broad spectrum of printed products including newspaper, laser written paper, xerographic paper, rotogravure, heatset, including coated and uncoated stock and high gloss multi-colored paper, such as magazines.
Conventional methods of deinking and reclaiming waste paper have involved cooking of waste stock in various aqueous deinking chemicals. Such methods were reasonably satisfactory and adequate a number of years ago when there was no need to deink and reclaim waste paper having little or no quantities of ground wood. Such papers were printed with standard inks which are more readily removed or saponified with chemicals at elevated temperatures.
In recent years, however, methods of deinking which involve cooking and the use of chemicals in aqueous media have become increasingly unsatisfactory for a number of reasons. Ink formulations have become more and more complex and involve an increasing use of a wide variety of synthetic resins and plasticizers; with each ink having its own special formulation. Also, increasing amounts of synthetic resins and plasticizers are being used in a wide variety of sizings, coatings, plastic binding adhesives, thermoplastic resins and pressure sensitive label adhesives. Furthermore, the use of multicolored printing and multicolored advertisements have become increasingly popular in recent years and these involve a wide variety of new ink formulations. Many of the new ink formulations incorporate new pigments, dyes and toners which are difficult to remove by conventional aqueous deinking chemicals. The former methods of deinking and reclaiming waste paper by chemical and cooking techniques are not adapted for, or adequate for, removing the new types of inks and coating resins. Due to high contents of thermoplastic resins, the softening action of heat and chemicals alone make their separation from the fibers very difficult. Additionally, the action of heat and chemicals tend to irreversibly set and more firmly bond some of the present day pigments to the fibers and fix dyes and toners to the fibers through staining.
For the above and other reasons, conventional deinking techniques used in reclaiming processes for waste paper are no longer efficient or effective for many current needs.
The need for a satisfactory deinking process has become increasingly important due to greatly expanded utilization of paper and difficulty in disposal of the old papers due to projected lack of landfill sites.
In this regard, to preserve natural resources and minimize environmental problems, the need for developing useful and efficient paper recycling processes becomes of critical importance.
Conventionally, cooking processes for deinking paper have utilized aqueous based suspensions. The stock to be salvaged is first thoroughly cleansed of superficial dirt and then macerated. The maceratum is boiled, subjected to cooking and defiberizing in a suitable aqueous alkali to soften the paper fibers, loosen and disintegrate at least part of the ink and other matter adhering to the fibers, and thoroughly agitated, either while in the alkaline solution or subsequently, to disintegrate and defiber the stock as thoroughly as possible. Thereafter, the pulp is riffled and screened and subsequently dewatered, preferably through suitable rolls, filters, or the like, to remove a considerable portion of the loosened ink. It is then washed and dewatered for removal of additional quantities of the loosened ink as many times as may be practical and expedient.
In general, conventional deinking agents have employed an aqueous alkali solution which may, in addition, contain one or more of the following: a nonionic detergent, a sodium soap of fatty acids or abietic acid sulfonated oil; a dispersing agent to prevent agglomeration of the pigment after release and to emulsify any unsaponifiable material; a softening agent such as kerosine or mineral oil to soften the vehicle of the inks; an agent such as clay, silicate, etc., for selective absorption of pigments after release from the fiber to prevent redeposition on the fiber; and a basic exchange chemical to prevent formation of calcium soaps.
The cooked and defibered pulp is then diluted to less than 1 percent concentration and riffled and screened to remove oversized objects and undefibered pieces of paper. This material is then washed with large amounts of water, an average of 20,000 gallons of water per ton of pulp, to separate the fiber from other substances by washing or screening or by a flotation process. The disposal of large amounts of water used in such processes pose a stream pollution problem which must be remedied.
Another area in which conventional deinking techniques are unsatisfactory in reclaiming waste paper is in the area of electrophotography, better known as xerography. In the art of xerography, an electrostatic xerography latent image is formed by uniformly charging a photoconductive insulating surface of a xerographic plate followed by exposing the charged surface to a pattern of light. The latent image formed by this technique is then developed with an electroscopic powder, also known as a toner, to form a powdered image which is then transferred to a sheet of normal bond paper. The powder image contained on the paper is then fused into the paper to form a permanent reproduction of an original image.
Another means of xerographic development is liquid electrophoretic development, which has particular utility when photoconductive paper is xerographically processed. Developers may be prepared by dispersing finely ground pigments, such as zinc oxide, phthalocyanine blue or nigrosine in an insulating hydrocarbon liquid such as toluene, carbon tetrachloride, or petroleum fractions. The pigment particles acquire electrical charges during dispersion and remain suspended in a liquid. When a photoconductive paper containing an electrostatic image of a polarity opposite to that of the dispersed particles is immersed in the liquid, the pigment particles migrate and become fixed on the latent image.
Laser writing processes also employ various complex dyes and pigments applied to paper by high temperature fusion. These processes are similar, in effect, to the xerographic processes in that ink removal is extremely difficult.
Since ever increasing amounts of xerographic and laser written paper are being used each year, effective processes for reclaiming this type of waste paper are very much needed. However, the effectiveness of any deinking process must take into account the fact that development compositions for xerographic and laser writing processes consist of complicated organic compositions fused under high heat to the paper. With regard to toner development, as heretofore indicated, the toner is usually made of fusible resins or resin blends in which a pigment, such as carbon black has been dispersed. The resins are selected to provide a melting point within the proper range for heat fixing or of a sufficient solubility for solvent vapor fixing. In essence, the action of heat and complex organic chemicals in these printing processes yield printed paper having almost irreversibly stained cellulosic fibers.
In the past, nonaqueous deinking processes have been employed that utilize various chemical additives such as surfactants. U.S. Pat. No. 3,072,521, for example, relates to a nonaqueous process of deinking cellulosic materials employing a surfactant-containing organic solvent. The surfactant is necessary to enable removal of ink from the paper.
Other deinking processes that have been developed utilize partial nonaqueous or immiscible solvents. U.S. Pat. No. 3,635,789, describes a deinking process whereby an immiscible solvent is added to an aqueous pulp suspension to facilitate the removal of ink from the pulp. U.S. Pat. No. 3,891,497, relates to a process for recovering of waste paper using steam and immiscible fluids and a small amount of water. The water is added to the waste paper to make it easier to break the bonds between the fibers. The process is conducted in a pulper at an elevated pressure because high temperatures are employed.
SUMMARY OF THE INVENTION
Thus, it is an object of the present invention to provide a deinking process with a non-aqueous solvent that does not require surfactants to enable complete ink removal.
It is another object of this invention to provide a process for deinking diverse types of waste paper that is both economical and relatively easy to perform.
It is even another object of this invention to provide a process for deinking waste paper that produces a high quality reclaimed pulp which may be adapted to the manufacture of conventional types of paper.
It is also an object of the present invention to provide a nonaqueous solvent that is economical and that is capable of fully removing ink from diverse types of paper.
It is also an object of the present invention to provide a deinking process that employs fewer chemical additives and less water that reduces the clean up costs and the negative impact on the environment.
In accordance with the present invention, a novel process for deinking waste paper is provided. The process provides a nonaqueous recycling technique that can remove ink from newspaper, rotogravure, heat set paper, including coated and uncoated stock, multicolored paper, including printed yellow directory paper, as well as xerox/laser written paper and high gloss multicolored paper, such as magazines.
It is also an objective of the present invention to eliminate "stickies" caused by solvent-based adhesives used in pressure sensitive labels and binders. When papers which include such adhesives are recycled, the adhesives tend to agglomerate. As a result, potentially severe processing problems can result. For example, during paper formation the agglomerates can deposit on the wire mesh and prevent water from draining properly through the mesh. Without proper drainage, "pin holes" will appear in the resulting paper. Also, agglomerates of adhesive in the resulting paper will provide a mechanism in which two separate sheets will adhere together when contacted in paper rolls. Adhesion between layers of a paper roll can necessitate a complete operation shutdown. As a result of these severe problems, expensive and complex systems have been developed to remove the solvent-based adhesives upon recycle. Such techniques are unnecessary with the process of the present invention.
A particular embodiment of the invention provides a multiple step deinking technique comprising, shredding or chopping cellulosic waste materials to create uniform paper shreds, immersing the paper sheets into a nonaqueous organic solvent while agitating the shreds, completely removing the solvent, bleaching the shreds to form a fiber pulp, diluting to form a suspension and submitting the suspension to high speed, high shear dispersion to separate residual pigments from the fibers before papermaking. Such a process can provide improved ink removal without the use of an abundance of water and a solvent/surfactant combination.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, waste paper or cellulosic material to be treated is preferably subdivided in relatively small pieces by passing the waste paper through a conventional shredding machine. The exact size of the pieces is not particularly material as it is necessary to merely subdivide the waste paper to an extent effective to provide a bulky mass having uniform paper shreds.
After the paper has been shredded or chopped, it is introduced into an agitation tank containing an organic solvent in sufficient quantity to form a mixture. In practice, the process can utilize a mixture of from about 1 to about 50 percent solids content, preferably from about 2 to about 15 percent.
The selection of the particular organic solvent employed in the deinking process of the invention is extremely important. The solvent must not be retained by the cellulosic fibers and must be efficient in removing various types of ink. Toluene has been found to be the most effective solvent to solvate ink oils, resins, lacquers and other polymeric contaminants and is not retained by the fibers. Moreover, toluene is not a halogenated hydrocarbon and, therefore, does not cause stratospheric ozone depletion. A comparison with other common solvents is illustrated in Table II. Toluene clearly yields a bright recycled paper with no solvent retention.
It also should be appreciated that efficacious results are obtained when employing the solvents of the present invention without the need for surfactants, as is necessary in other deinking processes.
The temperature of the prepared mixture is not particularly critical. As such, any temperature can be employed which is technologically practical. For example, a temperature below room temperature could be used, or a temperature up to the boiling point of the solvent can be used, if pressure equipment is employed. However, the agitation is preferably performed at room temperature to reduce operating costs.
The mass in the agitation tank is circulated for a time sufficient to extract most of the ink vehicles and resins from the shredded papers. The process also removes other contaminants, such as pressure sensitive adhesives and glues through chemical solvation and surface action of the solvent. The time required for this operation will vary with the particular apparatus employed and the condition of the processed material. Preferably, the agitation is conducted for about 2 to about 40 minutes.
After completion of agitation, the paper shreds are filtered from the agitation tank and the excess liquid is separated from the paper shreds which are then washed again, if desired with additional organic solvent. The solvent separation may, for example, be advantageously accomplished by passing the paper shreds from the agitation tank directly to a continuous filter. In this type of filter, a perforated drum rotates in a tank containing the paper shreds and by the action of reduced pressure or suction, the liquid is drawn through the perforations, leaving a mat of paper shreds on the surface of the drum, through which subsequent filtering occurs. During the rotation of the drum, the mat of paper shreds on the surface thereof can be subjected to sprays of the solvents for additional washing. Heat, in addition to reduced pressure, can also be employed to completely remove the solvent from the paper shreds. Other means for solvent removal can also be employed, such as hydrocyclones.
The solvent withdrawn from the paper shreds may be reused without purification for more than 10 times. When the efficiency of ink removal becomes unacceptable, the solvent and extracted ink or resins can be used as fuel for its heat value or the solvent may be recycled by removing the contaminants from the solvent medium using any suitable means. For example, filtration, settling and decantation, distillation, etc., and combinations thereof may be employed. Thereupon, the recycled solvent may be introduced to the agitation tank for further removal of ink, plasticizers and resins. The reuse of the solvent may be carried out batchwise or continuously depending on whether the deinking process is continuous.
Following the initial solvent filtration, the paper may again be washed with solvent. This step may be conducted several times if desired.
After solvent washing and drying, the paper shreds are baled and stored or are conveyed to a bleaching tank where aqueous bleaching agents are subsequently added. Preferably, an aqueous solution of 5 percent sodium silicate, 1 percent sodium hydroxide and 3 percent hydrogen peroxide is employed. It is desirable to bleach, under alkaline conditions, with a pH in the range of about 9.0 to about 12 and at a temperature in the range of about 20 to about 90° C. The temperature of the bleaching tank is raised to the desired operating temperature by means of inductive heating, or preferably by means of steam injection. These conditions increase the effectiveness of the bleaching chemicals and decrease the bleaching tank holding time to achieve a given degree of pulp brightness.
The bleaching time may vary depending on the bleaching tank temperature or the amounts of bleaching agents utilized. The pulp should be bleached from about 5 to about 20 minutes, and preferably from about 8 to about 12 minutes.
A mixer is provided in the bleaching tank to disperse the bleaching chemicals, converting the paper shreds into a fiber pulp, and to expose most of the surface areas of the pulp to an adequate amount of bleach. During the process, sufficient bleaching solution should be added to provide a fiber to liquid concentration varying from about 5 to about 40 percent, and preferably from about 10 to about 30 percent.
Following the bleaching step, the bleaching solution is drained and the pulp is removed from the bleaching tank and placed in a dispersion or defiberizeration tank. Water is added to the fiber pulp in a quantity sufficient to form from about 0.2 to about 2.0 percent concentration of fiber in water, and more preferably about 0.5 percent.
In the dispersion process, the pulp is subjected to a high speed, high shear environment in a suitable defiberizing apparatus, such as a hollander beater. The defiberizing apparatus can be any suitable mechanical device having blades rotating axially at high speeds to produce high shear on the waste paper. Rotating speeds range from about 10,000 to about 20,000 RPM, and preferably from about 14,000 to about 18,000 RPM. The dispersion process is conducted from about 1 to about 10 minutes and more preferably from about 2 to about 5 minutes. The high speed, high sheer action loosens and separates ink pigments lodged in the fibrillar surface of the fibers. The loose pigments are removed by high vacuum filtration or by other similar processes.
After the dispersion process, the fiber can be conveyed to a storage chest for use in the manufacture of paper or it is suspended in water and pumped to a dewatering device, such as a lap pulp machine, a belt press or other device that removes water from pulp without damaging the integrity of the pulp fibers.
In summary, the present invention possesses numerous advantages over prior art deinking processes. In particular, the agitation process according to the present invention utilizes a nonaqueous solvent that is inexpensive, readily available and can be recycled, and does not require any surfactants. The stream pollution and clean up costs are reduced. Moreover, the process can be carried out at room temperature in a short period of time which reduces production costs considerably.
Additionally, the nonaqueous solvent of the present invention, namely toluene, has provided unexpected beneficial ink removing results not obtainable by other nonaqueous solvents. More specifically, toluene has been found to provide brighter recycled paper from a diverse spectrum of waste paper.
The versatility of using toluene as the solvent in a deinking process according to the present invention can be seen from Table I below:
TABLE I______________________________________TOLUENE DEINKING PROCESSIN DIFFERENT PAPER GRADESPaper Grade Brightness Before Brightness After______________________________________Virgin Newsprint -- 56.0ONP 37.89 51.76Heatset Mag. Stock 53.83 61.46Yellow Phone Directory 30.87 51.21Gravure 37.76 52.49Xerography 74.39 74.12Laser Printed Paper 65.0 71.86______________________________________
As can be seen, the process improve the brightness of a wide spectrum of waste paper stock considerably.
To more clearly illustrate these results and the effect of using toluene according to the invention, various other nonaqueous solvents were employed in the process of the present invention. Each of these solvents, namely cyclohexane, N,N-dimethylformamide, isobutylalcohol, morpholine, 1-methyl-2-pyrolidinone, ethyl ether, ethylene glycol, acetone, hexanol, kerosine and piperazine yielded pulp having lower brightness than that produced by toluene and/or retained significant amounts of solvent. For example, recycled pulp obtained from the use of 1-methy-2-pyrolidinone and kerosine as the solvent possessed a brightness of 54.88 which represents the most advantageous results of the above mentioned solvents. Note, however, that the fibers retain solvent which renders the solvent unsatisfactory for deinking purposes. Toluene yields a brightness of 53.55 while not retaining any solvent after the process as shown in Table II.
TABLE II______________________________________SUMMARY OF SOLVENTSTESTED ON OLD NEWSPAPERS BRIGHT- WHITE-DESCRIPTION NESS NESS COMMENTS______________________________________20% 1-Methyl-2- 54.88 82.97 Fibers retainpyrolidinone (MPNE)/ solvent80% Kerosine, 1.5%consistency20% N,N-Dimethyl- 38.33 69.93 Fibers retainformamide/80% solventkerosine, 1.5%consistency50% Ethylene glycol 39.62 71.62 Fibers retain(EG)/50% Kerosine solvent20% MPNE/20% EG, 46.94 76.74 Fibers retain3% consistency solvent20% Hexanol/20% 52.24 81.49 Fibers retainMPNE/60% Kerosine solvent100% Cyclohexane, 51.24 79.78 Handsheetstir 10 minutes at deinked and dry10% consistencyMorpholine 100% 48.08 80.76 Fibers retain solventCyclohexanone 47.19 76.91 Fibers retain solventN,N-Dimethylformamide 52.32 81.05 Handsheet deinked and dry20% MPNE/20% EG/ 46.98 77.32 Fibers retain60% Kerosine solvent20% MPNE/20% 51.15 79.92 Fibers retainKerosine/40% EG/ solvent20% N,N-Dimethyl-formamideCyclohexane 52.11 80.63 Clean handsheetPiperazine/Acetone 39.40 71.94 Fibers retain solventToluene 53.55 81.79 Clean handsheet______________________________________
Other solvents that provide clean handsheets with somewhat advantageous results are also unsuitable as solvents in the process of the present invention. For example, N,N-dimethylformamide and cyclohexane yield relatively high brightness but are more volatile and flammable at ambient temperatures, are more difficult to distill from water, are more expensive on an industrial scale and are not as an effective solvent for lacquers, gums, oils, resins and coatings. Moreover, N,N-dimethylformamde is miscible in water.
Although waste paper has been used to illustrate the present invention, any imprinted cellulosic material can be recycled for reuse by the process of the present invention; for example, various kinds of imprinted paper, such as imprinted newsprint, rotogravure print, bookstock, heatset, including coated and uncoated stock, yellow directory paper, xerography or laser printer stock, magazine stock, ledger stock, cardboard, etc. In addition, the process may be used to dewax or remove plasticizers or resins from any cellulose stock.
The aforementioned process of the present invention is particularly effective for deinking a mixed stream of cellulosic starting materials. However, if the cellulosic starting material is from a particular single source, free of contaminants, it may not always be necessary to immerse the paper shreds into a non-aqueous organic solvent.
For example, an acceptable deinking may be obtained when either newspaper or multi-colored paper printed with aqueous-based ink is used as the sole source for the starting material. That is, if either is the sole source of cellulosic material, the solvent immersion step may not be necessary. On the other hand, papers printed by rotogravure and heat-set lithography do require solvent treatment for an acceptable deinked product. In all cases, however, better products will be obtained using the solvent immersion step.
While the invention has been herein shown and described in what is presently conceived to be the most practical and preferred embodiments thereof, it will be apparent to those of ordinary skill in the art that many modifications may be made thereof within the scope of the invention, which scope is to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent processes. | Disclosed is a method of deinking cellulosic materials comprising, shredding or chopping the cellulosic materials to create uniform paper shreds, immersing the paper shreds into a nonaqueous organic solvent while agitating the paper shreds, removing the organic solvent, bleaching the paper shreds to form a pulp, diluting said pulp to form a fiber suspension and submitting the suspension to high speed, high shear dispersion to form a pulp ready for papermaking. | 3 |
FIELD OF THE INVENTION
The present invention is directed to a solventless process for production of sulfophenethylsiloxane or sulfonaphthylethylsiloxanes, more specifically it is directed to a solventless process where the reaction is conducted in a reactor containing a self-cleaning agitator to deliver the sulfophenethylsiloxane or sulfonaphthylethylsiloxanes in form of a powder.
BACKGROUND OF THE INVENTION
Sulfophenethylsiloxane or sulfonaphthethylsiloxane and processes for their production are known. The U.S. Pat. No. 2,968,643 describes a reaction of chlorosulfonic acid and a phenyltrichlorosilane to form an intermediate followed by hydrolysis of this intermediate. However, an excess of chlorsulfonic acid is used which has to be separated. The U.S. Pat. No. 4,575,559 discloses a process for the production of sulfophenethylsiloxanes in the presence or absence of solvent. The solventless process in a stirred vessel is technically very difficult because the reaction mixture becomes solid. For this reason most examples use solvents, which must subsequently be removed.
The U.S. Pat No. 5,091,548 discloses a solventless process for the production of sulfophenethylsiloxanes or sulfonaphthylethylsiloxanes, wherein the reaction takes place in small droplets or in a thin film to avoid the handling of the solid intermediate in bulk form.
Object of the present invention was to provide a process for preparing sulfophenylalkylsiloxanes or sulfonaphthylalkylsiloxane which overcomes the problems of handling the solid intermediate and which avoids the use of a solvent. Another object was to provide the phenylalkylsiloxanes or sulfonaphthylalkyl-siloxanes in form of a powder.
SUMMARY OF THE INVENTION
The objects of the present invention could be achieved with a process for preparing a sulfophenylalkylsiloxane or a sulfonaphthylalkylsiloxane having either of the following formulae: ##STR1## in a reactor containing a self-cleaning agitator, comprising: a) adding an essentially equimolar ratio of chlorosulfonic acid to a phenylalkyltrichlorosilane or a naphthylalkyltrichlorosilane having either of the following formulae: ##STR2## wherein R of formulae I,II,III, and IV is individually hydrogen halogen, or an alkyl radical having 1 to 4 carbon atoms; R1 is an alkylene radical having 2 to 5 carbon atoms; R2 is R or ##STR3## with the proviso that at least one R 2 be ##STR4## R 3 is--H or ##STR5## with the proviso that at least one R 3 be ##STR6## R 4 is R or--R 1 SiCl 3 with the proviso that at least one R 4 be--R 1 SiCl 3 and
n is at least 1, preferably 2 to 4
m is 1 or 2
in said reactor under agitation at a temperature of from about 20° to about 80° C. and at a rate sufficient to control the formation of HCl;
b) raising the temperature up to about 80° to about 150° C. until HCl formation stops and a solid intermediate is formed;
c) optionally reducing the pressure in the reactor to about 300 to about 20 mbar;
d) hydrolyzing the intermediate by adding water in the reactor at a temperature of from about 20° C. to about 50° C. to form said sulfophenylalkylsiloxane or sulfonaphthylalkylsiloxanes and HCL;
e) reducing the pressure in the reactor to about 300 mbar to about 20 mbar at a temperature of from about 20° C. to about 95° C. until excess water and HCI is removed; and
f) removing the dry sulfophenylalkylsiloxane or sulfonaphthylalkylsiloxane from the reactor.
DETAILED DESCRIPTION OF THE INVENTION
The phenethyltrichlorosilane and naphthylethyltrichlorosilane compounds having structural formula III and IV are well known in the art.
R is hydrogen, halogen or an alkyl radical having 1-4 carbon atoms, R 1 is an alkylene radical having 2 to 5 carbon atoms and R 3 is R or--R 1 SiCl 3 with the proviso that at least one R 3 be--R 1 SiCl 3 .
Suitable examples of these compounds are β-phene-thyltrichlorosilane, α-phenethyltrichlorosilane and naphthylethyltrichlorosilane.
In the process for preparing the sulfophenethylsiloxane or sulfonaphthylethylsiloxane a reactor containing a self-cleaning agitator is used. The reactor must be suitable for handling paste and solid phases as well as high corrosive materials and the mixing elements must be in an order that they are self cleaning, which means that there are is virtually no dead space between the mixing elements themselves and the reactor walls. One suitable reactor is a so called "all phase" reactor which is commercially available under the trademark Discotherm™ B (List, Pratteln, Switzerland).
FIG. 1 shows a side view of the Discotherm™ B.
FIG. 2 shows a front view of a cut of the Discotherm™ B.
BRIEF DESCRIPTION OF THE FIGURES
The shell of the reactor consists of a double jacket (1). Inside the double jacket is a hollow shaft (2) with discs (3) containing kneading units (4).
Counter paddles (5), paired to the kneading units (4), are located on the inside of the walls of the double jacket (1) and fixd on the walls of the double jacket (1). These stationary units clean the agitator shaft and discs resulting in high efficiency mixing, while rendering the unit to be about 90% self cleaning.
The unit can process materials at temperatures from about -10° C. to about 300° C., using glycol/water, tempered water, pressurized steam, or hot oil as the fluid in the heating/cooling jacket. Practical speed varies with the size of the unit. For a small (1.5 Liter) unit, speeds can vary from about 3 to about 120 rpm. For larger (commercial scale) units, the maximum speed is reduced. The unit is normally suitable for 10 mbar to about 6 bar operating pressure, although it is conceivable that higher pressure ratings could be obtained by specialized construction.
The materials of construction of the reactor can be carbon steel, stainless steel, or Hastelloy, and because of the highly corrosive nature of the compounds used in this application, it is preferred to use Hastelloy B for those surfaces exposed to the reactants.
The process of the present invention comprises the following steps: Before charging the reactor with the reactants a nitrogen sweep might be used to dry the reactor and remove moisture. The nitrogen sweep may be used continuously during the whole process.
The phenylalkyltrichlorosilane or naphthylalkyltrichlorosilane is charged in step (a) to the reactor and while agitating, an essentially equimolar ratio of chloro-sulfonic acid is added at a rate sufficient to control foaming of the HCl by product to a manageable level. A slight reduction of pressure may be used in this step of from about 850 to 920 mbar. The temperature in this step ranges from about 20° to about 80° C., preferably from about 20° to about 50° C. When the chlorosulfonic acid addition is complete, the temperature is raised in step (b) to about 80° to 150° C., preferably to about 90° to 120° C. allowing the mixture to react under evolution of HCl, which causes foaming. When the foaming subsides the intermediate becomes more and more viscous to a pasty solid.
Optionally the pressure in the reactor is reduced in step (c) to about 300 to about 20 mbar, preferably to about 200 to about 20 mbar to evaporate the HCl over a time period of from about 10 minutes to about 100 minutes.
If this step (c) is performed, the pressure is increased again to normal, and the agitator speed may be reduced to about 30 to about 20 rpm. In step (d), the solid intermediate is hydrolyzed.
The hydrolysis of the intermediate is performed by adding distilled or demineralized water to the reactor or, preferably, by blowing steam through the reactor, optionally under vacuum. In this step sulfophenylalkylsiloxane or sulfonaphthylalkylsiloxane and HCl as a by-product is formed.
Excess water and the HCl by-product is removed in step (e) by reducing the pressure to about 300 to about 20 mbar, preferably to about 200 to about 20 mbar at a temperature of from about 20° C. to about 95° C., preferably from about 60° C. to about 95° C.
If necessary, the water or steam addition and pressure reduction could be repeated several times to ensure that hydrolysis is complete and HCl is removed.
The pressure is raised to normal and the resulting product is sulfophenylalkylsiloxane or sulfonaphthylalkylsiloxane in form of a powder with a particle size of from 20 to 200 microns.
EXAMPLE 1
First, a nitrogen sweep was used to dry the reactor and remove moisture. To the 770 ml Hastelloy® B Discotherm laboratory reactor, 279 ml of phenylethyltrichlorosilane was added. The agitator was started at 80 rpm and 88 ml of chlorosulfonic acid dripped in over an 8 minute period with the reactor under a slight vacuum (850 mbar absolute). The temperature was then raised slowly over 35 minutes to about 90° C. As the batch became quite viscous the rpm of the reactor was lowered to about 6 rpm. The temperature remained near 90° C. for another 25 minutes during which time, the pressure was lowered in steps to 500, 300 and then 100 mbar absolute. Cooling was then applied and the batch cooled to 52° C. The cooling separated most of the material from the surfaces of the reactor over a 15 minute period while the reactor temperature continued to fall to 39° C. 37 ml of water were then added to the reactor and the reactor agitated at 70 rpm for 25 minutes under 850 mbar pressure. Higher vacuum of 100 to 120 mbar was applied and held for 15 minutes. 10 ml more water was added and the reactor held at 850 mbar for another 20 minutes. Vacuum of 100 mbar absolute pressure was again applied for another 15 minutes and the product removed.
The off-white to tan, flowable powder analyzed as follow: 0.39 to 0.8% chloride, 2.4 to 2.57% sulfate, 23.2% SiO2 and 353.1 corrected equivalent weight. The adjusted assay which accounted for 8.3% water was 96.0% sulfophenylethylsiloxane. | Disclosed is a solventless process for the manufacture of sulfophenylalkylsiloxane or sulfonaphthylalkylsiloxanes, wherein the reaction between chlorosulfonic acid and a phenylalkyltrichlorosilane or a naphthylalkyltrichlorosilane is conducted in a reactor containing a self-cleaning agitator to deliver the sulfophenylalkylsiloxane or sulfonaphthylalkylsiloxane in the form of a powder. | 2 |
This application is a continuation of U.S. application Ser. No. 10/038,056, filed Jan. 3, 2002 now U.S. Pat. No. 6,637,991, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
The field of the present invention relates to aircraft cargo nets.
Aircraft cargo nets are used primarily to restrain cargo in aircraft after the cargo has been placed on an aircraft pallet. Today, virtually all aircraft cargo nets are made of rope fabricated into a large diamond- or square-patterned net structure. Initially, the nets were constructed entirely of woven webbing stitched together at the interstices to form the patterned net structure. Then, for reasons of cost and ease of manufacture, knotted rope replaced the stitched-together webbing as the material of choice for commercial aircraft cargo nets approximately twenty-five years ago. Since then, cargo nets comprising webbing have seen little, if any, commercial use as rope nets have been used almost exclusively.
In use, cargo nets are subjected to substantial wear and tear. The environment in which cargo nets are used creates extensive abrasion on the net structure. Cargo nets may be significantly damaged by exposure to extreme weather conditions, repeated attachment and removal from cargo pallets, dragging across tarmacs and floors, and being run into and over by machinery such as forklifts. As a result, the life span of a cargo net may be drastically reduced.
The purpose of the cargo net, of course, is to hold the cargo in place on the pallet—not only during the loading and unloading process, but also during flight. Planes must maintain balance within certain limits to remain flight-worthy, and if cargo nets failed during flight leading to a sufficiently large shifting of cargo and hence weight within the hold of an airplane, the plane's ability to fly could be compromised. Indeed, there have been plane crashes that were attributed to shifting of cargo.
Therefore, cargo nets are frequently inspected, and if damaged or worn, must be repaired or replaced. That creates cost and delay, and is therefore to be avoided to the extent possible.
Not surprisingly, it is the lower rope section of the cargo net, which is that section nearest where the cargo net attaches to the pallet, that suffers the most abrasion and wear and tear. The abrasion and wear and tear on this section of the net has several sources, with pallet attachment fittings causing the bulk of the damage by continuously rubbing against the ropes they are attached to. When the cargo net is not attached to an aircraft pallet, the fittings may slide freely back and forth along the rope and cause minor abrasions. When a cargo net is attached to a pallet, the net is tightened about the pallet and its contents. Tightening the net creates a great deal of additional pressure between the fittings and the ropes. The additional pressure only exacerbates the abrasive effect the fittings have on the ropes, especially as the pallet is moved and jostled about during transportation. Thus, the fittings steadily deteriorate the condition of the ropes they are attached to until the cargo net becomes unusable. The rope, being round, tends to allow the fittings to move more easily along the rope, and tends to concentrate the abrasion from the fittings on one side of the rope, thereby hastening the extent of the damage.
Therefore, there is a need in the art for an improved air cargo net that exhibits increased resistance to the wear and tear to which the nets are routinely subjected.
SUMMARY OF THE INVENTION
The present invention is a cargo net in which the upper sections of the net, that is the portions that in normal use will reside on the top and upper sides of the cargo on the pallet, being constructed of conventional knotted rope, but with the lower section of the net constructed with webbing. The rope and webbing sections are preferably joined together by knotting. Preferably, the webbing is flat on both sides. The flat sides of the webbing reduce the wear and tear on the lower section of the cargo net by spreading the abrasive forces over a larger surface area. Reducing wear and tear on the lower section of the cargo net increases the life span of the cargo net.
In the preferred embodiment of this invention, only the very lowest section of the net, that is, the section that is attached to the fittings, is comprised of webbing. Alternatively, a larger section of the cargo net or the entire cargo net could be comprised of knotted webbing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a cargo net as it exists in the prior art;
FIG. 2 is a close up of a cargo net with a bottom webbing according to a preferred embodiment;
FIG. 3 is a close up of a cargo net according to an alternative embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a cargo net 11 as it exists in the prior art. Previously, cargo nets have been fabricated entirely of strands of rope 21 . The strands are joined together 23 at regular intervals to form a lattice 25 of diamond shaped openings that is shaped like an open ended cube to fit over the pallet 27 and its contents 29 . The rope comprising the bottom-most section 31 of the lattice 25 passes through a plurality of pallet attachment fittings 33 , with one pallet attachment fitting 33 preferably positioned in each section of the diamond of the lattice 33 on the bottom section 31 . In some usages, the fittings 33 are not attached to each section, but every other section. The fittings are used to anchor the cargo net 11 to the pallet 27 and secure the contents 29 for transport.
FIG. 2 illustrates a preferred embodiment of the invention. Unlike the cargo net illustrated in FIG. 1 which is fabricated entirely of rope, the bottom section of rope is replaced with a flat webbing 103 . The upper section 110 of the cargo net 101 comprises strands of rope 105 joined together to form a lattice 107 of diamond shaped openings in the shape of an open ended cube. The webbing 103 is joined into the rope 105 at the open end of the cube to extend the lattice 107 , thus forming the bottom section 111 of the cargo net 101 . The knots 113 between the rope 105 and the webbing 103 are the same as the knots 115 in the upper section between strands of rope 105 . The webbing 103 passes through a plurality of pallet attachment fittings 117 , with one pallet attachment fitting 117 positioned in each section, or alternatively every other or every third section, of the diamond of the lattice 107 on the bottom section 111 .
Using webbing in lieu of rope for the bottom section provides the cargo net with increased resistance to abrasion. The webbing's flat surface is less readily abraded by the rubbing and pressures caused by the pallet attachment fittings because the flat surface spreads the abrasive forces out over a greater area. The increased surface area of the webbing also helps prevent wear and tear caused when the cargo is dragged across airport floors, ramps, and loading areas. The fittings also tend to not move on the webbing as much as with the rope, so the webbing is subjected to less wear and tear.
The webbing 103 is preferably constructed from a nylon or polyester material, however, other materials may be used including, but not limited to, polymeric reinforcing fibers such as Kevlar® or Spectra®, or any other material which can be manufactured into a webbing, has enough flexibility to be joined into the lattice, and serves the needs of the user. Preferably, the tensile strength of the webbing 103 is approximately equal to or greater than that of the rope 105 used for the upper section. However, because the webbing 103 has an increased resistance to abrasion, webbing with a strength rating less than that of the rope may be used. The webbing 103 may also be specially treated to give it additional abrasion resistance, but whether or not the webbing 103 is treated depends primarily on the needs of the user.
FIG. 3 illustrates an alternative embodiment in which a cargo net 201 comprises additional sections of rope replaced by webbing. Two or more sections of the net may comprise webbing, or alternatively the entire cargo net may comprise webbing. The amount of webbing included in the cargo net is entirely within the discretion of the manufacturer and user.
Incorporating the webbing into a cargo net is a relatively straightforward process. A cargo net having a bottom section comprising webbing may be fabricated in the same manner as a rope cargo net with only minor adjustments in the fabrication technique. These minor adjustments are needed to account for the flat shape of the webbing.
Thus, a cargo net with a bottom webbing is disclosed. While embodiments and applications of this invention have been shown and described, it would be apparent to those skilled in the art that additional modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the appended claims. | A cargo netting having a knotted bottom webbing and an upper knotted rope strand section. The bottom webbing is flat to reduce abrasion and wear and tear. The bottom webbing attaches to a cargo pallet using pallet attachment fittings. | 1 |
FIELD
The invention relates to a contact element for a connecting terminal, particularly a circuit board connecting terminal, and to a connecting terminal and to a plug link.
BACKGROUND
As understood in this document, a connecting terminal generally has several poles, to each of which a connecting lead can be attached in order to further transmit an electrical signal, specifically by clamping the lead to a contact element and fixing it in position there. As a rule, the electrical signal is then received from the contact element by one or more permanent or detachable electrical connections. Each pole of a connecting terminal thus corresponds to a clamping element, and the entire connecting terminal is constructed of a plurality of such clamping elements.
When connecting terminals are used to connect more than one connecting lead, and when circuit board connecting terminals, in particular, are used to connect a plurality of leads to circuit boards, it is often the case that two or more clamping elements must be electrically connected to each other in the connecting terminal. This is usually achieved by inserting a lead component that is bent into the shape of a U, or a stamped or punched part that has a U-shape, into the clamping point, where it is clamped into position. However, a problematic aspect of this procedure rests in the fact that an additional connecting lead must be attached to least one of the connected clamping points, which means that two elements must be clamped into position at this point. The result is that a secure contact for the two elements cannot be absolutely guaranteed, e.g., because the diameter of the U-shaped lead component or stamping may diverge from that of the connecting lead. Spring clamps, which are widely employed because of their unusually robust, economical, and easily handled clamping mechanism have proved to be particularly susceptible in this regard.
DE 10 2004 013 757 shows a way of circumventing this problem by installing separate electrical contacts when clamping elements of this kind must be linked together. Installation must be performed in advance, however. Moreover, the connection cannot be undone once it is made, and assembly costs consequently rise.
SUMMARY
The goal of the invention, therefore, is to provide a contact element for a connecting terminal, particularly a circuit board connecting terminal, as well as to provide a connecting terminal itself and a plug link for the connecting terminal, such that the poles of the connecting terminal can be connected in a manner that flexible, well-adapted to the market, and cost-effective.
The invention achieves this goal with a contact element for a connecting terminal with the features of patent claim 1 , with a connecting terminal with the features of patent claim 8 , and with a plug link for a connecting terminal with the features of patent claim 13 . Advantageous embodiments and elaborations of the invention are indicated in the secondary claims.
The basic idea of the invention is to design the contact element for a connecting terminal as a bent punched part, into which are integrated at least an initial clamping means for fixing a plug link in place and a second clamping means for fixing a connecting pin in place. “Integrated” is understood to mean specifically that the first and the second clamping means are integral parts of the bent punched part and that the corresponding sections of the bent punched part are provided by suitable mechanical pre-stressing, when necessary.
In this way, a separate clamping contact is provided for a plug link, by means of which different contact elements can be shorted with each other, while an optimal clamping effect for the pin and electrical conductors is simultaneously guaranteed at all the clamping contacts.
The multi-functional contact element elaborated by the invention can be produced simply and economically in a single step, namely by producing the bent punched part.
The bent punched part has an advantageous cage-like structure, which makes it possible, e.g., to close a flow of power that is introduced into the contact element by an additional clamping spring, which is positioned as a separate part in the contact element.
Contact elements have proven to be particularly suited when at least the first clamping means is flat, since this permits a particularly compact, space-saving design. It has proven to be particularly useful if the first clamping means has at least one leg, which clamps into position a contact finger that belongs to a plug link and that is inserted between the clamping leg and a wall or a second clamping leg.
An embodiment of the first clamping means which ensures a particularly secure clamping connection specifies that at least one clamping leg has a structural feature, e.g., an indentation or a bulge, that engages with a matching bulge or indentation belonging to a contact finger. Clamping means of this kind can be very simply provided by punching out the appropriate shape from strips of sheet metal.
A wide range of application for a single design of the contact element is provided if the second clamping means is so designed that the connecting pin can be inserted from three different spatial directions.
The contact element can be further improved if it also has a contact surface for testing, such as to permit the signal applied to this structural component to be tested.
The connecting terminal according to the invention, and the circuit board connecting terminal, in particular, has at least two clamping elements, each of which has an insulating housing and a contact element (as also specified by the invention), which is positioned inside the insulating housing.
It is particularly advantageous if the insulating housing of at least two of the clamping elements, specifically the clamping elements which are connected together in electrically conductive fashion, has a lead-insertion hole, a plug-link insertion hole that is separated from the lead-insertion hole, and at least one other hole for producing a plug contact with a pin or a multi-pin connector. This ensures that for each plug contact that is provided there can be an individual clamping point that is adapted to the special demands of the given plug contact.
It has also proved to be advantageous if the insulating housing has at least one locking device with click-in means which allow the insulating housing to be secured to a housing or circuit board.
For a variable electrical connection, which permits subsequent modification and which involves at least two clamping elements belonging to this kind of connecting terminal, a plug link is particularly suited—specifically, a plug link which, when inserted, is clamped by the first clamping means of the given contact element.
The plug link for a contact element according to the invention advantageously has a front part and at least two contact fingers. The plug link is particularly easy to handle when the front part is at least partially angled. In order to remove the plug link without danger, for all voltages applied to the contact element at a given moment, it very useful if the front part is at least partially covered with an insulation. The insulting cover may be an applied plastic or an injection-molded part.
A particularly secure seat for the plug link can be provided if at least one of the contact fingers has a bulge or indentation, so that a locking effect is provided with the assigned clamping means, and specifically when said clamping means has a corresponding indentation or bulge.
It also contributes to the secure seat if at least one of the contact fingers has an opening, since in this way the rims of the contact fingers will yield elastically in relation to each other and thereby provide a better contact.
It is expedient if the plug link is also designed as a bent punched part, and if it has a U-shape when the link is a bipolar one and a comb-shape when the link is a multi-polar one.
BRIEF DESCRIPTION OF THE DRAWINGS
An exemplary embodiment of the invention is next described in detail on the basis of the figures. Shown are:
FIG. 1 a view of the connecting terminal according to the invention, with an unplugged plug link
FIG. 2 a view of the connecting terminal according to FIG. 1 , with a removed lateral wall and an inserted plug link
FIG. 3 a cross-section through the connecting terminal according to FIG. 1
FIG. 4 an exemplary embodiment of a contact element for the connecting terminal according to FIG. 1 , in detail
FIG. 5 an exemplary embodiment of a plug link for a connecting terminal according to FIG. 1 , in detail
FIG. 6 a view from below of two adjacent contact elements belonging to a connecting terminal according to FIG. 1 , as connected by an inserted plug link.
Unless otherwise noted, identical reference numerals are used for identical components in all of the figures.
DETAILED DESCRIPTION
FIG. 1 gives a view of a connecting terminal 100 according to the invention and of an unplugged plug link 3 . The connecting terminal 100 shown in FIG. 1 is designed for four connection wires or leads which are not depicted, though a design that accommodates more or fewer connection leads is also possible. Providing the connecting terminal with a modular design, consisting of individual clamping elements 101 that can be joined together, is particularly suitable, though an inseparable design is also possible.
Each clamping element 101 has an insulating housing 1 , which as a rule is made of an electrically insulating material; it also has a lead-insertion hole 4 , a plug-link insertion hole 5 , and a pressing component 2 , which is also generally produced from an electrically insulating material and runs through the insulating housing 1 .
The insulating housing 1 also has at least one locking device 6 , which engages with a circuit board or the wall of a housing. On its side the connecting terminal 100 is sealed with a lateral wall 102 .
FIG. 2 gives a view of the connecting terminal 100 of FIG. 1 . The connecting terminal 100 is composed of four clamping elements 101 , and its lateral wall 102 is removed to provide a view into the interior of one of the clamping elements 101 . In addition to the lead-insertion hole 4 , the plug-bridge insertion hole 5 , and the pressing components 2 that penetrate the insulating housing, the insulating housing 1 also has three holes 10 , 11 , 12 for plug contacts that are not depicted. Positioned in the interior of the insulating housing 1 is a contact element 8 , which is accessible from the outside via a testing tap 9 .
FIG. 4 shows an exemplary embodiment of the contact element 8 belonging to the connecting terminal 100 of FIG. 1 . The contact element 8 is designed as a single-piece bent punched part. The contact element 8 is also designed in the shape of a cage. It is essential to the invention that there is incorporated into the contact element 8 an initial clamping means 13 and a second clamping means 15 , which specifically form a single piece with said contact element 8 and are integral to it. In the embodiment shown in FIG. 4 the first clamping means 13 comprises two clamping legs with an indentation 14 . The second clamping means 15 is designed as a contact spring, which has insertion aids 22 running in three directions; these insertion aids 22 facilitate the creation of a clamping contact with a connection pin (not shown), which is introduced from these directions. In addition, the contact element 8 in the embodiment shown in FIG. 4 has a testing contact surface 16 , which is accessible from the testing tap 9 . The testing contact surface 16 provided on the contact element 8 allows the current and voltage conditions that obtain on the contact element 8 at a given time to be tapped by means of the testing tap 9 and allows a measurement to be made.
The bent punched part that forms the cage-like structure of the contact element 8 shown in FIG. 4 is specifically composed as follows: with its crosswise dimension a base plate 401 describes an x-axis 419 , and with its longitudinal dimension a y-axis, and with its dimension with respect to thickness a z-axis, and these axes jointly form a right-handed Cartesian coordinate system. In the coordinate system thus defined, “forward” corresponds to larger x-values and “backwards” to smaller ones; “right” to larger y-values and “left” to smaller ones; and “upper” to larger z-values and “lower” to smaller ones.
At the border of the left rim of the base plate 401 there is a stamped out area 402 that produces the first clamping means 13 , which here takes the form of clamping legs, with recesses 14 provided in its interior.
Running from the right part of the front rim of the base plate 401 , basically parallel to the y-axis, there is a first material strip 408 , which extends further to the right across the right rim of the base plate 401 and which is bent upwards around an axis running basically parallel to the y-axis. The part of the first material strip 408 that borders the base plate 401 serves to laterally stabilize the elastic spring (not shown in FIG. 4 ) in the forward direction. As the material strip 408 extends further to the right, it first runs diagonally backwards and passes into a rectangular clamping area or surface 410 , which runs basically parallel to the y-axis. This clamping surface 410 is surrounded in the remaining three directions by areas 411 , 412 , 413 , which are tilted diagonally and forwards, relative to the clamping surface 410 . This portion of the first material strip 408 forms the first part of the clamping means 15 ; another material strip 414 , whose shape in described below, forms the second part of the clamping means 15 .
Bent forward from the upper rear wall 403 , which runs basically parallel to the y-axis, is a top plate 405 , which extends along the x-axis basically parallel to the base plate 401 . The lead (not shown) comes to rest on the side of the top plate 405 that faces the base plate 401 when said lead is inserted and is positioned by a clamping spring 7 , which is shown only in FIGS. 1 and 3 . Positioned on the front rim of the top plate 405 there is a rectangular stamped out area 406 , which serves to receive the pressing component 2 , which is shown in FIGS. 1 to 3 .
In the left lower area of the back wall 403 , a third material strip 407 is bent forward so that it runs parallel to the x-direction and so that the front rim of the base plate 401 , the front rim of the third material strip 407 , and the front rim of the top plate 405 lie on a single plane; at the same time, the left rim of the base plate 401 , the left rim of the third material strip 407 , and the left rim of the top plate 405 lie on a single plane. The material strip 407 serves to secure the clamping spring 7 (not depicted) when the contact element 8 is pushed in too far to the right.
In the right upper area of the back wall 403 a fourth material strip 409 is bent forward so that it runs parallel to the x-direction and so that the front rim of said fourth material strip 409 and of the top plate 405 lie on a single plane [sic]. The fourth material strip 409 serves as a support for the testing contact surface 16 , which is bent away from, and to the right of, said fourth material strip 409 on the latter's front rim, so that the testing contact surface 16 rests basically parallel to the top plate 405 and lies on the same plane as the latter, or slightly below it.
The fifth material strip 414 , already mentioned, extends, at first diagonally, from the right lower area of the back wall 403 and to the right. Along the y-coordinate of the left boundary line of the first clamping area 410 of the first material strip 408 , the fifth material strip 414 passes into a rectangular second clamping area 415 , which is parallel to the first clamping area and of equal size. This second clamping area 415 is surrounded in the remaining three directions by surfaces 416 , 417 , 418 , which run diagonally and backwards. Surfaces 411 and 416 , 412 and 417 , and 413 and 418 each form a common insertion aid for inserting a connecting pin 21 (not shown) into the second clamping means 15 formed by material strips 408 and 414 , and specifically for inserting said connecting pin 21 between the clamping area 410 and 415 .
Again with reference to FIG. 2 , the clamping spring 7 in the contact element 8 , is so inserted between the base plate 401 and the top plate 405 of the contact element 8 (or as the case may be, between the base plate 401 of the contact element 8 and the bottom of the pressing component 2 ) that a clamping effect can be exerted on a connecting lead (not shown) that is inserted into the lead-insertion hole 4 . The clamping spring 7 forms the third clamping means of the connecting terminal 100 . Visible in the rear area of the contact element 8 is the second clamping means 15 , which forms a single piece with said contact element 8 .
A plug link 3 is inserted into the two adjacent plug-link insertion holes 5 belonging to two adjacent clamping elements 101 , and the two clamping elements 101 are then joined together in electrically conductive fashion by this plug-link 3 . It is understood that the plug link 3 can also be designed so that more than two clamping elements 101 are connected in conductive fashion or that two non-adjacent clamping elements 101 are joined together.
The basic principle according to which terminal leads are connected through use of the connecting terminal can easily be understood from FIG. 2 . When a connecting lead (not shown) with a stripped end is inserted through the lead-insertion hole 4 and into the interior of a clamping element 101 it meets the blade-like front side (leading diagonally and upwards) of the clamping spring 7 and is thereby guided diagonally and upwards until it meets the actual supporting surface, formed by the inside area of the cover plate 405 , of the contact element 8 (not depicted in FIG. 2 ). When the connecting leads are sufficiently rigid, the exertion of further pressure causes the clamping spring 7 to be slightly depressed, and the stripped end of the connecting lead is squeezed between the supporting surface and the clamping spring 7 . When less rigid connecting leads are used, the clamping spring 7 can also be pressed down by pressure exerted on the pressing component 2 , which rests against a shoulder or contact surface of the clamping spring 7 . The connecting lead is then inserted and clamped into position when pressure on the pressing component 2 is released. In both cases, the connection is cancelled when pressure is exerted on the pressing element 2 , so that the clamping spring 7 is depressed and its clamping effect is negated. When the clamping spring 7 is in a depressed state, the connecting lead can be easily removed.
The contact element 8 is made of an electrically conductive material. Electrical signals fed by a connecting lead inserted into the clamping element 101 will therefore disperse through the contact element 8 , specifically into the contact spring for the plug contact. Using holes 10 , 11 and/or 12 , a plug contact can be produced with the second clamping means 15 , which is designed as a contact spring, and from three different directions, simply by inserting an electrically conductive connecting pin into the contact spring.
FIG. 3 provides a cross-section through the connecting terminal 100 of FIG. 1 . In addition to elements that are familiar from FIGS. 1 and 2 , this depiction shows further details, specifically with regard to the position of the clamping spring 7 in the contact element 8 .
FIG. 5 shows an exemplary embodiment of the detailed structure of the plug link 3 , which is designed to particular advantage as a bent punched part. It has an angled front portion 20 , which is advantageous, and from it extend two contact fingers 17 . In principle, the contact fingers 17 may lie in the same plane as the front part 20 , but the angled design facilitates manipulation, particularly the removal of the plug link 3 . The number of contact fingers can also be larger, so that a comb-like structure is produced. The inserted plug link 3 is fixed in position by a reciprocal clamping effect with the first clamping mean 13 , which is integrated into the contact element 8 (compare FIG. 3 ). A secure seat for the plug link 3 upon insertion is achieved, in particular, by the provision of bulges 18 , which engage with the indentations 14 of the first clamping means 13 belonging to the contact element 8 (shown in FIG. 4 ) when the plug link is inserted, and by a recess 19 , which improves the elasticity of the rims of the contact fingers 17 and thus improves the contact itself. The front part 20 and the contact fingers 17 will be made, as a rule, from an electrically conductive material; however, the front part 20 can be enclosed, at least in part, by an insulating layer (not shown).
FIG. 6 gives a view from below of two contact elements 8 according to FIG. 4 , which lie adjacent to each other, but are spaced at a slight distance. The contact elements 8 belong to a connecting terminal and are joined by an inserted plug link 4 . This perspective view from below clearly shows the contact legs which create the first clamping means 13 and the indentation 14 . Also clearly visible are the second clamping means 15 , in the form of a contact spring for the plug contact, and the testing contact areas 16 .
FIG. 6 shows with particularly clarity the interaction between the contact legs 13 of the contact elements 8 , including the indentations 14 , on the one hand, and the contact fingers 17 , including the bulge 18 and the recess 19 , on the other hand, to thereby ensures a secure but also reliably detachable connection between the contact elements 8 via the plug link 3 . An essential feature here is that the first clamping means 13 is designed to be separate from the second clamping means 15 and also separate from the third clamping means, which takes the form of clamping spring 7 , in order to reliably position the plug link 3 , independent of the positioning of the connecting pin 21 using the clamping means 5 and independent of the positioning of the connecting lead using the clamping spring 7 .
LIST OF REFERENCE NUMERALS
1 insulating housing
2 pressing component
3 plug link
4 lead insertion hole
5 plug-link insertion hole
6 locking device
7 clamping spring
8 contact element
9 testing tap
10 hole for plug contact with pin
11 hole for plug contact with pin
12 hole for plug contact with pin
13 first clamping means
14 indentation
15 second clamping means
16 testing contact surface
17 contact finger
18 bulge
19 recess
20 angled front part
21 connecting pin
22 insertion aid
100 connecting terminal
101 clamping element
102 lateral wall
401 base plate
402 stamping
403 back wall
404 material strip
405 top plate
406 stamping
407 material strip
408 material strip
409 material strip
410 clamping surface
411 surface
412 surface
413 surface
414 material strip
415 clamping surface
416 surface
417 surface
418 surface
419 x-axis
420 y-axis
421 z-axis | The invention relates to a contact element for a connecting terminal, where the contact element consists of a bent punched part, into which are integrated at least an initial clamping means for fixing a plug link into position and a second clamping means for fixing a connecting pin into position. The invention also relates to a connecting terminal, particularly a circuit board connecting terminal, with at least two clamping elements, where the clamping elements each have an insulating housing, with a contact element of the described type positioned within said insulating housing. Finally, the invention relates to a plug link for such a connecting terminal. | 7 |
INCORPORATION BY REFERENCE
[0001] The disclosure of Japanese Patent Application No. 2010-079146 filed on Mar. 30, 2010 including the specification, drawings and abstract is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to an automatic transmission control device controlling an automatic transmission mounted in a vehicle having a motor, wherein the automatic transmission engages a first friction engagement element and a second friction engagement element by a fluid pressure from a pump operating using motive power from the motor when a shift position is at a reverse traveling position, places the first friction engagement element on standby at a predetermined standby pressure that is higher than a stroke starting pressure by which a piston stroke is started and lower than a complete engagement pressure or engages the first friction engagement at the complete engagement pressure when the shift position is at a non-traveling position, and engages a third friction engagement element as a starting shift speed when the shift position is at a forward traveling position.
DESCRIPTION OF THE RELATED ART
[0003] In the related art, as an automatic transmission control device of this type, there has been proposed an automatic transmission control device which selectively turns on or off three clutches C- 0 to C- 2 and five brakes B- 0 to B- 4 based on an operation of a select lever, so as to switch a parking (P) position, a reverse (R) position, a neutral (N) position, and a drive (D) position (see Japanese Patent Application Publication No. JP-A-H05-157164). In this control device, when the select lever is in the R position, three elements of the clutch C- 2 , the brake B- 0 , and the brake B- 4 need be engaged. Accordingly, when the select lever is in the N position as a non-traveling position, the brake B- 4 which does not contribute to motive power transmission is placed in an engagement state in advance, and thus a hydraulic pressure is newly applied only to the clutch C- 2 and the brake B- 0 when the select lever is switched to the R position. In this manner, it is possible to suppress delay in operation of clutches and brakes, that is, delay in response to a shift operation, without increasing the capacity of a hydraulic pressure generation source.
SUMMARY OF THE INVENTION
[0004] Considering switching from the D position to the R position via the N position, when there is a sufficient stop period at the N position, the brake B- 4 can be engaged during this period, and thus the remaining clutch and brake can be engaged relatively quickly when the shift position has reached the R position. However, when there is no sufficient stop period at the N position and a shift operation from the D position to the R position is performed quickly, engagement of the brake B- 4 is not completed on time, and all the necessary clutch and brakes including the brake B- 4 should be engaged when the shift position has reached the R position. Thus, formation of the R position is delayed.
[0005] It is a main object of an automatic transmission control device of the present invention to enable quick formation of a reverse traveling shift speed without increasing the capacity of a fluid pressure generating source even when a shift operation from a forward traveling position to a reverse traveling position is performed quickly.
[0006] In the automatic transmission control device of the present invention, the following means are employed to achieve the above-described main object.
[0007] An automatic transmission control device according to a first aspect of the present invention controls an automatic transmission mounted in a vehicle having a motor. The automatic transmission engages a first friction engagement element and a second friction engagement element by a fluid pressure from a pump operating using motive power from the motor when a shift position is at a reverse traveling position, places the first friction engagement element on standby at a predetermined standby pressure that is higher than a stroke starting pressure by which a piston stroke is started and lower than a complete engagement pressure or engages the first friction engagement at the complete engagement pressure when the shift position is at a non-traveling position, and engages a third friction engagement element as a starting shift speed when the shift position is at a forward traveling position. In the automatic transmission control device, when the shift position is at the forward traveling position, the first friction engagement element is placed on standby at the predetermined standby pressure if a vehicle speed is lower than a first predetermined vehicle speed, or releases the predetermined standby pressure if the vehicle speed is equal to or higher than the first predetermined vehicle speed.
[0008] In this automatic transmission control device according to the first aspect of the present invention, in the automatic transmission that engages the first friction engagement element and the second friction engagement element by the fluid pressure from the pump operated using motive power from the motor when the shift position is at the reverse traveling position, places the first friction engagement element on standby at a predetermined standby pressure that is higher than the stroke starting pressure by which the piston stroke is started and lower than the complete engagement pressure or engages the first friction engagement element at the complete engagement pressure when the shift position is at a non-traveling position, and engages the third friction engagement element as the starting shift speed when the shift position is at the forward traveling position, with the shift position at the forward traveling position, the first friction engagement element is placed on standby at the predetermined standby pressure if a vehicle speed is lower than a first predetermined vehicle speed, or the standby pressure is released if the vehicle speed is equal to or higher than the first predetermined vehicle speed. Placing the first friction engagement element on standby at a standby pressure higher than the stroke starting pressure when the shift position is at the forward traveling shift position reduces the number of friction engagement elements to which the fluid pressure should be supplied with the shift position at the reverse traveling position, even when a shift operation from the forward traveling position to the reverse traveling position is performed quickly. As a consequence, formation of the reverse traveling shift speed can be performed in a shorter time. The flow rate of a fluid supplied to the first friction engagement element increases while a piston of the first friction engagement element is stroking, that is, while the volume of an operating fluid chamber of the first friction engagement element to which an engagement fluid pressure is supplied is changing. By supplying a fluid pressure equal to or higher than the stroke starting pressure to the first friction engagement element in advance, the change amount of the volume of the operating fluid chamber of the first friction engagement element can be reduced when a shift operation to the reverse traveling position is performed, and the flow rate of a fluid supplied to the first friction engagement element when the shift operation to the reverse traveling position is performed and the discharge amount of fluid required by the pump can be reduced. Accordingly, the pump can be made smaller. Normally, the reverse traveling position is not accepted when the vehicle speed is relatively high. Thus, releasing of the standby pressure when the vehicle speed is equal to or higher than the first predetermined vehicle speed prevents occurrence of dragging of the first friction engagement element depending on the shift speed being formed, and the efficiency of the vehicle can be improved further. The “predetermined standby pressure” includes a fluid pressure larger than the stroke end pressure which causes engagement of the first friction engagement element with slipping, and a fluid pressure lower than the stroke end pressure. The “complete engagement pressure” is a hydraulic pressure which causes engagement of the first friction engagement element without slipping.
[0009] In the automatic transmission control device according to a second aspect of the present invention as above, the first friction engagement element may be placed on standby at the predetermined standby pressure on a condition that a rotation speed of the motor is equal to or higher than a predetermined rotation speed. This makes it possible for the first friction engagement element to be placed on standby at an engagement standby pressure after confirming that the fluid pressure discharged from the pump is sufficient.
[0010] In the automatic transmission control device according to a third aspect of the present invention, when the vehicle speed becomes lower than the first predetermined vehicle speed when other different friction engagement element from the first friction engagement element is being engaged, the first friction engagement element may be placed on standby at the predetermined standby pressure after waiting until the engagement of the other friction engagement element is completed. Accordingly, the discharge amount of the pump required at a time can be reduced, and the pump can be made small. In the automatic transmission control device according to a fourth aspect of the present invention that performs neutral control is performed to place the third friction engagement element in a predetermined neutral state when the shift position is at the forward traveling position and a neutral control condition is met, and hill-hold control is performed to engage a fourth friction engagement element for suppressing reverse rotation of an output shaft of the automatic transmission. In the automatic transmission control device of this aspect, while the hill-hold control to engage the fourth friction engagement element as the other different friction engagement element is being performed, the first friction engagement element may be placed on standby at the predetermined standby pressure after waiting until the engagement of the fourth friction engagement element is completed. When the motor is structured as an internal combustion engine, the internal combustion engine is placed in an idle-rotation state during the neutral control. Thus, by supplying a hydraulic pressure to the first friction engagement element after waiting until engagement of the fourth friction engagement element is completed, the necessary discharge amount of the pump when the rotation speed of the internal combustion engine is low can be reduced, and the pump can be made smaller.
[0011] In the automatic transmission control device according to a fifth aspect of the present invention, formation of a reverse traveling shift speed is prohibited regardless of the shift position when the vehicle speed is equal to or higher than a second predetermined vehicle speed. In the automatic transmission device of this aspect, the first predetermined vehicle speed may be set to a vehicle speed higher than the second predetermined vehicle speed. Accordingly, even when a certain length of time is required for placing the first friction engagement element on standby at the predetermined standby pressure, such standby at the predetermined standby pressure can be established by the time when formation of the reverse traveling shift speed is permitted. As a consequence, no matter what timing the shift operation from the forward traveling position to the reverse traveling position is performed, it is possible to suppress occurrence of delay in formation of the reverse traveling shift speed.
[0012] The automatic transmission control device according to a sixth aspect of the present invention further includes a planetary gear mechanism that has a first rotation element connected to an input shaft side via a first clutch, a second rotation element connected to the input shaft side via a second clutch and connected to a case via a second brake, a third rotation element connected to an output shaft side, and a fourth rotation element connected to the input shaft side via a third clutch and connected to the case via a first brake, which have a relation of rotation speed ratios in order of the fourth rotation element, the second rotation element, the third rotation element, and the first rotation element, wherein the first friction engagement element is the second brake, the second friction engagement element is the third clutch, and the third friction engagement element is the first clutch. In the automatic transmission control device of this aspect, while the vehicle is coasting with the shift position at a neutral position as the non-traveling position, the predetermined standby pressure on the second brake may be released or no engagement pressure may be supplied thereto. When none of the first to third clutches and the first and second brakes are engaged, the third rotation element coupled to the output shaft side of the planetary gear mechanism rotates at a rotation speed depending on the vehicle speed, and the other three rotation elements rotate in a balanced manner independently from the rotation of the third rotation element. However, when the second brake is engaged, the second rotation element to which the second brake is connected is fixed, and thus rotation of the first rotation element accelerates with respect to the rotation speed of the third rotation element. This acceleration in rotation may adversely affect efficiency of the planetary gear mechanism, and may cause dragging of the first clutch connected to the first rotation element. Therefore, while the vehicle is coasting with the shift position at the neutral position, occurrence of such a disadvantage is avoided by releasing the standby pressure on the second brake or by supplying no engagement pressure thereto, and traveling resistance can be reduced.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a structural diagram illustrating an overview of the structure of an automobile 10 having a transmission apparatus as one embodiment of the present invention;
[0014] FIG. 2 is an explanatory diagram illustrating an operation table of an automatic transmission 20 ;
[0015] FIG. 3 is a collinear diagram illustrating a relation of rotation speeds of respective rotation elements of the automatic transmission 20 ;
[0016] FIG. 4 is a flowchart illustrating an example of a shifting control routine executed by an ATECU 29 ;
[0017] FIG. 5 is a flowchart illustrating an example of a B 2 standby engagement permission setting routine executed by the ATECU 29 ;
[0018] FIG. 6 is a flowchart illustrating an example of a coasting determination routine executed by the ATECU 29 ;
[0019] FIG. 7 is a structural diagram illustrating an overview of the structure of an automatic transmission 120 of a modification example; and
[0020] FIG. 8 is an explanatory diagram illustrating an example of an operation table of the automatic transmission 120 .
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0021] Next, an embodiment of the present invention will be described using examples.
[0022] FIG. 1 is a structural diagram illustrating an overview of the structure of an automobile 10 having a transmission apparatus as one embodiment of the present invention. FIG. 2 illustrates an operation table of an automatic transmission 20 . FIG. 3 is a collinear diagram illustrating a relation of rotation speeds of respective rotation elements of the automatic transmission 20 . As illustrated in FIG. 1 , the automobile 10 of the embodiment has: an engine 12 as an internal combustion engine outputting motive power by explosive combustion of hydrocarbon fuel such as gasoline and diesel oil; a torque converter 24 with a lock-up clutch attached to a crank shaft 14 of the engine 12 , the stepped automatic transmission 20 having an input shaft 21 connected to an output side of the torque converter 24 and an output shaft 22 connected to driving wheels 18 a , 18 b via a gear mechanism 26 and a differential gear 28 , and shifting the motive power inputted to the input shaft 21 and transmitting the shifted motive power to the output shaft 22 ; and a main electronic control unit (hereinafter referred to as a main ECU) 60 controlling the entire vehicle.
[0023] The operation of the engine 12 is controlled by an engine electronic control unit (hereinafter referred to as an engine ECU) 16 . Although not illustrated in detail, the engine ECU 16 is structured as a microprocessor with a CPU as a main component, and has a ROM storing processing programs, a RAM temporarily storing data, an input/output port, and a communication port besides the CPU. To this engine ECU 16 , signals from various sensors required for controlling operation of the engine 12 , such as an engine speed sensor attached to the crank shaft 14 , are inputted via an input port, and from the engine ECU 16 , a drive signal to a throttle motor adjusting a throttle opening, a control signal to a fuel injection valve, an ignition signal to spark plugs, and so on are outputted via an output port. The engine ECU 16 communicates with the main ECU 60 , controls the engine 12 by a control signal from the main ECU 60 , and outputs data related to the operation state of the engine 12 to the main ECU 60 as necessary.
[0024] The automatic transmission 20 is structured as a stepped six-speed transmission, and has a single pinion type planetary gear mechanism 30 , a Ravigneaux type planetary gear mechanism 40 , three clutches C 1 , C 2 , C 3 , two brakes B 1 , B 2 , and a one-way clutch F 1 . The single pinion type planetary gear mechanism 30 has a sun gear 31 as an external gear, a ring gear 32 as an internal gear arranged concentrically with the sun gear 31 , a plurality of pinion gears 33 meshing with the sun gear 31 and with the ring gear 32 , and a carrier 34 rotatably and revolvably holding the plurality of pinion gears 33 . The sun gear 31 is fixed to a case 38 , and the ring gear 32 is connected to the input shaft 21 . The Ravigneaux type planetary gear mechanism 40 has two sun gears 41 a , 41 b as external gears, a ring gear 42 as an internal gear, a plurality of short pinion gears 43 a meshing with the sun gear 41 a , a plurality of long pinion gears 43 b meshing with the sun gear 41 b and the plurality of short pinion gears 43 a and with the ring gear 42 , and a carrier 44 coupling the plurality of short pinion gears 43 a and the plurality of long pinion gears 43 b and holding these pinion gears rotatably and revolvably. The sun gear 41 a is connected to the carrier 34 of the single pinion type planetary gear mechanism 30 via the clutch C 1 . The sun gear 41 b is connected to the carrier 34 via the clutch C 3 and to the case 38 via the brake B 1 . The ring gear 42 is connected to the output shaft 22 . The carrier 44 is connected to the input shaft 21 via the clutch C 2 . The carrier 44 is connected to the case 38 via the brake B 2 , and to the case 38 via the one-way clutch F 1 .
[0025] In the automatic transmission 20 thus structured, it is possible to switch among first to sixth forward speeds, a reverse speed, and a neutral, by combinations of turning on and off of the clutches C 1 to C 3 (hereinafter, turning on refers to engagement and turning off refers to disengagement, and the same applies thereafter) and turning on and off of the brakes B 1 , B 2 , as illustrated in the operation table of FIG. 2 and the collinear diagram of FIG. 3 .
[0026] A state of the first forward speed can be formed by turning on the clutch C 1 and turning off the clutches C 2 , C 3 and the brakes B 1 , B 2 , or by turning on the clutch C 1 and the brake B 2 and turning off the clutches C 2 , C 3 and the brake B 1 . In this state, motive power inputted to the ring gear 32 of the single pinion type planetary gear mechanism 30 from the input shaft 21 is decelerated by receiving a reaction force on the sun gear 31 side by fixing the sun gear 31 , and is transmitted to the sun gear 41 a of the Ravigneaux type planetary gear mechanism 40 via the carrier 34 and the clutch C 1 . Motive power inputted to the sun gear 41 a is decelerated by receiving a reaction force on the carrier 44 side by fixing the carrier 44 by the one-way clutch F 1 , and is outputted to the output shaft 22 via the ring gear 42 . Thus, motive power inputted to the input shaft 21 is decelerated with a relatively large speed reduction ratio and outputted to the output shaft 22 . In the state of the first forward speed, while engine braking is performed, the carrier 44 is fixed instead of the one-way clutch F 1 by turning on the brake B 2 . A state of the second forward speed can be formed by turning on the clutch C 1 and the brake B 1 and turning off the clutches C 2 , C 3 and the brake B 2 . In this state, motive power inputted to the ring gear 32 of the single pinion type planetary gear mechanism 30 from the input shaft 21 is decelerated by receiving a reaction force on the sun gear 31 side by fixing the sun gear 31 , and is transmitted to the sun gear 41 a of the Ravigneaux type planetary gear mechanism 40 via the carrier 34 and the clutch C 1 . Motive power inputted to the sun gear 41 a is decelerated by receiving a reaction force on the sun gear 41 b side by fixing the sun gear 41 b by the brake B 1 , and is outputted to the output shaft 22 via the ring gear 42 . Thus, motive power inputted to the input shaft 21 is decelerated with a smaller speed reduction ratio than that of the first forward speed and outputted to the output shaft 22 . A state of the third forward speed can be formed by turning on the clutches C 1 , C 3 and turning off the clutch C 2 and the brakes B 1 , B 2 . In this state, motive power inputted to the ring gear 32 of the single pinion type planetary gear mechanism 30 from the input shaft 21 is decelerated by receiving a reaction force on the sun gear 31 side by fixing the sun gear 31 , and is transmitted to the sun gear 41 a of the Ravigneaux type planetary gear mechanism 40 via the carrier 34 and the clutch C 1 . Motive power inputted to the sun gear 41 a is outputted at equal speed to the output shaft 22 via the ring gear 42 by integral rotation of the Ravigneaux type planetary gear mechanism 40 by turning on the clutch C 1 and the clutch C 3 . Thus, motive power inputted to the input shaft 21 is decelerated with a smaller speed reduction ratio than that of the second forward speed and outputted to the output shaft 22 . A state of the fourth forward speed can be formed by turning on the clutches C 1 , C 2 and turning off the clutch C 3 and the brakes B 1 , B 2 . In this state, motive power inputted to the ring gear 32 of the single pinion type planetary gear mechanism 30 from the input shaft 21 is decelerated by receiving a reaction force on the sun gear 31 side by fixing the sun gear 31 , and is transmitted to the sun gear 41 a of the Ravigneaux type planetary gear mechanism 40 via the carrier 34 and the clutch C 1 and, on the other hand, transmitted to the carrier 44 of the Ravigneaux type planetary gear mechanism 40 directly from the input shaft 21 via the clutch C 2 , thereby determining driving conditions of the ring gear 42 , that is, the output shaft 22 . Thus, motive power inputted to the input shaft 21 is decelerated with a smaller speed reduction ratio than that of the third forward speed and outputted to the output shaft 22 . A state of the fifth forward speed can be formed by turning on the clutches C 2 , C 3 and turning off the clutch C 1 and the brakes B 1 , B 2 . In this state, motive power inputted to the ring gear 32 of the single pinion type planetary gear mechanism 30 from the input shaft 21 is decelerated by receiving a reaction force on the sun gear 31 side by fixing the sun gear 31 , and is transmitted to the sun gear 41 b of the Ravigneaux type planetary gear mechanism 40 via the carrier 34 and the clutch C 3 and, on the other hand, transmitted to the carrier 44 of the Ravigneaux type planetary gear mechanism 40 directly from the input shaft 21 via the clutch C 2 , thereby determining the driving conditions of the ring gear 42 , that is, the output shaft 22 . Thus, motive power inputted to the input shaft 21 is accelerated and outputted to the output shaft 22 . A state of the sixth forward speed can be formed by turning on the clutch C 2 and the brake B 1 , and turning off the clutches C 1 , C 3 and the brake B 2 . In this state, motive power inputted to the carrier 44 of the Ravigneaux type planetary gear mechanism 40 from the input shaft 21 via the clutch C 2 is accelerated by receiving a reaction force on the sun gear 41 b side by fixing the sun gear 41 b by the brake B 1 , and is outputted to the output shaft 22 via the ring gear 42 . Thus, motive power inputted to the input shaft 21 is accelerated by a smaller speed reduction ratio than that of the fifth forward speed and outputted to the output shaft 22 .
[0027] A state of a first reverse speed can be formed by turning on the clutch C 3 and the brake B 2 and turning off the clutches C 1 , C 2 and the brake B 1 . In this state, motive power inputted to the ring gear 32 of the single pinion type planetary gear mechanism 30 from the input shaft 21 is decelerated by receiving a reaction force on the sun gear 31 side by fixing the sun gear 31 , and is transmitted to the sun gear 41 b of the Ravigneaux type planetary gear mechanism 40 via the carrier 34 and the clutch C 3 . Motive power inputted to the sun gear 41 b is rotated in reverse by receiving a reaction force on the carrier 44 side by fixing the carrier 44 by the brake B 2 and outputted to the output shaft 22 via the ring gear 42 . Thus, motive power inputted to the input shaft 21 is decelerated with a relatively small speed reduction ratio and outputted to the output shaft 22 as motive power of reverse rotation.
[0028] A state of neutral can be formed by turning on the brake B 2 and turning off the clutches C 1 to C 3 and the brake B 1 , or by turning off all of the clutches C 1 to C 3 and the brakes B 1 , B 2 . In this embodiment, the state of neutral is formed by the former.
[0029] The automatic transmission 20 is drive-controlled by an automatic transmission electronic control unit (hereinafter referred to as an ATECU) 29 . The ATECU 29 is structured as, although not illustrated in detail, a microprocessor with a CPU as a main component, and has a ROM storing processing programs, a RAM temporarily storing data, an input/output port, and a communication port besides the CPU. To the ATECU 29 , an input shaft rotation speed Nin from an input shaft rotation speed sensor attached to the input shaft 21 , an output shaft rotation speed Nout from an output shaft rotation speed sensor attached to the output shaft 22 , an oil temperature Toil from an oil temperature sensor attached to the hydraulic circuit 50 , and so on are inputted via an input port. From the ATECU 29 , a drive signal to a hydraulic actuator 50 for turning on and off the clutch C 1 , a drive signal to a hydraulic actuator 52 for turning on and off the clutch C 2 , a drive signal to a hydraulic actuator 54 for turning on and off the clutch C 3 , a drive signal to a hydraulic actuator 56 for turning on and off the brake B 1 , a drive signal to a hydraulic actuator 58 for turning on and off the brake B 2 , and so on are outputted via an output port. The ATECU 29 communicates with the main ECU 60 , controls the automatic transmission 20 by a control signal from the main ECU 60 , and outputs data related to the state of the automatic transmission 20 to the main ECU 60 as necessary. The hydraulic actuators 50 to 58 are formed of linear solenoids and the like which adjust a hydraulic pressure from a mechanical oil pump 59 actuated by motive power from the engine 12 and output the adjusted hydraulic pressure to the respective clutches C 1 to C 3 , and brakes B 1 , B 2 .
[0030] The main ECU 60 is structured as, although not illustrated in detail, a microprocessor with a CPU as a main component, and has a ROM storing processing programs, a RAM temporarily storing data, an input/output port, and a communication port besides the CPU. To the main ECU 60 , a shift position SP from a shift position sensor 62 detecting an operation position of the shift lever 61 , an accelerator operation amount Acc from an accelerator pedal position sensor 64 detecting a depressed amount of an accelerator pedal 63 , a brake switch signal BSW from a brake switch 66 detecting depression on a brake pedal 65 , a vehicle speed V from a vehicle speed sensor 68 , and so on are inputted via an input port. Here, for the shift lever 61 in the embodiment, a parking (P) position, a reverse (R) position, a neutral (N) position, and a drive (D) position are arranged in this order, and the clutches C 1 to C 3 and the brake B 1 , B 2 are turned on and off according to the position selected therefrom. As described above, the main ECU 60 is connected to the engine ECU 16 and the ATECU 29 via the communication port, and exchanges various control signals and data with the engine ECU 16 and the ATECU 29 .
[0031] Here, the automatic transmission 20 and the ATECU 29 correspond to the transmission apparatus of the embodiment.
[0032] Next, operation of the transmission apparatus of the embodiment included in the thus structured automobile 10 , particularly, operation when a shift operation from the D position to the R position is performed will be described. FIG. 4 is a flowchart illustrating an example of a shifting control routine executed by the ATECU 29 . This routine is repeatedly executed at every predetermined time (for example, every few msec) from when the ignition is turned on until the ignition is turned off.
[0033] When the shifting control routine is executed, the CPU of the ATECU 29 first performs processing by which necessary data for control such as the shift position SP, the accelerator operation amount Acc, the vehicle speed V, and so on are inputted to the ATECU 29 (step S 100 ). Here, the shift position SP, the accelerator operation amount ACC, and the vehicle speed V which are detected by the shift position sensor 62 , the accelerator pedal position sensor 64 , and the vehicle speed sensor 68 , respectively, are inputted from the main ECU 60 via communication. After the data are inputted, the inputted shift position SP is checked (step S 110 ). When it is determined that the shift position SP is at the N (neutral) position, the value of a B 2 standby engagement permission determination flag Fb 2 , which will be described later, indicating whether standby engagement of the brake B 2 is permitted or not is checked (step S 115 ). When the B 2 standby engagement permission determination flag Fb 2 has a value 1, it is determined that the standby engagement of the brake B 2 is permitted, and the hydraulic actuator 58 is controlled so that the brake B 2 is turned on (step S 120 ). When the B 2 standby engagement permission determination flag Fb 2 has a value 0, it is determined that the standby engagement of the brake B 2 is prohibited, and the hydraulic actuator 58 is controlled so that the brake B 2 is turned off (step S 195 ) and this routine is finished. On the other hand, when it is determined that the shift position SP is at the R position, it is determined whether or not the vehicle speed V is lower than a reverse traveling shift speed forming permission vehicle speed Vref 2 (step S 130 ). When the vehicle speed V is lower than the reverse traveling shift speed forming permission vehicle speed Vref 2 , the hydraulic actuators 54 , 58 are controlled so that the clutch C 3 and the brake B 2 are turned on (step S 140 ) and this routine is finished. When the vehicle speed V is equal to or higher than the reverse traveling shift speed forming permission vehicle speed Vref 2 , the current state of clutches and brakes is maintained (step S 135 ) and this routine is finished. Accordingly, when a shift operation from the N position to the R position is performed, only the clutch C 3 needs be turned on. Thus, the discharge amount required at a time from the mechanical oil pump 59 can be reduced, and the first reverse speed can be formed quickly.
[0034] When it is determined in step S 110 that the shift position SP is at the D (drive) position, whether a shifting condition is met or not is determined (step S 150 ), and whether a hill-hold control condition is met or not is determined (step S 160 ). Here, the determination of the shifting condition can be performed by setting a target shift speed based on the accelerator operation amount Acc, the vehicle speed V, and a shift map, and comparing the set target shift speed with the current shift speed. The determination of the hill-hold control condition can be performed by determining whether or not all of the following conditions are met: the shift position SP is at the D position, the vehicle speed V is lower than a predetermined vehicle speed, the accelerator is off, the brake is on, the engine 12 is operating, and so on. Note that the hill-hold control condition is met when a neutral control condition in which the clutch C 1 is on standby at a hydraulic pressure equal to or lower than a stroke end pressure and the input shaft 21 and the output shaft 22 are disengaged is met. When the shifting condition is met, the shift speed for which the condition is met is set among the first forward speed to the sixth forward speed, and the respective hydraulic actuators 50 to 58 are controlled so that the necessary clutch and brake illustrated in FIG. 2 among the clutches C 1 to C 3 and the brakes B 1 , B 2 are turned on according to the set shift speed, and the unnecessary clutch and brake which are on are turned off (step S 170 ). When the hill-hold control condition is met, the hydraulic actuators 50 , 56 are controlled to turn on the brake B 1 for suppressing reverse rotation of the output shaft 22 (hill-hold control) (step S 180 ), in addition to neutral control. Then the value of the B 2 standby engagement permission determination flag Fb 2 is checked (step S 190 ). When the B 2 standby engagement permission determination flag Fb 2 has a value 1, it is determined that the standby engagement of the brake B 2 is permitted, and the hydraulic actuator 58 is controlled so that the brake B 2 is turned on (step S 120 ). When the B 2 standby engagement permission determination flag Fb 2 has a value 0, it is determined that the standby engagement of the brake B 2 is prohibited, and the hydraulic actuator 58 is controlled so that the brake B 2 is turned off (step S 195 ) and this routine is finished. Here, since this routine is repeatedly executed at every predetermined time (for example, every several msec), the processing of step S 170 of shifting control, the processing of step S 180 of hill-hold control, and the processing of step S 120 of standby engagement of the brake B 2 are performed repeatedly until these steps are completed (turning on and turning off of the corresponding clutch and brake are completed). The brake B 2 is standby-engaged in this manner also when the shift position SP is at the D position because, considering the case where the shift operation from the D position to the R position via the N position is performed, when there is a sufficient stop period at the N position, the brake B 2 is standby-engaged in this period, but when there is no sufficient stop period at the N position, the standby engagement of the brake B 2 at the N position may not be performed on time. Accordingly, when the shift operation from the D position to the R position is performed quickly, only the clutch C 3 needs be turned on when the position R is reached. Thus, the discharge amount required at a time from the mechanical oil pump 59 can be reduced, and the first reverse speed can be formed quickly. Here, in this embodiment, the standby engagement of the brake B 2 is performed by applying a hydraulic pressure slightly higher than the stroke end pressure to the brake B 2 , and is performed only when the shift speed is the first forward speed or the second forward speed. At the first forward speed, the brake B 2 is engaged completely instead of the standby engagement during engine braking. When the shift operation to the R position is performed in a state that the brake B 2 is not engaged completely, it is necessary to supply the hydraulic pressure until the brake B 2 is engaged completely, but the discharge amount required at a time from the mechanical oil pump 59 can be reduced as compared to the one which does not standby-engage the brake B 2 . The B 2 standby engagement permission determination flag Fb 2 in steps S 115 , S 190 is set by executing the B 2 standby engagement permission setting routine exemplified in FIG. 5 . This B 2 standby engagement permission setting routine is repeatedly executed at every predetermined time (for example, every several msec) from when the ignition is turned on until the ignition is turned off similarly to the shifting control routine, and the value of the flag Fb 2 used in step S 190 of shifting control routine is updated every time the B 2 standby engagement permission setting routine is executed.
[0035] When the B 2 standby engagement permission setting routine is executed, the CPU of the ATECU 26 first performs processing by which necessary data for control such as the shift position SP, the accelerator operation amount Acc, the vehicle speed V, the engine speed Ne, the oil temperature Toil, the output shaft rotation speed Nout, and so on are inputted to the ATECU 26 (step S 200 ). Here, the oil temperature Toil and the output shaft rotation speed Nout detected by the oil temperature sensor and the output shaft rotation speed sensor, respectively, are inputted. The engine speed Ne detected by the engine speed sensor is inputted from the engine ECU 16 via the main ECU 60 by communication. Inputting of the shift position SP, the accelerator operation amount Acc, and the vehicle speed V is described above already.
[0036] When the data are inputted in this manner, determinations are made as to whether the vehicle is in a condition other than coasting (step S 210 ), whether the vehicle is in a condition other than the above-described shifting control (step S 220 ), whether the vehicle is in a condition other than engagement of the brake B 1 by the above-described hill-hold control (step S 230 ), whether the vehicle is in a condition other than N-D control to turn on the clutch C 1 when a shift operation from the N position to the D position is performed (step S 240 ), whether the shift position SP is at any other position than the R position (step S 250 ), whether the oil temperature Toil is equal to or higher than a threshold Tref (step S 260 ), whether the vehicle speed V is lower than a threshold Vref (step S 270 ), and whether the engine speed Ne is equal to or higher than a threshold Nref (step S 280 ). When all the determinations of steps S 210 to S 280 are affirmative, a value 1 is set to the B 2 standby engagement permission determination flag Fb 2 to permit the standby engagement of the brake B 2 (step S 290 ). When any one of the determinations of steps S 210 , S 250 to S 280 is negative, a value 0 is set to the B 2 standby engagement permission determination flag Fb 2 , the standby engagement of the brake B 2 is prohibited (step S 295 ), and this routine is finished. When any one of the determinations of steps S 220 to S 240 is negative, the value of the B 2 standby engagement permission determination flag Fb 2 is checked (step S 245 ). When the B 2 standby engagement permission determination flag Fb 2 has a value 1, permission of the standby engagement of the brake B 2 is continued (step S 290 ). When the B 2 standby engagement permission determination flag Fb 2 has a value 0, prohibition of the standby engagement of the brake B 2 is continued (step S 295 ), and this routine is finished. Here, the determination of coasting is made by executing a coasting determination routine illustrated in FIG. 6 . In this coasting determination routine, it is determined whether a state in which the vehicle speed V is equal to or higher than the threshold Vref 2 continues for a predetermined time Tref (several seconds for example) or longer (step S 300 ). When the state does not continue for the predetermined time, it is determined that it is not appropriate to determine coasting, and this routine is finished. On the other hand, when it is determined that the state in which the vehicle speed V is equal to or higher than the threshold Vref 2 continues for the predetermined time Tref or longer, then determinations are made as to whether the shift position SP is at the N position (step S 305 ), whether the output shaft rotation speed Nout is equal to or higher than a threshold Nref 2 (step S 310 ), whether the accelerator is off (throttle is off) (step S 320 ), and whether the brake is off (step S 330 ). When all of the determinations of steps S 305 to S 330 are affirmative, it is determined that the vehicle is coasting (step S 340 ). This determination of coasting is continued until any one of the determinations of steps S 305 to S 330 becomes negative. When it is determined that any one of these determinations is negative, it is determined that the vehicle is not coasting (step S 350 ), and this routine is finished. Considering the case where none of the clutches C 1 to C 3 and brakes B 1 , B 2 are engaged at the N position, in the Ravigneaux type planetary gear mechanism 40 , the ring gear 42 connected to the output shaft 22 rotates at the rotation speed of the output shaft 22 , and the sun gears 41 a , 41 b and the carrier 44 rotate independently from the rotation of the ring gear 42 in a balanced manner with a relatively small difference in rotation from each other. On the other hand, considering the case where only the brake B 2 is engaged at the N position, rotation of the carrier 44 connected to the brake B 2 is fixed. Thus, the sun gear 41 a accelerates with respect to the rotation speed of the ring gear 42 and its rotation resistance increases, and dragging of the clutch C 1 may occur depending on the remaining hydraulic pressure on the clutch C 1 connected to the sun gear 41 a . The standby engagement of the brake B 2 is prohibited while the vehicle is coasting at the N position so as to avoid such a disadvantage and decrease traveling resistance accompanying the coasting. The standby engagement of the brake B 2 is prohibited: for supplying to a clutch and a brake a necessary hydraulic pressure for the shifting control during the shifting control; for supplying to the brake B 1 a necessary hydraulic pressure for the hill-hold control when the brake B 1 is being engaged in the hill-hold control; and for supplying to the clutch C 1 a necessary hydraulic pressure for switching from the neutral to the first forward speed during the N-D control. Accordingly, a situation that the hydraulic pressure is supplied at a time to two or more clutches and brakes is avoided, and the clutches and the brakes can be turned on appropriately by a sufficient hydraulic pressure. Therefore, when the shifting control, the hill-hold control (engagement of the brake B 2 ), or the N-D control is completed, the standby engagement of the brake B 2 is permitted if the other conditions are met. In the determination in step S 250 in this embodiment, it is determined whether the shift speed is the first forward speed or the second forward speed when the shift position is at the D (drive) position as described above. The threshold Tref used in step S 260 is defined as a value near the lower limit of an appropriate temperature range, and the threshold Vref used in step S 270 is defined as a value slightly higher than the threshold Vref 2 which is the reverse traveling shift speed forming permission vehicle speed, and the threshold Nref used in step S 280 is defined as a value near the lower limit of the engine speed by which the mechanical oil pump 59 can be operated. Therefore, in the determinations in steps S 260 to S 280 , it is determined whether or not the oil temperature Toil is at an appropriate temperature, whether or not the vehicle speed V is lower than the vehicle speed (threshold Vref) slightly higher than the reverse traveling shift speed forming permission vehicle speed Vref 2 , and whether or not the engine speed Ne is at a sufficient rotation speed for operating the mechanical oil pump 59 , respectively. Since the standby engagement of the brake B 2 is performed for forming the first reverse speed quickly when the shift operation to the R position is performed, basically, it may be performed when the vehicle speed V is lower than the reverse traveling shift speed forming permission vehicle speed Vref 2 . However, in this embodiment, the threshold Vref is defined as a value higher than the reverse traveling shift speed forming permission vehicle speed in consideration of the time required for the standby engagement.
[0037] According to the transmission apparatus of the embodiment described above, in the vehicle including the automatic transmission 20 which forms the first reverse speed by turning on the brake B 2 and the clutch C 3 when the shift position SP is at the R (reverse) position, the brake B 2 is standby-engaged if the standby engagement of the brake B 2 is permitted due to that the vehicle speed V is lower than the threshold Vref, and so on, when the shift position SP is at the D (drive) position in addition to when the shift position SP is at the N (neutral) position. Thus, when the shift lever 61 is operated quickly from the D position to the R position, the hydraulic pressure needs to be applied only to the remaining clutch C 3 , and the first reverse speed can be formed quickly. As a consequence, a small pump can be used as the mechanical oil pump 59 , and the entire apparatus can be made smaller. Moreover, since the threshold Vref is set to the value slightly higher than the reverse traveling shift speed forming permission vehicle speed Vref 2 in consideration of the time required for the standby engagement of the brake B 2 , the shift operation to the R position can be accepted in a state that the brake B 2 is standby-engaged immediately when the vehicle speed V changes from a speed equal to or higher than the reverse traveling shift speed forming permission vehicle speed Vref 2 to a speed lower than the reverse traveling shift speed forming permission vehicle speed Vref 2 . Since the standby engagement of the brake B 2 is not performed when the shift position SP is at the N position and the vehicle is coasting, it is possible to prevent increase in traveling resistance due to engagement of the brake B 2 while the vehicle is coasting. Further, since the standby engagement of the brake B 2 is also prohibited when the brake B 1 is being engaged by the shifting control or the hill-hold control, it is possible to prevent supply of hydraulic pressure to two or more clutches and brakes at a time from the mechanical oil pump 59 . Engagement of respective clutches and brakes can be performed more appropriately, and the mechanical oil pump 59 can be made small.
[0038] In the transmission apparatus of the embodiment, a hydraulic pressure slightly higher than the stroke end pressure is applied as the standby engagement of the brake B 2 , but as long as the hydraulic pressure is higher than a stroke starting pressure by which a piston stroke is started, a hydraulic pressure at any level may be applied within the range not affecting formation of a shift speed. However, for a shift speed (for example, the second forward speed) that is subject to, for example, dragging, by engagement of the brake B 2 , use of a hydraulic pressure lower than the stroke end pressure may be desired.
[0039] In the transmission control of the embodiment, the standby engagement of the brake B 2 when the shift position is at the D position is performed only for the first forward speed and the second forward speed. However, the transmission control may be performed only for the first forward speed, may be performed for the first to third forward speeds, may be performed for the first to fourth forward speeds, may be performed for the first to fifth forward speeds, or may be performed for all the shift speeds.
[0040] In the transmission apparatus of the embodiment, in the B 2 standby engagement permission determination routine of FIG. 5 , the conditions for permitting the standby engagement of the brake B 2 include that the vehicle is not coasting and that the oil temperature Toil is equal to or higher than the threshold Tref. However, any one of or both of the conditions may be omitted.
[0041] In the transmission apparatus of the embodiment, the automatic transmission 20 is structured of a stepped six-speed transmission of first forward speed to sixth forward speed. However, the automatic transmission is not limited to this, and may be structured of a stepped transmission with two to five speeds or may be structured of a stepped transmission with seven or more speeds. For example, as illustrated in an automatic transmission 120 of a modification example in FIG. 7 , the transmission apparatus may be structured of a stepped transmission with eight speeds. The automatic transmission 120 of the modification example has, as illustrated in FIG. 7 , a double pinion type planetary gear mechanism 130 , a Ravigneaux type planetary gear mechanism 140 , four clutches C 11 , C 12 , C 13 , C 14 , two brakes B 11 , B 12 , and a one-way clutch F 11 . The double pinion type planetary gear mechanism 130 has a sun gear 131 as an external gear, a ring gear 132 as an internal gear arranged concentrically with the sun gear 131 , a plurality of first pinion gears 133 a meshing with the sun gear 131 , a plurality of second pinion gears 133 b meshing with the first pinion gear 133 a and with the ring gear 132 , and a carrier 134 rotatably and revolvably holding the first and second pinion gears 133 a , 133 b . The sun gear 131 is fixed to a case 38 , the ring gear 132 is connected to a rotation shaft 136 via the clutch C 13 , and the carrier 134 is connected to the rotation shaft 136 via the clutch C 14 . This rotation shaft 136 is structured to freely rotate or be fixed by turning on or off the brake B 11 . The Ravigneaux type planetary gear mechanism 140 has two sun gears 141 a , 141 b as external gears, a ring gear 142 as an internal gear, a plurality of short pinion gears 143 a meshing with the sun gear 141 a , a plurality of long pinion gears 143 b meshing with the sun gear 141 b and the plurality of short pinion gears 143 a and with the ring gear 142 , and a carrier 144 coupling the plurality of short pinion gears 143 a and the plurality of long pinion gears 143 b and holding these pinion gears rotatably and revolvably. The sun gear 141 a is connected to the ring gear 132 of the double pinion type planetary gear mechanism 130 via the clutch C 11 . The sun gear 141 b is connected to the rotation shaft 136 . The ring gear 142 is connected to an output shaft 22 . The rotational of the carrier 144 is restricted to one direction by the one-way clutch F 11 and freely rotates or is fixed by turning on or off the brake B 12 , and is connected to the input shaft 21 via the clutch C 12 . An operation table of the automatic transmission 120 of the modification example is illustrated in FIG. 8 .
[0042] Here, the correspondence between the major elements of the embodiments and the major elements of the invention described in the Summary of the Invention section will be described. In the embodiments, the engine 12 corresponds to the “motor”, the mechanical oil pump 59 corresponds to the “pump”, the brake B 2 corresponds to the “first friction engagement element”, the clutch C 3 corresponds to the “second friction engagement element”, and the clutch C 1 corresponds to the “third friction engagement element”. The brake B 1 corresponds to the “fourth friction engagement element”. The clutch C 1 corresponds to the “first clutch”, the clutch C 2 corresponds to the “second clutch”, the clutch C 3 corresponds to the “third clutch”, the brake B 1 corresponds to the “first brake”, and the brake B 2 corresponds to the “second brake”. Here, the “motor” is not limited to internal combustion engines outputting motive power by using hydrocarbon fuel such as gasoline or diesel fuel, and may be any type of internal combustion engine such as a hydrogen engine, or may be a motor such as an electric motor. It should be noted that the correspondence between the major elements of the embodiments and the major elements of the invention described in the Summary of the Invention section are examples for specifically describing the best modes for carrying out the invention described in the Summary of the Invention section, and thus the correspondence does not limit the elements of the invention described in the Summary of the Invention section. That is to say, the invention described in the Summary of the Invention section should be construed based on the description in that section, and the embodiments are merely specific examples of the invention described in the Summary of the Invention section.
[0043] In the foregoing, the best modes for carrying out the present invention has been described using the embodiments, but the present invention is not limited to such embodiments at all. It is needless to mention that the present invention can be implemented in various modes within the range not departing from the scope of the invention.
[0044] The present invention may be applied to the automobile industry. | A control device controlling a vehicle's automatic transmission. The automatic transmission engages first and second friction engagement elements by fluid pressure from a pump operating using motive power from the vehicle's motor when a shift position is at a reverse traveling position, places the first friction engagement element on standby at a predetermined pressure that is higher than a stroke starting pressure by which a piston stroke is started and lower than a complete engagement pressure or engages the first friction engagement at the complete engagement pressure when the shift position is at a non-traveling position, and engages a third friction engagement element as a starting shift speed when the shift position is at a forward traveling position. When the shift position is at the forward traveling position, the first friction engagement element is placed on standby at the predetermined pressure if a vehicle speed is lower than a predetermined vehicle speed, or releases the predetermined standby pressure if the vehicle speed is equal to or higher than the predetermined vehicle speed. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
Not Applicable
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable
THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT
Not Applicable
INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC
Not Applicable
BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to endoprosthetic devices and, more specifically, to a scapular endoprosthetic device for full repair of glenoid defects.
Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
Patients suffering from diseases or deformities of the glenoid fossa of the scapula, prior to the instant invention, have very few options for repair. Bone grafts are sometimes utilized, relying on healthy bone (if available) from another area of the patient's body, donated bone from a cadaver, or synthetic bone in certain situations. However, such real bone grafts are limited in usefulness due to the complexities of the shoulder joint, and are problematic with regard to patient reactions to medication, bleeding, post-operative infection, and attendant pain at the harvest and graft sites. Synthetic bone, on the other hand, while reducing the incidence of rejection and post-operative infection, is limited in usefulness as well due to, again, the complexities of the shoulder joint and the physical stresses experienced therein during normal joint operation.
Current glenohumeral repair techniques include hemiarthroplasty (resurfacing or stemmed), total shoulder replacement, or reverse total shoulder replacement. Resurfacing hemiarthroplasty involves resurfacing of the humeral head joint surface with a cap-like prosthesis of highly polished metal. This is a relatively minimal repair, that relies on the existence of adequate cartilage within the glenoid fossa and a generally otherwise healthy humerus. A stemmed hemiarthroplasty involves a prosthetic humeral head joint surface with an intramedullary stem for fixation within the humeral shaft. This type of repair is often necessitated by severe fractures of the humeral head, but requires a relatively healthy glenoid with intact cartilage surface.
Total shoulder replacement, as the name implies, involves replacement of the entire glenohumeral joint and is typically necessitated by severe arthritis, physical damage, or disease action resulting in loss of joint cartilage. In a standard total shoulder replacement a stemmed hemiarthroplasty repair is mated with a glenoid socket prosthetic component to complete the artificial shoulder joint. The glenoid socket component is either cemented or “press-fit” into the bone of the original glenoid fossa. In a reverse total shoulder replacement scenario the socket and ball components of the repair are reversed, such that the socket portion is fixated on the humeral head and the metal ball portion is fixated in the glenoid fossa.
The current repair methods—hemiarthroplasty and total shoulder repair—each require adequate scapular structure for support and fixation. In instances where disease process has deteriorated the scapular structure such that the glenoid fossa and surrounding bone is not viable, existing repair devices and techniques are useless. What is needed is a scapular glenoid fossa replacement device to effect shoulder repair to restore patient function in such instances of scapular deficiency.
BRIEF SUMMARY OF THE INVENTION
The present invention is embodied in numerous forms, including an embodiment of a glenoid fossa endoprosthetic device, the device comprising: a glenosphere or glenosocket joint component including a first and second fixation plate affixed thereto, the first and second fixation plates disposed to form a space therebetween for receiving a scapula neck of a patient, the first fixation plate having a plurality of holes for placement of setscrews, the threads of which to be received by the second fixation plate. In another embodiment the device further comprises an oblique setscrew for fixation of the device to the inferior body of the scapula neck. In yet another embodiment the device, wherein the second fixation plate comprises a plurality of setscrew holes that correspond with the first fixation plate setscrew holes, the device further comprises a thread engagement plate for attachment to the first or second fixation plate, the attached thread engagement plate for receiving the threads of a setscrew placed in the hole of the other fixation plate. In yet another embodiment the device further comprises a porous mesh surface treatment on an inner surface of a fixation plate to improve osteoconductivity.
The present invention includes another embodiment of a glenoid fossa endoprosthetic device comprising: a Morse taper and a first and second fixation plate affixed thereto, the first and second fixation plates forming a space therebetween for receiving a scapula neck of a patient, the first fixation plate having a plurality of holes for placement of setscrews, the threads of which to be received by the second fixation plate, the Morse taper for receiving a glenosphere or glenosocket joint component. In yet another embodiment the device further comprises a glenosphere or glenosocket joint component. In yet another embodiment the device further comprises an oblique setscrew for fixation of the device to the inferior body of the scapula neck. In yet another embodiment the device, wherein the second fixation plate comprises a plurality of setscrew holes that correspond with the first fixation plate setscrew holes, the device further comprises a thread engagement plate for attachment to the first or second fixation plate, the attached thread engagement plate for receiving the threads of a setscrew placed in the hole of the other fixation plate. In yet another embodiment the device further comprises a porous mesh surface treatment on an inner surface of a fixation plate to improve osteoconductivity.
The present invention is also embodied in a glenoid fossa repair method, the method steps comprising: resecting all or a portion of a glenoid fossa of a scapula of a patient to remove diseased or damaged tissue; selecting a glenosphere or glenosocket joint component, the component comprising a first and second fixation plate affixed thereto, the first and second fixation plates disposed to form a space therebetween for receiving a scapula neck of a patient, the first fixation plate having a plurality of holes for placement of setscrews, the threads of which to be received by the second fixation plate; positioning the first and second fixation plates over the scapular resection to position the glenosphere or glenosocket joint component in the approximate position of the resected glenoid fossa; fixating the first and second fixation plates to the scapula by passing a setscrew through each of the first fixation plate setscrew holes and corresponding holes formed in the scapula neck of the patient to engage the corresponding hole in the second fixation plate, wherein the setscrew threads grip the second fixation plate to compress the scapula neck between the first and second fixation plates; and completing the shoulder joint repair. Steps of additional embodiments further comprise: installing an oblique setscrew through the lateral end of the glenosphere or glenosocket joint component for fixation of the joint component to the inferior body of the scapula neck. In another embodiment, wherein the second fixation plate comprises a plurality of setscrew holes that correspond with the first fixation plate setscrew holes, the method steps further comprise: installing a thread engagement plate on the second fixation plate, the attached thread engagement plate for receiving the threads of a setscrew placed in the hole of the first fixation plate. Another embodiment, wherein the joint component further comprises a Morse taper, the method steps further comprise: selecting a glenosphere head or a glenosocket head for the shoulder repair and installing the selected head on the Morse taper. In another embodiment, wherein the joint component further comprises a Morse taper, the method steps further comprise: installing an oblique setscrew through the Morse taper for fixation of the joint component to the inferior body of the scapula neck; and selecting and installing on the Morse taper a glenosphere head or a glenosocket head for the shoulder repair.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
The present invention will be more fully understood by reference to the following detailed description of the preferred embodiments of the present invention when read in conjunction with the accompanying drawings, wherein:
FIG. 1 is a depiction of an embodiment of the glenoid fossa endoprosthetic device invention featuring a glenosocket joint component;
FIG. 2 is a depiction of another embodiment of the glenoid fossa endoprosthetic device invention featuring a glenosphere joint component;
FIG. 3 is a depiction of another embodiment of the glenoid fossa endoprosthetic device invention featuring a Morse taper device allowing for interchangeable glenosphere and glenosocket members;
FIG. 4 is a depiction of the glenoid fossa endoprosthetic device invention as installed in a standard total shoulder repair arrangement; and
FIG. 5 is a depiction of the glenoid fossa endoprosthetic device invention as installed in a reverse total shoulder repair arrangement.
The above figures are provided for the purpose of illustration and description only, and are not intended to define the limits of the disclosed invention. Use of the same reference number in multiple figures is intended to designate the same or similar parts. Furthermore, when the terms “top,” “bottom,” “first,” “second,” “upper,” “lower,” “height,” “width,” “length,” “end,” “side,” “horizontal,” “vertical,” and similar terms are used herein, it should be understood that these terms have reference only to the structure shown in the drawing and are utilized only to facilitate describing the particular embodiment. The extension of the figures with respect to number, position, relationship, and dimensions of the parts to form the preferred embodiment will be explained or will be within the skill of the art after the following teachings of the present invention have been read and understood.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 is a depiction of an embodiment of the glenoid fossa endoprosthetic device invention featuring a glenosocket joint component ( 100 ). As shown, the glenosocket member ( 102 ) has a lateral face ( 104 ) with which to engage the complimentary humeral head feature on a patient's humerus, and a medial face ( 106 ) having a first fixation plate ( 108 ) and a second fixation plate ( 110 ) extending therefrom. The fixation plates are substantially rigid, and are either formed as part of the medial face during the machining process, or otherwise attached using a common metal bonding process. The machined members and all other metal components of the embodiment are manufactured from biologically compatible and stable metals. In the instant embodiment the glenosocket joint components are titanium, but may be surgical stainless steel, niobium, gold, platinum, or the like, or some combination thereof. Moreover, combinations of metals and/or biocompatible polymers may also be utilized and are within the scope of the claimed invention.
The fixation plates ( 108 and 110 ) are substantially parallel and are positioned to form a space therebetween for receiving the resected scapula neck area of the scapula of a patient. The anteroposterior thickness of the scapula in this area varies among patients, with an adult patient measuring approximately 15 mm to 22 mm and a child patient approximately 10 mm to 15 mm. However, the thickness and composition of the fixation plates ( 108 and 110 ) is such that a minimal amount of flexure is accommodated to allow for superior gripping of the resected scapula area during fixation. The device is easily sized in this regard in order to accommodate any patient.
The first fixation plate ( 108 ) features a plurality of holes ( 112 ) to allow placement and passage of fixation setscrews ( 114 ). In the instant invention the setscrews ( 114 ) are hex headed countersunk screws that utilize a countersunk hole to maintain the head of the screw substantially flush with the fixation plate upon installation. Further, the thread tip is tapered and features a cutting edge feature for cutting threads in metal upon rotation. A plurality of corresponding holes ( 116 ) in the second fixation plate ( 110 ) receives the threaded portion of the setscrews and allows threads to be cut therein. Accordingly, upon device installation, the gap between the first and second fixation plates decreases as the setscrews draw the fixation plates inward with setscrew ( 114 ) rotation. Though a particular setscrew is depicted and described, one of ordinary skill will appreciate that other common setscrews may also be utilized.
In another embodiment the glenoid fossa endoprosthetic device also utilizes a thread engagement plate ( 118 ) for gripping of the threaded portion of the setscrews ( 114 ). As depicted the thread engagement plate ( 118 ) is formed to provide a channel to receive the first or second fixation plate ( 108 and 110 ). In this configuration the setscrew holes in each fixation plate are of the same diameter to allow the setscrews to be placed from either direction. For example, if the surgeon chooses to place the setscrews through the first fixation plate ( 108 ) and into the second fixation plate ( 110 ), the thread engagement plate ( 118 ) is added to the second fixation plate ( 110 ) as shown so that the setscrew ( 114 ) thread tip may cut threads into the thread engagement plate ( 118 ) holes.
It is also possible to splay the setscrews ( 114 ), or otherwise allow one or more of the setscrews to enter a hole at an oblique angle. The device also allows the use of an oblique setscrew ( 118 ) that enters from the glenosocket face ( 104 ) on an oblique angle in order to engage the remaining scapula body inferiorly to provide added fixation and stability to the repair.
FIG. 2 is a depiction of another embodiment of the glenoid fossa endoprosthetic device invention featuring a glenosphere joint component ( 200 ). As shown, the glenosphere member ( 202 ) has a lateral face ( 204 ) with which to engage the complimentary humeral head feature on a patient's humerus (in this instance, in a reverse total shoulder arrangement), and a medial face ( 206 ) having a first fixation plate ( 208 ) and a second fixation plate ( 210 ) extending therefrom. Other than the glenosphere member ( 202 ), this embodiment shares features and functionality with the previous embodiment. Each fixation plate ( 208 and 210 ) features a plurality of holes ( 212 and 216 ) for placement of setscrews ( 214 ) therethrough. Threads from the setscrews ( 214 ) may engage the fixation plate ( 210 ) material, or an optional thread engagement plate ( 218 ).
FIG. 3 is a depiction of another embodiment of the glenoid fossa endoprosthetic device invention featuring a Morse taper device allowing for interchangeable glenosphere and glenosocket members ( 300 ). As shown, the device utilizes a Morse taper member ( 302 ) for accepting either a glenosphere member ( 304 ) or a glenosocket member ( 306 ). The benefit to this configuration is that a single shoulder joint repair kit may include the option of a standard or reverse total shoulder configuration. The device configuration may be determined prior to installation, and the appropriate glenosocket/glenosphere member may be subsequently installed.
The medial face, as with the previous embodiments, has a first fixation plate ( 308 ) and a second fixation plate ( 310 ) extending therefrom. Setscrews utilize the holes therethrough for affixation of the device to the resected scapula as before. Additional oblique setscrews may be utilized ( 312 ) for added stability. A porous mesh surface treatment is also applied to the inner surfaces ( 314 ) of the fixation plates ( 308 and 310 ) to improve osteoconductivity. This porous mesh surface treatment may be utilized in the previous embodiments and has the added benefit of providing for greater stability of the overall repair.
FIG. 4 is a depiction of the glenoid fossa endoprosthetic device invention as installed in a standard total shoulder repair arrangement. As shown, an embodiment of the glenosocket joint component ( 100 ) is chosen, but the Morse taper embodiment with a glenosocket feature may also be utilized. One of ordinary skill will appreciate that the repair relies on common surgical procedures for performing a standard total shoulder joint repair.
The patient's glenoid fossa/scapula neck ( 402 ) area is exposed and the diseased or injured tissue is removed to achieve a clean margin. The remaining bone is prepared, with sufficient bone removed to prevent impingement with the repair device ( 100 ). The repair device first and second fixation plates ( 108 and 110 ) are positioned over the scapular resection to position the glenosocket joint component in the approximate location of the original glenoid fossa. The device is thin fixated by installing the setscrews ( 114 ) through the first fixation plate ( 108 ) into the second fixation plate ( 110 —not shown). The setscrews ( 114 ) may engage the second fixation plate directly, or may engage an added thread engagement plate as described above. As the setscrews ( 114 ) are tightened the fixation plates ( 108 and 110 ) compress slightly to further grip the scapula. An optional oblique setscrew ( 118 ) may also be utilized to engage the remaining scapula neck inferiorly. The shoulder joint repair may then be completed as with a standard total shoulder repair by joining the glenosocket ( 102 ) with the humeral head component ( 404 ).
FIG. 5 is a depiction of the glenoid fossa endoprosthetic device invention as installed in a reverse total shoulder repair arrangement. As shown, an embodiment of the glenosphere joint component ( 200 ) is chosen, but the Morse taper embodiment with a glenosphere feature may also be utilized. One of ordinary skill will appreciate that this repair, likewise, relies on common surgical procedures for performing a reverse total shoulder joint repair.
As above, the patient's glenoid fossa/scapula neck ( 502 ) area is exposed and the diseased or injured tissue is removed to achieve a clean margin. The remaining bone is prepared, with sufficient bone removed to prevent notching with the repair device ( 100 ). The repair device first and second fixation plates ( 208 and 210 ) are positioned over the scapular resection to position the glenosocket joint component in the approximate location of the original glenoid fossa. The device is thin fixated by installing the setscrews ( 214 ) through the first fixation plate ( 208 ) into the second fixation plate ( 210 —not shown). The setscrews ( 214 ) may engage the second fixation plate directly, or may engage an added thread engagement plate as described above. As the setscrews ( 214 ) are tightened the fixation plates ( 208 and 210 ) compress slightly to further grip the scapula. The shoulder joint repair may then be completed as with a standard total shoulder repair by joining the glenosphere ( 202 ) with the complimentary humeral head component ( 504 ).
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive. Accordingly, the scope of the invention is established by the appended claims rather than by the foregoing description. All changes that come within the meaning and range of equivalency of the claims are to be embraced by the claims. Further, the recitation of method steps does not denote a particular sequence for execution of the steps. Such method steps may therefore be performed in a sequence other than that recited unless the particular claim expressly states otherwise. | An endoprosthetic device for replacement of a diseased or damaged scapular glenoid fossa. The device includes a glenosphere or a glenosocket member, or provides the option of mating a glenosphere or glenosocket member via a Morse taper. The device also features opposing fixation plates that grip resected scapular area anteroposteriorly to fixate the device through use of a plurality of setscrews. An Oblique setscrew that engages the scapular body inferiorly may be added for improved fixation. A porous mesh surface treatment on the inner faces of the fixation plates may be utilized to improve osteoconductivity. | 0 |
FIELD OF THE INVENTION
This invention relates to flat panel display backlight units and in particular to reflectors for direct backlighting units.
Direct backlighting of liquid crystal displays is well known and reflectors for such backlighting units have been developed. For example, U.S. Pat. No. 5,253,151 which issued Oct. 12, 1993 discloses such reflectors.
It is desirable in backlighting units for flat panel displays that the light produced by the backlight unit be uniform and capable of a high intensity over the entire viewing area of the display. In addition, especially for industrial computer displays where failure of the display can result in a costly loss of production, it is desirable that these backlight displays be durable and reliable, and that they do not fail disastrously.
SUMMARY OF THE INVENTION
The invention provides a reflector for multiple parallel cylindrical light sources of the type having an arcuate reflective surface section for each parallel source. Each surface section defines an apex ridge directly behind the corresponding source and the surface section extending from both sides of the apex ridge in arcuate surfaces. An improvement of the invention is that the arcuate surfaces extending from the apex ridge are defined by constant radius surfaces. Thereby, light being transmitted directly rearward from the source is redirected by the constant radius surface to be reflected by another reflector surface back toward the display. The result is to increase the diffusion of the light reflected from the sources, use more of the light to illuminate the display, and reduce the effect of an adjacent lamp dimming or failing completely, all of which contributes to the effectiveness of a reflector of the invention.
In one useful aspect, at least one of the constant radius surfaces is joined at its edge opposite from the apex ridge by a hyperbolic surface. This is desired in areas of the reflector where dispersion and diffusion of the light from the corresponding bulb is desired, such as for the interior surface sections of the reflector. Thereby, when one lamp burns out, light from the adjacent lamps will be reflected into the area of the burned out lamp to fill in for it and largely preserve the visibility of the display until the backlight unit can be replaced.
For interior surface sections, hyperbolic surfaces are preferably provided on both sides of the apex ridge, whereas for the end surface sections, a parabolic surface is preferable provided on the outer side of the apex ridge. The parabolic surface in this location is useful to collimate the light reflected from the corresponding lamp, so as to direct it toward the display and prevent it from escaping past the edge of the display. A further improvement is that a flat reflector surface may be provided outside from each parabolic surface, to direct redirect light toward the display.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a cabinet which incorporates the invention illustrated in an open position:
FIG. 2 is a front plan view of a backlight unit of the invention;
FIG. 3 is a vertical sectional view through the cabinet shown in FIG. 1 illustrated in a closed position;
FIG. 4 is a detail view of a portion of FIG. 3; and
FIG. 5 is a schematic ray tracing of the backlight unit illustrated in FIGS. 1-4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a cabinet 10 incorporating the invention includes a front panel 12 and a cover 14. The cover 14 is secured to the front panel 12 by a hinge 16 secured along corresponding vertical edges of the panel 12 and cover 14 so as to allow pivoting of the cover 14 relative to the panel 12 between the open position shown in FIG. 1 and the closed position shown in FIG. 3.
As best shown in FIGS. 1 and 3, the front panel 12 includes a flat panel display 18 which may be, for example, a thin film transistor (TFT) or metal insulator metal (MIM) type display. However, any flat panel liquid crystal display which is backlit in operation may be used to practice the invention. Preferably, a diffuser plate 19, which may be for example a sheet of white opaque acrylic to diffuse light transmitted against the back of the display 18, directly overlies the back of the display so as to enhance the uniformity of the light transmitted by a backlight unit 22.
The front panel 12 also includes a bezel 20 which frames the display 18 and to which the hinge plate 16A of the hinge 16 is directly connected. Hinge plate 16B of hinge 16 is directly connected to a vertical panel of flange 21 of the cover 14. The cover 14 is made generally in the form of a box so as to house most of the electronic components of the enclosure 10, such as the computer which controls the display 18.
The backlight unit 22 is releasably secured with screws 24 to the front of the cover 14 so that when the cover 14 is pivoted to the open position shown in FIG. 1, the front of the backlight unit 22 is exposed as are the heads of the screws 24. The backlight unit 22 is shown by itself in FIG. 2. When the cover 14 is closed as shown in FIG. 3, the backlight unit 22 is moved to within close proximity of the rear of the display 18 and to being parallel to the display 18 so as to transmit light against the rear of the display 18, through the diffuser plate 19. This provides backlighting to the display 18 which is necessary for a user to view the indicia generated by the display 18. In order to ensure adequate cooling of the display 18, it is preferable to maintain an air gap of 1/4 to 3/8 inches between the closest surface of the backlight unit 22 and the rear of the diffuser panel 19 in the closed position.
The backlight unit 22 includes a molded plastic reflector 26 which doubles as the structural foundation to which the other components of the backlight unit 22 are secured. These other components include 6 straight cylindrical cold cathode fluorescent lamps (CCFL's) 28A-F, metal strips 30 and 32 along the respective left and right ends of the lamps 28A-F to hold the lamps in position, a left connector strip 34 for making contact with the left electrodes of the lamps 28A-F and a right connector strip 36 for making a electrical contact with the right electrodes of the lamps 28A-F. Elastomeric material 38 is preferably placed between the strips 30 and 32 and the reflector 26 so as to hold the lamps 28A-F securely in position.
In addition, the right connector strip 36 preferably includes a plug half 40 to mate with a mating plug half 42 which is wired to the electronics in the cover 14 so that the backlight unit 22 may be releasably electrically connected to the enclosure 10. Screws 44 secure the strips 30 and 32 to the reflector 26, and screws 46 secure the connector strips 34 and 36 to a peripheral flange 52 of the reflector which extends all the way around the reflector 26, and a wall 53 may be molded at one or both ends of the reflector 26 so as to shield wires routed to the connector strips 34 and 36 from a user. In addition, capacitors 48 may be provided on the right connector strip 36 as is well known so that a single power supply (housed in the cover 14, may be used to power all 6 lamps 28A-F, so as to run the minimum number of wires from the power supply in the cover 14 to the backlight unit 22.
The reflective surface 50 of the reflector 26 is preferably non-specular, for example white. This surface may be painted white using a very white paint. White is the preferred color of the surface 50 so that it reflects light from the lamps 26A-F diffusely, and does not provide any undesirable color shift to the light reflected into the display.
The reflective surface 50 has a unique shape. The reflective surface 50 is constant in cross-sectional shape in the horizontal direction for its length coincident with the horizontal width of the illumination required for the diffuser and display, but vertically the shape of the surface 50 is defined by a complex surface.
The reflective surface 50 is defined by a series of surface sections 54A-F, each of said sections corresponding to one of the lamps 28A-F and being coterminous with the next adjacent section(s), e.g., at its upper edge, surface 54B is coterminous with surface 54A, and at its lower edge, section 54B is coterminous with section 54C. The interior sections 54B-E are shaped identically to one another, and the end sections 54A and F are mirror images of one another.
For clarity, only the interior section 54B will be described completely, it being understood that the interior sections 54C-E are identical to the section 54B, and how the end sections 54A and F differ will be described. Corresponding elements of each surface section are identified with the alphabetic character which identifies that section.
The section 54B is divided in half by an apex ridge B1 which runs laterally parallel to the lamp 28B. On each side of the apex ridge B1, the section 54B curves away from the apex B1 with surfaces B2 and B3 of a fixed radius R (FIG. 5) centered at points B8 and B9 for approximately 90°. In the preferred embodiment, this radius R is 2 millimeters and is equal to the radius of the lamp 28B. Of course, other dimensions could be used to practice the invention.
The constant radius surfaces B2 and B3 fade into respective surfaces B4 and B5 at their edges opposite from the apex B1. The surfaces B4 and B5 are defined by a hyberbolic function of the form: x 2 /m-y 2 /n=k, where x and y are the dimensions as indicated in FIG. 5 as measured from point P B , and k, m and n are constants. In the preferred embodiment, k=1 millimeter and m and n are 93.3 millimeters and 158.3 millimeters, respectively. In addition, the dimension B is approximately 7.39 millimeters and A is 9.635 millimeters.
The outer sections 54A and F are the same as the interior sections 54B-E except that the surfaces A4 and F5 are parabolic rather than hyperbolic and are coterminous at their outer ends with a flat angled surface A6 and F6, respectively. A flat angled surface similar to the surfaces A6 and F6 may also be used to join the surface 50 at its lateral ends to the flange 52.
The parabolic function defining the surfaces A4 and F5 is of the form y 2 =kx (millimeters) where x and y are as defined above and for values of y greater than R and, in the preferred embodiment, less than 9.39 millimeters.
FIG. 5 illustrates section 54A and the surfaces B2 and B4 of section 54B. Since the surfaces A3 and A5 of section 54A are identical to the corresponding surfaces in the interior sections,-surfaces B2 and B4 are identical to the corresponding surfaces in the interior sections and to F2 and F4, and the surfaces A2, A4 and A6 are mirror images of the surfaces F3, F5 and F6, respectively, FIG. 5 is used to give a complete description of the reflection pattern of the entire reflector 26.
First, the function of the radiused surfaces A2, A3, B2 and B3 is to reflect the light being transmitted rearwardly from the corresponding lamp (28A or B) toward the display 18. This can be explained by reference to ray 60. Light impinging on Constant radius surface A3 is reflected therefrom toward hyperbolic surface A5 and therefrom is reflected toward the interior of the display 18, crossing over the next adjacent surface section 54B. Thus, if the lamp 28B were to become dim or burn out, light reflected from lamp 28A would serve to fill in the space otherwise illuminated by light 28B, and also light from the lamp 28C would serve to fill in the same space. The hyperbolic surfaces (A5-E5 and B4-F4) also serve to fan out the light rays impinging directly upon them, as illustrated by rays 61-64, to help fill in the next adjacent space should the lamp in that space become dim or fail completely.
The parabolic surfaces A4 and F5 in contrast tend to collimate the light reflected from them. Collimation rather than dispersion is desired here so as to direct the light toward the display 18, rather than outwardly past the edge of the display 18 where it would only serve to illuminate the ambient. Such collimation is represented by rays 65-68. The flat angled surfaces A6 and F6 also serve the function of reflecting light back toward the display. This is represented by ray 69.
Preferred embodiments of the invention have been described in considerable detail. Many modifications and variations to the preferred embodiments described will be apparent to those skilled in the art. For example, the invention is not strictly limited to being used with separate straight cylindrical parallel lamps, but could be used with a serpentine cylindrical lamp having straight parallel light source sections. Therefore, the invention should not be limited to the embodiments described, but should be defined by the claims which follow. | Backlighting for an LCD display is provided by a direct backlight unit which is hinged to the front panel in which the display is mounted. When closed, the backlight unit lamps and reflector transmit light directly against the back of the display. The reflector surfaces are made by a combination of constant radius, hyperbolic, parabolic and flat surfaces which maximize the emitted light transmitted to the display and help fill in for any failed or dimmed light sources. | 5 |
FIELD AND BACKGROUND OF THE INVENTION
This invention relates to a slice lip applicable to a head box for a paper-making machine.
FIG. 1(a) shows an example of the slice lip at the tip of a conventional head box. The slice lip 1 is deflected in the Z-direction by means of a jack rod 2 with a pitch of about 150 mm and an interconnecting metal 3 so that the lip opening is changed. Thus, the flow rate in the direction of the width perpendicular to the surface of drawing is also changed and fine adjustment of the weight profile in the direction of the width is effected.
In this case, pressure is applied to a liquid-contacting surface, at A, of the slice lip 1 in order to obtain a jet J whereby the slice lip 1 is likely to be forced up and off a slice body 5. To prevent this displacement, a spring 6 is provided. However, reproducibility of the fine adjustment of the slice lip 1 in the direction of the width is low partly because the sliding frictional force of the slice body 5 is increased due to the force of this spring 6, partly because there is a relative slip between the slice lip 1 and the interconnecting metal 3, partly because the slice lip has bending rigidity in the direction of the width, and so forth.
Furthermore, since there is a corner formed at the joint surface or portion A, between the slice body 5 and the liquid-contacting surface of the slice lip 1, an unsteady flow is generated. This unsteady flow not only disturbs the jet J but also collects scum at the portion A.
In this case, such turbulence which occurs on the surface of the jet J, produces streaks and the like which eventually leads to a problem in the quality of products being formed. In FIG. 1(b), which shows in detail the portion X in FIG. 1(a), the error in the flatness of the surface K at the tip of the slice lip 1 results in the error in the lip opening and invites the non-uniformity of the jet J. The reference numeral 13 (FIG. 1(a) designates a wire or forming wire and the reference numeral 14 designates a forming roll.
SUMMARY OF THE INVENTION
The present invention is directed to the elimination of these problems of the conventional device and to the provision of a slice lip having a construction in which the main body and the joint portion on the liquid-contacting side of the lip are fitted on the same plane. A neck portion of the device has a low rigidity for bending in the orthogonal direction of the flow and is formed in the direction of the width between a fitting portion of a tip to the main body and the tip portion of the lip. The adjustment of a tip gap between the lip and a mating lip is effected only by bending the lip on the tip side with respect to and from the neck portion by means of plural adjusting rods disposed in the direction of the width, and the liquid-contacting surface of the lip is shaped into a smooth surface so as to constantly compress the flow and have a streamline shape toward the tip. According to this construction, it is possible to prevent contamination on the back of the lip, to improve reproducibility of adjustment and to minimize jet disturbance.
Further, the present invention provides a slice lip in which, at the tip portion of the lip which is deflected to expand and narrow the gap between it and the mating lip thereby to make fine adjustment of the weight distribution in the direction of the width, there is disposed a rectifying portion having a slight compressing inclination which is parallel or which does not expand with respect to the mating lip. According to this construction, the jet can be jetted uniformly in the direction of the width and the disturbance on the jet surface can be minimized.
Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1(a) is a sectional side view of an example of the slice lip at the tip of a conventional head box;
FIG. 1(b) is a detailed view of the portion X of FIG. 1(a);
FIGS. 2 through 4 are sectional side views of the slice lip in accordance with the embodiments of the present invention, respectively;
FIGS. 5(a) is a schematic view showing the state of a jet formed by the conventional slice lip; and
FIGS. 5(b) and 5(c) are schematic views showing the state of the jet by still other embodiments of the present invention, respectively.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 2 and 3, a slice lip 7 having a tip portion 7a, a fitting or connecting portion 7b and a neck portion 7c, is shown fixed to a slice body 8 through the fitting portion 7b by means of bolts 9. A joint portion of the lip, on the liquid-contacting side thereof, is shaped into a flat surface (see reference character B in FIG. 2 and reference character C in FIG. 3). FIG. 2 shows an embodiment in which an adjusting jack rod 10 is directly fitted to the tip portion 7a of the slice lip 7 while FIG. 3 shows another embodiment in which the adjusting jack rod 10 is interconnected with the slice lip 7 via an interconnecting metal 11 that is divided in the direction of the width. In other words, in the embodiment shown in FIG. 3, the jack rod 10 is screwed to the slice lip 7 and at the same time, a set screw 12 is rotated from a hole 11a formed on the side surface of the interconnecting metal 11 so that the tip portion 11b of the interconnecting metal 11 and the set screw 12 clamp the slice lip 7 between them and connect the slice lip 7 to the jack rod 10.
The slice lip 7 as described above has the fitting portion 7b at which it is fitted to the slice body 8 by the bolts 9 and the neck portion 7c between the fitting portion 7b and the tip portion 7a of the slice lip. The neck portion has low bending rigidity or flexibility in the orthogonal direction with respect to the flow and as compared to the remainder of the lip. Further, the liquid-contacting surface of the slice lip 7, that is its lower surface that comes into contact with the jet flow, is formed in a smooth shape D in such a manner as to constantly compress and be streamline in shape toward the tip portion 7a. Further, the tip portion 7a of the slice lip 7 is formed in a sharp edge in such a manner as to sharply cut the water of the jet. Reference J designates the jet; reference numerals 15, a mating lip; 16, a wire or forming wire; and 17, a forming roll respectively. The construction of the interconnecting metal 11 shown in FIG. 3 is not restrictive, in particular.
Next, another embodiment of the present invention will be described. In FIG. 4, the slice lip 107 is shown fixed to slice body 108 by the bolts 109 and its joint portion B on the liquid-contacting side is shaped flat. The adjusting jack rod 110 is directly fitted to the slice lip 107.
Thus, the slice lip 107 has a neck portion 107c of low rigidity between the fitting portion 107b, at which the slice lip is fitted to the slice body 108 by the bolts 109, and the tip portion 107a of the slice lip. When the jack rod 110 is moved in the Z direction, the tip portion 107a of the slice lip 107 is so deflected as to expand the gap between it and the lower or mating lip 112, whereby the lip opening is changed and, hence, the flow rate in the direction of width, so that fine adjustment of the weight profile in the direction of the width is effected.
The slice lip 107 is further equipped with a rectifying portion H at its tip portion 107a, the rectifying portion H having a slight compressing inclination which is parallel or which does not expand with respect to the lower lip 112. In FIG. 4, even if the rigidity at the tip portion is increased by disposing this rectifying portion H, the adjustment of the opening in the direction of the width is not at all hindered because the neck portion 107c exists. The reference numeral 113 designates a wire or forming wire and the reference numeral 114 designates a forming roll respectively.
As described in detail in the foregoing, in the present invention, the joint portion of the main body and the liquid-contacting side of the lip are shaped flat. Accordingly, the flow of the raw material is hardly disturbed. Further, the neck portion having low bending rigidity in the orthogonal direction of the flow is formed in the direction of width between the fitting portion of the lip to the lip main body and the tip portion of the lip, and the plural adjusting rods connected to the tip portion of the lip are so disposed as to be capable of adjusting the tip gap between the lip tip and the mating lip in the direction of the width. According to this arrangement, the adjustment of the lip in the direction of the width is effected through the adjustment of the adjusting rod in the Z direction which bends the neck portion in the sectional direction as well as the tip portion, on the front side from the neck portion, in the direction of the width. Since this construction does not include the slide surface of the conventional device, reproducibility in the adjustment in the direction of the width can be improved.
Since the liquid-contacting surface of the lip is shaped into a smooth form in such a manner as to constantly compress the flow and be streamline toward its tip, it has no possibility of disturbing the flow and no scum is likely to deposit. Moreover, an unsteady flow occurs only with difficulty and the jet is hardly disturbed. If the lip and the adjusting rod are coupled to each other either by directly screwing the adjusting rod to the lip or via the interconnecting metal, the moving distance of the adjusting rod in the Z direction is as such transmitted to the lip.
In the present invention, there is disposed the rectifying portion having a slight compressing inclination, which is parallel or which does not expand with respect to the mating lip, at the tip portion of the lip which is deflected in such a direction as to expand or narrow the gap between it and the mating lip and which is to perform the fine adjustment of the weight distribution in the direction of the width. When the jet J is sprayed from the tip of the slice tip, the jet flow is allowed to pass between the mating lip and the rectifying portion H having a slight compressing inclination, which is parallel or which does not expand with respect to the mating lip, thereby directing the streamline flow. Thus, the jet can be stabilized and jetted smoothly.
FIG. 5(a) shows an embodiment in which the conventional slice lip 1 is used whereas FIG. 5(b) shows the embodiment in which the slice lip 217 of the present invention is used. The difference in the action and effect between them will be described by referring to these drawings. In FIG. 5(a), the flow in the X direction impinges against the flow in the Y direction so that turbulence occurs in the flow and due to its influence, the jet surface is rapidly disturbed. In FIG. 5(b), according to the slice lip 217, the flows in both X and Y directions are rectified by the rectifying portion H, having a slight inclination which is parallel or which does not expand with respect to the mating lip, and the turbulence is attenuated so that the jet is not disturbed and its flying distance is increased as shown in the drawing. The reference numeral 212 designates a lower lip or mating lip, the reference numeral 213 designates a wire or forming wire and the reference numeral 214 designates a forming roll respectively.
In FIG. 5(c) showing still another embodiment of the present invention, wherein a slice lip 307 is moved in the C direction as well as in the D direction. This arrangement makes it possible to reduce the impinging angle between the jet J and the wire 313 of the forming roll 314, to minimize the disturbance of the jet when the jet J gets on the wire 313 and to eliminate any collapse of the formation. The reference numeral 312 designates a lower lip.
As described above, in accordance with the present invention, jetting of the jet can be stabilized, the turbulence on the jet surface can be minimized and the occurrence of the streaks can also be minimized. In comparison with the conventional slice lip, the jet is allowed to flow out uniformly in the direction of the width if the portion of the relatively large area of the rectifying portion is uniform in the direction of the width. Unlike the conventional slice lip, the slice lip of the present invention minimizes the non-uniformity of the jet even if there is an error in the flatness of the K surface at the tip of the slice lip. This facilitates production.
In accordance with the present invention, further, since the turbulence of the jet is less and its flying distance is great, the slice lip portion can be moved in the C direction as shown in FIG. 5(c). It is therefore possible to increase the thickness of the lower lip and to reduce the machining strain of the lower lip, its strain due to heat and fluid pressure, and so forth. | An improved slice lip applicable to a head box for a paper-making machine. The improvement includes a main body and the joint portion on the liquid-contacting side of the lip being fitted on the same plane, a neck portion having low bending rigidity in the orthogonal direction of the flow formed between the fitting portion of the lip to the main body and the tip portion of the lip in the direction of the width, and a plurality of adjusting rods connected to the tip portion of the lip which are so disposed as to be capable of adjusting a tip gap between the tip portion of the lip and its main lip in the direction of the width whereby a sheet-like jet can be obtained. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional patent application No. 61/932,954, filed Jan. 29, 2014, for “Multifunctional Finish Treatment for Textiles.” Such application is incorporated herein by reference in its entirety.
BACKGROUND
[0002] The present invention relates to an engineered combinatorial material architecture across length scale hierarchy for multifunctional treatment of synthetic, semi-synthetic, and non-synthetic (natural) substrates. The functional attributes of the nanoengineered material architecture may be flame retardant or in combination with antimicrobial and/or insect repellent, and/or hydrophobic properties.
[0003] The use of flame-retardant treatment processing of various synthetic, semi-synthetic, and natural-made industrial products such as textiles is common, as safety standards and concerns have required certain materials to be capable of inhibiting, suppressing, or delaying the production of flames. Halogen-based materials, for example, are known, but raise significant toxicity concerns. Antimicrobial treatment products including silver have become popular in order, for example, to control odor. An improved multifunctional, combinatorial material architecture for treatment processing of various substrates that provides one or more of these functions, with improved properties, is desirable.
BRIEF SUMMARY
[0004] The present invention is directed in certain embodiments to a nanoengineered combinatorial material architecture consisting of organic-inorganic-metallic complexes that may, in certain embodiments, comprise micro-scale inorganic crystallites, surface activated by metallic and/or pyrethroid complexes in a composite architectural complex to improve the function of the substrate treatment. The metallic and/or pyrethroid deposits size may vary from micro to nano range and be of random shapes within the complex. In various implementations, this nanoengineered composite serves as a multifunctional treatment for substrates capable of serving antimicrobial, insecticidal, and environmentally friendly flame-resistance functions. In various implementations, the composition may yield a multifunctional treatment capable of flame resistance combined with either or both antimicrobial and insect-repellent functions. The material may be produced through a nanomanufacturing process. The use of metallic deposits as part of the composite material complex boosts the thermal properties/behavior of the material, thereby improving its fire-retardant properties. Depending upon the metal chosen in various implementations, the material may also exhibit antimicrobial (bacterial and fungus resistance) functions. The multifunctional treatment is capable of being used on synthetics, semi synthetics and non-synthetic substrates. One example may be textile fabrics such as cotton, nylon, polyester, or a blend of cotton-synthetics.
[0005] In various implementations, the chemical architecture of the nanoengineered solid-phase composition consists of sub-micro inorganic crystallites surface activated by depositing a metallic deposit(s) and/or permethrin on the crystallite surface through a chemical nanomanufacturing process. The metallic component may comprise deposits in certain implementations with a diameter range from 5-100 nanometers or alternatively up to micrometers and may be, for example, copper, silver, or copper-silver complex/compound. The inorganic crystallites in various implementations can range in size between 0.2-50 microns or alternatively up to hundreds of microns and may include phosphorous-containing and nitrogen-containing compounds, including but not limited to, Ammonium Polyphospate (APP), Meamine Polyphosphate (MP), Calcium Carbonate (CaCO 3 ), Magnesium Hydroxide, Gypsum, Silicon Dioxide (SiO 2 ), Aluminosilicate Clay, or a combination of more than one type of these or other inorganic materials. The composite may also include deposits of quaternary ammonium compounds for further antimicrobial function. The type of deposit on the inorganic crystallites depends on the desired function of the treatment—whether flame resistant and antimicrobial; flame resistant and insect-repellent; flame resistant-hydrophobic, or flame resistant, antimicrobial, hydrophobic, and insect-repellent. The engineered combinatorial material will be referred to in places as a composite from here onwards.
[0006] These and other features, objects and advantages of the present invention will become better understood from a consideration of the following detailed description of the preferred embodiments and appended claims in conjunction with the drawings as described following:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0007] FIG. 1 is an illustration of the functions of one embodiment of the invention, wherein the selected treatment acts as a flame-retardant, insect-repellent, and antimicrobial agent.
[0008] FIG. 2 is a diagram of a composite architecture coating according to one embodiment of the invention.
[0009] FIG. 3 is two high-resolution transmission electron images at varying resolutions showing a composite architecture according to one embodiment of the invention.
[0010] FIG. 4 is an illustration of the pad drying process of textiles and knife edge, a method for treating the textiles with the nanoengineered composite.
[0011] FIG. 5 is a set of bar graphs showing experimental results of an implementation of the invention for treated textiles relative to untreated textiles.
DETAILED DESCRIPTION
[0012] With reference to FIG. 1 , an illustration of the function of an implementation of the present invention for use as a multifunctional treatment for substrates may be described. A treatment of certain composition, chosen based on the desired function of the treatment, is applied to a substrate. This implementation in this case is a metallic-quaternary ammonium-synthetic permethrin (pyrethroid) deposit composition corresponding to a treatment that functions as a flame-resistant, antimicrobial, and insect-repelling agent. The release of ions, for example copper or silver ions, provides protection against odor-causing and pathogenic bacteria as well as fungus. As further explained below, the metallic portion of the composite architecture also improves flame-retardant properties of the materials, with the permethrin protects against insects such as mosquitoes.
[0013] FIG. 2 provides an illustration of a composite architecture of a textile treatment architecture according to certain implementations, while FIG. 3 provides a corresponding representative high-resolution transmitting electron image of one embodiment of the invention, wherein inorganic crystals are formed into a composite architecture with nano-sized metallic deposits. Other embodiments of the invention would, for example, further comprise (in addition to the metallic deposits) either quaternary ammonia deposits, permethrin deposits, or both, depending on the desired function of the treatment. FIG. 2 , for example, shows the organic-inorganic complex of materials 14 with permethrin deposits 10 , and multiple metallic deposits on the composite (such as copper and silver) at 12 . Although the metallic deposits 12 and permethrin deposits 10 are shown as circles in FIG. 2 , the invention is not so limited, and these deposits can vary in both size and shape. The micrograph of FIG. 3 , showing examples of the combinatorial material architecture at different scales, shows that in fact the metallic deposits within the architecture of the inorganic crystals may be in relatively random positions, different shapes, and different sizes. These deposits may vary within the micro- and nano-range sizes in various implementations.
[0014] Candidate materials for the inorganic crystallites in the composite architecture may be, in various embodiments, materials that comprise phosphorous-and nitrogen-rich materials. When exposed to flame, such materials together form a char barrier on the substrates due to decomposition. The char layer insulates the remaining substrate, thereby blocking oxygen from coming into further contact and thus preventing or inhibiting further combustion. Particular candidate materials for the inorganic crystallites in the composite architecture may be, in various implementations, ammonium polyphosphate (APP) long chain and short chain, melamine (M), melamine polyphosphate (MPo), and melamine pyrophosphate (MPy).
[0015] In addition, gaseous water-releasing materials may be included in the composite, in certain implementations candidate materials including alumina trihydrate (ATH), magnesium hydroxide (Mg(OH) 2 ), zinc borate, and gypsum. At high temperatures, these materials decompose endothermically to release gaseous-phase water that is chemically combined into the material. The continuous release of gaseous water phase retards the combustion process.
[0016] Protecting barrier forming materials may also be included in the composite, candidate materials including calcium carbonate (CaCO 3 ), silicon dioxide (SiO 2 ), Halloysite, Bentonite clay, titanium dioxide (TiO 2 ), and zinc oxide (ZnO). These materials act as inorganic barriers for heat and mass transport during an event of fire, thereby decreasing flammability and improving thermal stability.
[0017] In certain implementations, particle sizes for these crystallites including phosphorous- and nitrogen-rich materials, gaseous water-releasing materials, and protective barrier materials may range from 0.2-100 microns.
[0018] Metallic deposits may include any metals in various implementations, but in particular certain implementations may include copper, silver, aluminum, nickel, chromium, and cobalt. Copper and silver have antimicrobial (including anti-fungal) properties. The size of the metallic deposits may be greater than 10 nm in certain implementations, or may be in the range of 5-100 nm in certain embodiments.
[0019] The presence of the metallic deposits within the architecture improves the flame retardant properties of the material. Experimental results show that a typical treatment of inorganic crystallites including long chain ammonium polyphosphate and melamine polyphosphate will produce a protective char layer at temperatures above 300° C. Because the metallic deposits exhibit high thermal conductivity, the addition of metallic deposits to the composite complex lower the temperature at which the char layer may be formed, thereby further protecting the substrate from combustion. In one experimental set-up, the addition of copper metallic deposits lowered the temperature at which the char layer formed to within the range of 220°-240° C. The surface deposition of the thermally conductive metallic deposit imparts temperature adaptability to the composite. In effect, it reduces the thermal dissociation temperature or decomposition temperature of the inorganic materials to enable the instigation of flame retardant activity at lower-than-usual temperatures. This enables the flame to be retarded more quickly and inhibits the spread of flame before further damage to life or property may occur as a result of combustion of the substrate.
[0020] Smaller (i.e., nano-scale) metallic deposits may be more desirable as a flame-retardant addition to the composite architecture because they pick up heat from a flame adjacent to the textile more quickly, and because they exhibit greater surface area for a particular volume or weight of metallic deposit that is employed. The quantity of metallic deposit employed may be particularly significant for certain costly metals, such as silver. The smaller footprint of the metallic deposits yields enhanced thermal activity per unit area of coverage. To expand upon and provide another example to that provided above, a composite employed was composed of APP-MP-Cu, ammonium polyphosphate and melamine polyphosphate yield high content of ‘P’ (28-30%) and ‘N’ (53-55%). Under normal circumstances, both APP and MP decompose at temperatures above 300° C. However, due to high thermal conductivity and heat sink properties of copper deposits on APP-MP, the decomposition of the composite is enabled at even lower surrounding temperatures (220-240° C.). In other words, the presence of copper rapidly triggers the flame retardant activity of APP-MP composite for maximum control of the initiation and propagation of flames/fire.
[0021] The inorganic-metallic composite architecture describes in various implementations herein can be applied as flame retardant treatment to a variety of consumer substrates and systems, including but not limited to woven and non-woven textiles (nylon, cotton, polyesters, and blends), wood and wood-polymer composite products, polymeric components and systems (including plastics and epoxy), polymeric paints, coatings, and foams, etc.
[0022] For flame retardant treatment of textiles, the nanoengineered composite can be augmented with different types of organic resins depending on the type of textile material (nylon, cotton, polyester, synthetic-cellulosic blend, or other synthetics). The composite is compatible for application to finished textiles via back coating as well as different chemical finishing, including but not limited to padding, kiss rolling, foaming, spraying, and exhaustion processes. The composite can also be applied to textiles during yarn processing, weaving, and other stages of textile processing.
[0023] The precise process for the application of various implementations of the invention may depend upon the particular type of substrate chosen. For example, in the case of nylon, the composite architecture material applied to the relatively non-absorbent nylon fiber results in a lower melting temperature for the material, in certain embodiments the change being from about 220° C. to about 180° C. As a result, the nylon material may melt, but is prevented from becoming hot enough to actually combust. In a nylon treatment application, materials may include the “core ingredients” of a phosphorous-rich, nitrogen-rich, and metallic deposit previous described, along with thiourea, urea-formaldehyde (as cross-linker for durability), a wetting agent, a pH balancing material, and other catalysts/auxiliaries.
[0024] In the case of cotton (cellulosic based textiles), the fiber is absorbent, and thus can absorb the composite architecture material employed. In addition to the core ingredients of the composite containing phosphorous-rich, nitrogen-rich, and metallic deposit previously described, the material may include organophosphorous and carbamide, as well as a wetting agent, a pH balancing material, and other auxiliaries. The result is a treated cotton fiber that is flame resistant.
[0025] In the case of polyester, the composite may be supplemented with cyclic phosphate as well as a surfactant and pH balancer.
[0026] The invention in various implementations may also be supplemented with materials exhibiting hydrophobic properties in order to add a water resistant property. Such materials may include, for example, fluorocarbons and polytetrafluoroethylene (PTFE) particles. Short-chain (C6) PFC-based fluorocarbons may be used due to safety concerns, and due to the resulting applicable regulations pertaining to the use of fluorocarbons with longer carbon chains. It may be noted that PTFE and C6 fluorocarbons are combustible materials, and thus the flame-retardant aspects of the composite architecture material described herein with one or more of these hydrophobic materials may be particularly advantageous.
[0027] In the case of certain metallic deposits, the antimicrobial function is provided by the release of metallic ions with antimicrobial effect. For example, in the presence of water, copper results in the production of Cu II (cupric) ions (Cu 2+ ) and silver results in the production of silver ions (Ag + ). These ions are effective inhibiting microbes including various types of bacteria as well as various types of fungi. Cupric and silver ions have different efficacy with different microbes, and thus the choice of metallic deposit within the composite architecture may be driven by a desire to defeat a particular microbial agent or agents.
[0028] In those embodiments that encompass an insecticidal feature, pyrethroid (synthetic permethrin) in either liquid or solid form may be used in the composite. In certain implementations, particle sizes for these deposits may be greater than 10 nm.
[0029] As noted, the size of the metallic deposits in the composite architecture may range from the micro- to nano-scale, but in particular implementations may range from 5-100 nanometers, while the size of the inorganic crystallites may also range from the micro- to the nano-scale, but in particular implementations may range from 0.2-50 microns. The inorganic crystallites are surface activated by depositing the metallic material, the metallic-permethrin complexes, the metallic-ammonium complexes, or the metallic-permethrin-ammonium complexes through a chemical nanomanufacturing process. This nanomanufacturing process involves the absorption/adsorption of solutions of metal salt precursors, optionally quaternary ammonium salts, and permethrin by the solid inorganic crystallites, followed by a chemical reduction process, wherein the metal salts are reduced to their elemental form. This reduction process takes place in the presence of antioxidants and capping agents. The resultant metal-permethrin-inorganic composite paste is heat cured and milled to a desired powder size.
[0030] More particularly describing the nanomanufacturing process for the synthesis of the composite, the process involves adsorption and absorption of metal salt solution (precursor of the desired metallic deposits) and/or permethrin by the inorganic microcrystals. Next, chemical reduction of the metallic deposits occurs from the precursor salt inside and on the surface of the inorganic crystals. Controlled thermal consolidation of the composite is followed by powder milling and/or screening. Candidate metal salts may include, in various implementations, metal nitrate, metal chloride, metal sulfate, and metal acetate. Candidate reducing agents may include, in various implementations, hydrazine monohydrate and sodium borohydride. Capping agents may include sodium dodecyl sulfate, ethylene glycol, polyethylene glycol (PEG), polyacrylic acid, and cetyl (trimethyl) ammonium bromide. Antioxidants used may include ascorbic acid and citric acid.
EXAMPLE 1
[0031] This example presents a composite mix of ammonium polyphosphate and melamine polyphosphate with nano-sized deposits of Cu (II) and Ag (I).
[0032] In this particular example, to a suitable high-shear mixer with heating capability, a 50-50 mix of ammonium polyphosphate (long chain APP) and melamine polyphosphate powders (93 wt. % of total composite mass) were discharged. Separate water-based solutions containing 3.67% copper nitrate and 1.57% silver nitrate salt solution were added to the powder mix. The content of water was adjusted to form a thick slurry paste with the powders. Mixing continued at a temperature of 140° F. until a thick homogeneous paste was formed after the complete absorption of liquid contents by the powder particles. The mixing is further followed by the addition of a 2.08% hydrazine monohydrate solution containing 1% ascorbic acid and 1% polyethylene glycol. The mixing was continued until the metal salts were chemically reduced to metal nano-sized deposits, marked by a uniform change of color of the paste to dark grey. The resultant composite paste was dried and cured to form solid flakes in a vacuum furnace at a temperature of 150° C. The dried flakes were milled and ground to a fine micronized powder (2.5 μm) using a powder granulator. The final powdered product is a composite of 50-50 mix of ammonium polyphosphate and melamine polyphosphate with nano-sized deposits of 1% Cu (II) and 1% Ag (I) (20 nm or less average particle size). The results of this example are shown in the micrographs of FIG. 3 .
EXAMPLe 2
[0033] With reference to FIG. 4 , a process for applying the composite material to a nylon textile fabric previously manufactured may be described. Into a suitable mixing vessel with heating capability, 10 parts Thiourea (as organosulfur), 5 parts urea-formaldehyde polymer resin, 1 part formalin (37% concentrate), and 36 parts DI water were added and mixed to a homogeneous solution. The temperature was maintained between 130-140° F. during mixing. This solution was referred to as Resin A. Resin A was transferred to a suitable mixing vessel and to it, 5 parts of the composite of Example 1, 0.25 part of clay-based rheological modifier, 0.25 part of cationic surfactant, and 38.5 parts of DI water were added and mixed at room temperature and thereafter, ultrasonicated until the composite powder particles were uniformly dispersed in the solution. To this solution, 1 part of wetting agent, 1.5 parts of ethylene-vinyl chloride-based binder, and 1.5 parts of methylated melamine cross-linker resin were added and mixed in a high-shear homogenizer. The above-described solution was used for the treatment of 100% nylon fabric samples. The treatment was applied using one dip and one nip pad-cure process as shown in FIG. 4 . Curing was performed at temperatures between 360-375° F. With adequate curing, the treated nylon yielded durable flame resistance and greater than 99.99% antimicrobial efficacy without perceptibly altering the hand and color of the nylon fabrics.
EXAMPLE 3
[0034] The following example illustrates treatment for 100% cotton fabric with the composite. Into a suitable mixing vessel with heating capability, 40 parts of Tetrakis (hydroxymethyl) phosphonium sulfate (as Organophosphorus), 10 parts urea (as Carbamide), 5 parts urea-formaldehyde polymer resin, 5 parts cyclic phosphonate, 0.5% non-ionic wetting agent, 0.75% of methylated melamine cross-linker resin and 38.75 parts DI water were added and mixed to a homogeneous solution. The temperature was maintained between 130-140° F. during mixing. This solution was referred to as Resin A. Into a suitable mixing vessel, 5 parts of composite of Example 1, 0.25 part of clay-based rheological modifier, 0.25 part of cationic surfactant, and 91.75 parts of DI water were added and mixed at room temperature and thereafter, ultrasonicated until the composite powder particles were uniformly dispersed in the solution. To this solution, 0.5 part of wetting agent, 1.5 parts of ethylene-vinyl chloride-based binder, and 0.75 parts of methylated melamine cross-linker resin were added and mixed in a high-shear homogenizer. This solution was referred to as Resin B.
[0035] The above-described solutions (Resin A and B) were used for the treatment of 100% cotton fabric samples in two steps. The first processing step used pad application of Resin A and curing at 300-340° F. The second and final treatment processing used pad application of Resin B and curing at 360-375° F. When cured properly, the treated cotton fabrics showed durable flame resistance and greater than 99.99% antimicrobial efficacy without perceptibly altering the hand and color of the fabrics. FIG. 5 shows some of the results from ASTM D6413 vertical flammability tests on treated fabrics in bar graph form.
EXAMPLE 4
[0036] The present invention can also be applied as a combination of chemical treatment (as in Example 2 and 3) and back coating. The following example illustrates a method to finish synthetic fabrics by chemical treatment for antimicrobial and insect-repellent functions and back coating for flame resistance. The chemical treatment used Finish Resin B of Example 2, with 0.5 parts and 0.75 parts of additional non-ionic wetting agent and methylated melamine cross-linker resin, respectively. Chemical treatment involved one dip and one nip padding process, followed by curing at 360-375° F. After curing, FR back coating was applied on the fabrics using a knife-edge coating method, as shown in FIG. 4 . Back coating was accomplished in two steps. First step included a back coating of 1 oz. (per ft 2 of fabric) of cyclic phosphonate (150,000 cps at 68° F.) and then cured at 390-395° F. A second back coating of 0.5 oz. of urethane was applied on top of the cyclic phosphonate coating using the same knife-edge coating method and a curing temperature of 300° F. The fabrics finished with the above methods yielded durable flame resistance and antimicrobial activity.
[0037] The present invention has been described with reference to the foregoing specific implementations. These implementations are intended to be exemplary only, and not limiting to the full scope of the present invention. Many variations and modifications are possible in view of the above teachings. The invention is limited only as set forth in the appended claims. All references cited herein are hereby incorporated by reference to the extent not inconsistent with the disclosure herein. Unless explicitly stated otherwise, flows depicted herein do not require the particular order shown, or sequential order, to achieve desirable results. 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. Any disclosure of a range is intended to include a disclosure of all ranges within that range and all individual values within that range. | A multifunctional material composition functioning as a halogen-free flame-retardant finish combined with in certain implementations one or both of antimicrobial and insect-repellant is nanomanufactured by the absorption/adsorption of metallic salts with one or more additional compounds by inorganic crystallites. The identity of the additional compounds is determined by the desired functionality of the substrate. The material composition can be chemically and mechanically applied to substrates (e.g. to cotton, nylon, and polyester based textile fabrics), for example, to yield durable antimicrobial, insecticidal, and environmentally friendly flame retardant materials. The addition of nano-scale metallic deposits to a phosphorous-rich and nitrogen-rich architecture complex improves the flame retardant properties of the substrates. | 2 |
BACKGROUND OF THE INVENTION
The invention relates to a device for the generation of hydrodynamic power by conversion of the energy of waves of an open body of water, with at least one fixed float, at least one extendable pumping element and one pressure medium.
Waves of open bodies of water, in particular sea waves, have a high energy content, are practically inexhaustible, can be used without charge and processed without any ecologically harmful residue. Use of wave energy on an industrial scale is not yet known, mainly because of corrosion problems.
The energy content of waves is transferred by the circular oscillations of the water. These cause a float to lift, leading to a corresponding energy loss of the wave. Obviously a higher wave can give more energy than a low wave.
The power obtained from the wave movement can be converted to energy in the physical equation
Work=Energy=Force×Distance.
DE,A1 3419565 lists numerous devices and processes which exploit the energy of sea waves. A device is described for the generation of hydraulic or electrical energy from sea waves using a floating body, an energy converter and a connecting element to the sea floor. The length of the connecting element can be changed, controllable by the working limits of the energy convertor and adaptable to the sea depths. The connecting element is also fitted with a device or guided via a device which increases the acting force or the path of the force. This increase is given via a lever ratio or a block and pulley device. It also shows how the float can develop its maximum lifting force in a specific immersion depth.
SUMMARY OF THE INVENTION
The task of the invention is therefore to create a device of the type described above which avoids the complicated mechanical devices such as levers and blocks and pulleys which are required to generate hydrodynamic power, and which as far as possible works with materials which are not sensitive or only slightly sensitive to corrosion.
The task is solved by the invention in that the pumping element attached to the float comprises at least one gas- and/or fluid-impermeable hose which expands radially while shortening in the longitudinal direction and which has one inlet and/or outlet opening for at least one hydraulic and/or pneumatic pressure medium, that each hose has flexible longitudinal fibers of high tensile strength which have an upper force attachment connected to the float and a lower force attachment connected to a fixing, so that the tensile force in the longitudinal direction of the pumping element is never applied to a hose. Special design forms and further developments of the device are shown herein.
The fibers with tensile strength preferably consist of known materials such as for example glass, carbon, silicon carbide, paramide, a plastic or a stainless steel. The fibers can also be coated in a known process.
The hose itself preferably consists of an elastic material which expands on introduction of a pressure medium. In one variant, the hose can have longitudinal folds in which longitudinal fibers are laid. Under the effect of pressure, the folds are extended which has the same effect for the fibers as the expansion of an elastic material. The flexible fibers with extremely low longitudinal elongation under tension follow the movement of the sheath, and the pump element is shortened because of the distortion of the fibers.
As a pumped pressure medium water is ideal, but any hydraulic or in certain cases pneumatic pressure medium can be suitable which can be obtained without harm to the environment at low cost and which is easy to handle. For the external stationary pressure medium of a double pumping element, compressed air and similar compressible gases are mainly suitable, but also fluids, again preferably water.
The pump elements shown herein can of course have other means of activation than waves, the only condition being an oscillating movement also combined with a rotation movement, for example a hand pump. the application limits lie mainly in the economic area as the drive energy must be cheap and readily available as is the case with wave energy in particular.
The device according to the invention has numerous possible applications, for example:
the generation of electrical energy
water pump for the supply and storage of water
mixing and aeration of standing water
desalination of seawater by inverse osmosis.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is explained in more detail using the design examples in the drawings. The drawings show:
FIG. 1 the principle of a single pump element at low tensile force;
FIG. 2 the principle of a pump element of FIG. 1 at high tensile force;
FIG. 3 the principle of double pump element at high tensile force;
FIG. 4 the principle of a pump element to FIG. 3 at low tensile force;
FIG. 5 the functional structure of a single pump element at low tensile force;
FIG. 6 a pump element of FIG. 5 at high tensile force;
FIG. 7 the functional structure of a double pump element at high tensile force;
FIG. 8 a pump element of FIG. 7 at low tensile force;
FIG. 9 a variant of a single pump element at low tensile force;
FIG. 10 a variant of a double pump element at low tensile force;
FIG. 11 a wave energy convertor with a single pump element;
FIG. 12 a wave energy convertor with double pump element;
FIG. 13 a system of a wave power station with open pump circuit;
FIG. 14 a diagram of a wave power station with a closed pump circuit;
FIG. 15 a wave power station with parallel pump elements;
FIG. 16 an optimized float on a wave crest; and
FIG. 17 an optimized float in a wave trough.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A pumping element 10 shown in FIG. 1 and FIG. 2 essentially comprises a flexible, gas- and fluid-tight hose 12 with arranged thereon flexible fibers 14 with tensile strength, with an upper force attachment 16 which is arranged on a float (not shown) and a lower force attachment 18 which can be the foundation or attached to this.
At regular intervals, the hose is passed through a ring 20 also known as a clamping ring. These rings 20 can be attached to a protective sheath 22 shown partly in FIG. 1 so that with the hose stretched (FIG. 2) with parallel fibers 14, they cannot fall out. The term "ring" applies to all means of clamping eg. tires ring shaped chains etc.
FIG. 1 shows the condition under low tensile force. At low pressure, usually in the range of 1-10 bar above ambient water pressure, a pressure medium 24 is pumped in the direction of arrow 26 into the hose 12 shown closed at the top and largely unpressurized. Because of the slightly raised pressure, the hose bulges between the rings 20 taking fibers 14 with it.
In FIG. 2, the upper force attachment 16 lies essentially higher. The high tensile force Z applied stretches the fibers 14, which push the hose 12 into a straight almost tube-like form without significant bulges. The reduction in volume expels pressure medium 24 under high pressure which can amount to several hundred bar, in the direction of arrow 28.
FIGS. 1 and 2 clearly show that in its longitudinal direction, the direction of arrows 26, 28, no force acts on the hose 12.
A damage hose 12 can easily be replaced.
The design form of the pumping element of FIGS. 3 and 4 essentially differs in that the internal pressure medium 24 i flows in the direction of arrow 26 when the pump element is extended (FIG. 3), and as tensile force Z diminishes is pressed out in the direction of arrow 28.
This is achieved in that an inner hose 12 i , supported by rigid internal rings 20 i , and an outer hose 12 e also supported by flexible outer rings 20 e , provides a flexible chamber for the outer pressure medium 24 e , in this case elastic compressed air. The internal and external hoses 12 i ,e also have internal and external fibers 14 i ,e which completely absorb the tensile force.
The inner hose 12 i also defines a flexible chamber for the internal pressure medium 24 i , which is pumped. The elastic external pressure medium 24 e presses the hoses 12 i ,e apart with a pressure in the range of 5-10 bar, which is limited by the internal and external fibers 14 i ,e and the surrounding internal and external rings 20 i ,e.
When the tensile force is removed (FIG. 4), the inner hose 12 i bulges outwards, so the internal pressure medium 24 i is forced in the direction of arrow 28. At high tensile force (FIG. 3), fibers 14 i ,e are stretched parallel, the hoses 12 i ,e are compressed more and more longitudinally by the fibers, leading to an increase in pressure in the outer pressure medium 24 e , until they are practically cylindrical. The interior volume formed by the internal hose 12 i has multiplied in size, external pressure medium is drawn in in the direction of arrow 26 or transferred under hydrostatic pressure.
FIGS. 5 and 6 show the principle of a single pump element 10 of FIGS. 1 and 2 as a functional structure. In an open body of water 30, waves 32 are formed. FIG. 5 shows a float 34 in the area of a wave trough. The upper force attachment 16 of the pumping element 10 is connected to the float 34 via a tension element 36. The low position of the float 34 and hence of the upper force attachment 16 allow the hose 12 to bulge out under the low pressure of the pressure medium 24 flowing in the direction of arrow 26. The float 34 is only immersed slightly into water 30 as a consequence of the low load.
FIG. 6 shows float 34 raised in the area of a wave crest 32 and immersed up to half in the water 30. Because of the upward force of float 34 which can have a volume for example of 5 m 3 to far more than 100 m 3 , a strong force is applied to the upper force attachment 16. The practically fully extended, parallel fibers 14 form hose 12 into a virtual cylinder. Thus, the internal pressure medium 24 is expelled in the direction of arrow 28.
Fibers 14 are firmly clamped into the upper and lower force attachment 16, 18, for which an overlap sleeve 37 is used. It is again clear that no tensile force Z is exerted on the hose 12. A concrete plate cast into the bed of the water body may serve for example as a fixing 38.
The working stroke ΔL corresponds to the difference in distance L 1 between the uppermost and lowest ring 20 according to FIG. 5 and the distance L 0 of these rings in FIG. 6.
The pump shown in FIGS. 7 and 8 for conveying surface water to a depth functions on the principle of FIGS. 3 and 4.
With regard to FIGS. 5 and 6 described above, the following differences apply:
The inner hose 12 i is open at the top and bottom, for which an inlet valve 42 and an outlet valve 44 are provided. During the raising of float 34 to its end position according to FIG. 7, the inlet valve 42 is open and surface water is drawn in. The outlet valve 44 however remains closed for deep water. In the sinking movement of the float 44 to its end position shown in FIG. 8 however, the outlet valve 44 in deep water is open and the oxygen rich surface water can flow out. The inlet valve 42 for surface water remains closed.
A compressed air storage unit 46 is arranged in float 34 which can maintain the high pressure of external pressure medium 24 e . Numeral 46 can also refer to a general pressure medium storage unit, which in the case where a fluid is used as an external pressure medium 24 e must be elastic.
FIG. 9 shows in particular the fixing of the replaceable hose 12 and fibers 14 on the upper and lower force attachments 16, 18.
A connecting support 48 has a large axial bore for pressure medium 24 and a smaller radial hole as a ventilation outlet 50. The connecting carrier 48, which tapers in the direction of the functional pump element, forms the end of a cap-like fibre carrier 52 which firmly clamps the hose 12 so as to seal but not be tension-resistant. The fibers 14 are fixed to a fiber holder 54. Fiber carrier 52 with its fibers 14 is covered with fiber protection 56 designed as a protective sheath.
According to FIG. 10 with a double pumping element 10, a compressed air channel 47 leads to the flexible chamber formed by the inner and outer hoses 12 i ,e with external pressure medium 24 e . Obviously another external pressure medium than air can be passed through this channel 47.
The inlet of the internal pressure medium 24 i into the upper area is achieved in a ring chamber 58, which is protected from the outside by a cylindrical shell in the form of a grid 60. The inlet valve 42 and the outlet valve 44 have a spherical valve body which lies on the seat (inlet valve 42) or on a carrier (outlet valve 44).
FIG. 11 shows a wave energy convertor with a single pumping element 10 according to FIG. 9, and which is connected via its upper articulated joining element 62 to a float 34 and via lower articulated joining elements 64 to a fixing 38.
FIG. 12 shows a wave energy converter with a double pump element 10 according to FIG. 10, which is connected via its upper articulated joint 62 to a float 34 and via lower articulated joint 64 to a fixing 38.
FIG. 13 shows a diagram of a wave power station with an open system. The single or double pump element 10 corresponds to the design forms shown before. With falling pressure, inlet valve 42 opens and allows water 30 to flow in as pressure medium 24. With rising pressure however, outlet valve 44 opens with inlet valve 42 closed as soon as the critical pressure on the high pressure side is exceeded. Via control valves 68, 70, the water under high pressure reaches a turbine 72 which in turn drives a generator 74 to generate electric current as shown by arrow 76. Arrow 78 indicates the water flowing out of turbine 72.
A high pressure storage unit 80 is used for compensation when no water is supplied by pumping element 10, when the high pressure unit discharges partially, but is refilled on the next movement of pump element 10.
A micro-processor 84 is connected to all control elements via lines 82, which are not shown in detail for the sake of clarity.
FIG. 14 shows a diagram of a wave power station with a closed circuit. Here the internal pressure medium 24 is preferably water, but may also be hydraulic oil. As in the open system of FIG. 13, a single or a double pump element 10 can be used e.g. of one of the previous figures.
At high pressure in a single pump element 10, the high pressure valve 44 in the form of an outlet valve opens, pressure medium 24 is passed to turbine 72 via a control valve 86, and the remainder fills the high pressure storage unit 80. When the pressure in pumping element 10 falls, high pressure valve 44 closes and when a preset value is reached, the low pressure valve 42 acting as an input valve opens. A supply pump 88 working with low pressure draws water from a compensation vessel 94 and passes this to pumping element 10 and also to low pressure storage unit 90 under the processor control. Another control valve 92 completes the closed hydraulic system.
FIG. 15 shows several floats 34 which are connected to a hydraulic system via a pumping element 10, shown in part. Several pumping elements 10 can be connected to the same float 34, for example up to 20.
The frogmen shown indicate the height of the unit, which can be up to 30 m.
The outer parts 108 of float 34 are attached flexibly to a centre part 106, where the form of the waves can be exploited functionally as shown in FIGS. 16 and 17 to increase the working stroke ΔL (FIGS. 5, 6).
The known fixings of float 34 have been omitted for the sake of clarity.
A fitting 96 attached flexibly in the foundation 38 contains a high pressure valve (44 in FIG. 14), which on opening passes a high tension pressure medium via a high pressure line 98 to a high pressure pipe 100, and a low pressure valve (42 in FIG. 14), which on opening allows the depressurized medium to flow out of the low pressure pipe 102 via a low pressure line 104 into pumping element 10. Several pumping elements per float 34 have a common high and low pressure valve. FIGS. 16 and 17 show a three-part float 34 on a crest and in a trough of a wave 32. With such a float 34 which has a centre part 106 and flexibly attached side parts 108, the wave movement can be exploited to an optimum as the vertical path of float 34 and hence the working stroke ΔL is enlarged. The optimization device 110 consists of three hoses 112, 114 and 116 reinforced with fibers 14, which are connected together and contain a prestressed fluid or gaseous pressure medium. The entire tensile force of the device falls upon fibers 14 of sheath 116. These fibers 14 can also be made integral with those of pumping element 10. Fibres 14 of hoses 112 and 114 are connected with the longitudinal rib 118 of center part 106 and a longitudinal rib 118 of each side part 108 of the float 34. There is no communicating link of the pressure medium to the hoses of the tensile element 10. | The device exploits the energy of waves (32) of an open water body (30). It comprises at least one fixed float (34), at least one extendable pumping element (10) and one pressure medium (24). The pumping element (10) attached to float (34) has at least one gas- and/or fluid-impermeable hose (12) which expands radially while shortening in the longitudinal direction and which has one inlet and/or outlet opening for at least one hydraulic and/or pneumatic pressure medium (24). On each hose (12) lie flexible longitudinal fibers (14) of high tensile strength, which run preferably parallel when extended. The fibers (14) have an upper force attachment (16) connected to the float (34) and a lower force attachment (18) connected to a fixing (38). The tensile force (Z) is applied in the longitudinal direction of the pumping element (10) and never to a hose.
Ideally the fibers (14) are arranged in guide rings (20) at regular intervals.
The device is used for example as an energy source for an electric power station, water supply, water storage, mixing and aeration of standing water and the desalination of sea water. | 5 |
RELATED APPLICATION DATA
[0001] This patent application is a continuation of U.S. patent application Ser. No. 11/530,391, filed Sep. 8, 2006 (published as US 2007-0027818 A1), which is a continuation of U.S. patent application Ser. No. 09/790,322, filed Feb. 21, 2001 (U.S. Pat. No. 7,111,168). The 09/790,322 application claims the benefit of U.S. Provisional Application No. 60/257,822, filed Dec. 21, 2000. The 09/790,322 application is also a continuation-in-part of U.S. application Ser. No. 09/562,049, filed May 1, 2000 (U.S. Pat. No. 7,191,156). The above patent documents are hereby incorporated by reference.
[0002] The subject matter of the present application is related to that disclosed in copending U.S. application Ser. Nos. 09/127,502, filed Jul. 31, 1998 (now U.S. Pat. No. 6,345,104); 09/074,034, filed May 6, 1998 (now U.S. Pat. No. 6,449,377); 09/343,104, filed Jun. 29, 1999; 09/503,881, filed Feb. 14, 2000 (now U.S. Pat. No. 6,614,914); 09/547,664, filed Apr. 12, 2000; 09/562,516, filed May 1, 2000; 09/562,524, filed on May 1, 2000 (now U.S. Pat. No. 6,724,912); 09/571,422, filed May 15, 2000 (now U.S. Pat. No. 6,947,571); 09/636,102, filed Aug. 10, 2000; and in U.S. Pat. No. 5,862,260. Each of these patent documents is hereby incorporated by reference.
FIELD OF THE INVENTION
[0003] The present invention relates to hidden data systems, and is particularly illustrated with reference to documents employing digital watermarks.
BACKGROUND AND SUMMARY OF THE INVENTION
[0004] Digital watermarking technology, a form of steganography, encompasses a great variety of techniques by which plural bits of digital data are hidden in some other object without leaving human-apparent evidence of alteration. Many such techniques are detailed in the above-cited documents.
[0005] In accordance with one embodiment of the present invention, watermarking is employed to facilitate e-commerce transactions. More particularly, watermarking is employed to assure that an on-line purchaser of goods has physical custody of the credit card being charged. Without such custody, the credit card issuer will refuse the requested transaction.
[0006] According to another embodiment, a method of commerce over the internet between a user and a merchant is provided. The user is in possession of a document including an embedded watermark. The method includes the steps of: i) extracting identifying data from the watermark, and passing the identifying data to a central site; ii) at the central site, identifying a financial institution identifier associated with the document and passing the identifier and a session ticket to the user; iii) contacting the financial institution via the financial institution identifier and passing the session ticket to obtain an authentication ticket; iv) passing the authentication ticket from the user to the merchant to facilitate a transaction; and v) providing the authentication ticket from the merchant to the financial institution.
[0007] In still another embodiment, a method of verifying data is provided. The method includes the steps of: i) digitally capturing an image; ii) computing a hash of the captured image; and iii) comparing the hash with a database of hashes, the database of hashes comprising hashes corresponding to previously captured images.
[0008] A system for exchanging data is provided according to yet another embodiment. The system includes a user terminal and a central site. The user terminal includes a watermark reader, and a capturing device to capture an image. The central site includes a database of image hashes. The user terminal communicates with the central site. Also, the reader reads a watermark and computes a hash of a captured image and passes the hash to the central site for comparison with the database of image hashes.
[0009] According to another embodiment, a method is provided for commerce over a communications system between a user and a merchant. The system includes a central computer, a user computer, a merchant computer and a financial institution computer. The user computer includes a watermark reader. The various computers communicate via a network. The method includes the steps of: i) accessing the merchant computer from the user computer; ii) launching on the user computer the watermark reader to read a document comprising an embedded watermark, the watermark reader extracting identifying data from the watermark; iii) accessing the central computer from the user computer to obtain a URL for the financial institution computer and a ticket, the URL being identified from the extracted identifying data; iv) passing the ticket from the user computer to the financial institution computer to obtain an authorization; v) upon receipt of the authorization, passing the authorization from the user computer to the merchant computer; and vi) passing the authorization from the merchant computer to the financial institution computer.
[0010] A computer readable medium having a data structure stored thereon is provided according to another embodiment. The data structure includes a document identifier, a document type identifier; a hash of an image from which the document identifier and document type identifier were extracted from.
[0011] The foregoing and other features and advantages of the present invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 illustrates a system according to an illustrative embodiment of the present invention.
[0013] FIG. 2 illustrates a system according to an illustrative embodiment of the present invention.
[0014] FIGS. 3 a through 8 further illustrate the system of FIG. 2 .
DETAILED DESCRIPTION
[0015] In accordance with one embodiment 10 of the present invention, a document 12 includes plural-bit digital data steganographically encoded therein (e.g., by digital watermarking). The document can be a photo ID (e.g., a driver's license, student ID, or passport), a value document (e.g., a banknote, stock certificate, or other financial instrument), a credit card, a product manual, bank or credit account card, registration card, or virtually any other type of document.
[0016] The encoding of the document can encompass artwork or printing on the document, the document's background, a laminate layer applied to the document, surface texture, etc. If a photograph is present, it too can be encoded. A variety of watermark encoding techniques are detailed in the cited patents and applications; artisans in the field know many more.
[0017] For expository convenience, this section focuses on photo ID cards and credit cards, but it will be recognized that the invention is not so limited.
[0018] In an illustrative embodiment, the card is encoded with a payload of 32 bits. This payload is processed before encoding, using known techniques (e.g., convolutional coding, turbo codes, etc.), to improve its reliable detection in adverse conditions. In other embodiments, a payload larger or smaller than 32 bits can naturally be used (e.g., 8-256 bits).
[0019] The encoded card is presented to a reader station 14 for reading. The reader station 14 includes an input device 16 and a processor 18 .
[0020] The input device 16 can take various forms, including a flatbed scanner, a hand scanner (including an imaging mouse), a video camera, etc.
[0021] The processor 18 can be a general purpose or dedicated computer, incorporating a CPU 20 , memory 22 , an interface 24 to the input device, a display screen or other output device 26 , and optionally a network connection 28 . The network connection can be used to connect, through an intranet, internet, or otherwise, to a remote computer 30 .
[0022] Suitable software programming instructions, stored in memory 22 of processor 18 , or in a memory of remote computer 30 , can be used to effect various types of functionality for embodiment 10 .
[0023] One functionality is to increase security for credit card-based e-commerce transactions. Presently, all that is required to purchase goods on-line is a credit card number. Credit card numbers may be obtained illicitly in numerous ways, from dumpster diving to intercepting unencrypted internet transmissions, or by hacking into an online database.
[0024] In accordance with this application of the invention, a bank or other entity that issues credit cards may offer a service to its subscribers that requires physical presentment of a credit card before certain purchases (e.g., on-line purchases) can be made. If a subscriber has elected to participate in such a program, the issuer will refuse to authorize payment for any transaction in which the credit card has not been physically presented.
[0025] In one such arrangement, a subscriber's home computer, with associated web cam, serves as the reader station 14 . On presenting the credit card to the web cam 16 , software in the computer decodes a watermark encoded in the credit card artwork, surface texture, etc. Only if this watermark is properly decoded is the card deemed to be present.
[0026] The actual verification process can take numerous forms. In one, the credit card number is not passed to the vendor until it is locally verified by reference to the watermark data. In one such arrangement, the card number is provided to the computer in one of various ways (e.g., by typing into a web form presented by internet browser software; by serving from a secure cache, etc.). Before, or after, the computer decodes the watermark data from the physical credit card presented to the web cam. The computer then checks for a predetermined type of correspondence between the credit card number and the watermark data (e.g., the credit card number, processed by a hash function, must yield the watermark payload). Only if the watermark data and credit card number properly correspond is the credit card number transmitted from the browser to the vendor. This approach has, as one of its advantages, that the data exchange protocols between the user, the vendor, and the issuer, needn't be changed.
[0027] In another arrangement, both the decoded watermark data and the credit card number are passed to the vendor, and from the vendor to the card issuer. The card issuer can then confirm that the watermark data and credit card number correspond in a predetermined manner, and authorize the transaction if such correspondence is found. This approach has as one of its advantages that the correspondence check is not made at the user's computer, thereby making the verification algorithms employed more secure against hacking.
[0028] In still other arrangements, the user does not enter the credit card information at the time of the transaction. Instead, the card number may have already been stored at a remote site on the internet, e.g., at a vendor's database. A cookie stored on the user's computer may be checked by the vendor to determine the identity of the consumer, and thereby identify the corresponding credit card number.
[0029] To guard against unauthorized charging in this context, the issuer can refuse charge authorization when the card number is forwarded to it by the vendor. With its refusal, the issuer can provide an error code that indicates, to the vendor, that the user must demonstrate physical custody of the card before the charge will be authorized. The vendor can then query the user computer for this information. If the user has not already done so, the card can be presented to the web cam, and the decoded watermark data then passed to the vendor, and then to the issuer for confirmation of the necessary correspondence.
[0030] The back-and-forth just described can be overcome by storing data in the cookie indicating that physical presentment of that user's credit card is required before any credit card transaction can be approved. Such indicia can be added to the cookie the first time a charge authorization is refused for lack of such presentment. Thereafter, when the vendor detects such indicia in the user cookie, it can query the user for watermark data (e.g., inviting the user to present the credit card to the web cam, if necessary) before passing the transaction data to the issuer.
[0031] If this (or other) physical presentment technology becomes sufficiently widespread, standards may evolve by which vendors can discern—from data on the user's computer—whether physical presentment is required for credit card transactions. In such case, individual vendor cookies on a user's machines needn't be updated. Instead, a single datum (a cookie or otherwise)—referred to by all vendors—can be used to flag the need for presentment.
[0032] (The reference to “other” physical presentment technology anticipates that alternative arrangements may be employed to confirm user custody of a credit card. These may involve magnetic stripe readers, detection of other physical features, communication with a processor-, memory-, or other circuitry-embedded in a card, etc.)
Secure Transaction System
[0033] A secure transaction system is described with reference to FIG. 2 . FIG. 2 illustrates system 40 , which facilitates a transaction for goods, financial instruments, services, etc. The transaction occurs online (e.g., over the internet). However, the principles described herein are equally applicable to transactions occurring over dedicated networks, wireless networks, intranets, WANs, LANs, etc. The overall system 40 components are described with reference to FIG. 2 . Further system operations are described with respect to FIGS. 3 a - 8 .
[0034] In the present invention, communication between a client and a host (or a plurality of hosts) is facilitated. The client and host may both reside locally, or may communicate over remote channels. Communication between the client and host may occur via internet protocols (e.g., TCP/IP), or other communication techniques. In one embodiment, the client is maintained on a user terminal (or user computer, server, etc.), while the host resides on a central site. In another embodiment, the client and host are incorporated within a local system. In still another embodiment, the host is dispersed throughout various sites. These and other such variations are within the scope of the present invention.
[0035] With reference to FIG. 2 , system 40 includes a user terminal 42 , merchant site 44 , central site 46 , financial institution site 48 , and (optionally) remote terminal 50 . The user terminal 42 may include a general purpose or dedicated computer incorporating at least a CPU, memory, interface to an input device (e.g., web cam, digital video camera, scanner, and/or still digital camera, etc.) 43 , a display (or other output device), and a network connection. The network connection may be used to connect through an intranet, the internet, or otherwise communicate with sites 44 , 46 , and/or 48 . Of course, the user terminal 42 may alternatively include a portable computing unit, such as a personal financial assistant, PocketPC, PalmPilot, etc., with associated components and/or wireless, cable, phone or other networking access. Suitable client software programming instructions, stored in the user terminal memory, or in a memory of a remote computer, can be used to effect various types of functionality for the user terminal 42 .
[0036] Merchant site 44 , central site 46 , and financial site 48 each include a computer or server (or a plurality of interconnected servers). As will be appreciated by those skilled in the art, these computers maintain and execute software, e.g., for hosting (and/or supporting) web pages, communication, database management, etc. These sites 44 , 46 , and 48 also maintain suitable software program instructions to facilitate the system operations described herein. Of course, system 40 may include a plurality of merchant and financial sites, and additional and/or alternative central sites.
[0037] With reference to FIG. 3 a , a user initiates an online purchase by accessing a website or other interface supported by merchant site 44 , e.g., with the aid of an interface residing on user terminal 42 . The interface may include a dialog box, web browser, application, and/or other communication mechanism. A secure, session-oriented internet protocol (“SIP”) connection is preferably created between the merchant site 44 and the user terminal 42 . This type of connection helps to prevent unauthorized eavesdropping by a third party.
[0038] In one embodiment, the user makes a transaction selection via the merchant's website and proceeds to an online checkout location. The checkout location is preferably a graphical user interface (e.g., a dialog box), which allows the user to select at least one secure checkout option 60 . Of course, the checkout could be integrated into another application or interface. As shown in FIG. 3 b , one secure checkout option 60 is a “PortalCard™” checkout option. A PortalCard™ may be a digitally watermarked credit card, access token, voucher, check, note, other watermarked document, etc. The documents discussed above are broadly defined so as to include a PortalCard™. (For consistency, the term “document” will be used hereafter instead of PortalCard™). Upon selecting the secure checkout option 60 , a watermark decoder (e.g., a browser software plug-in) is launched on the user terminal 42 . As an alternatively arrangement, instead of launching the decoder upon selecting the secure checkout option 60 , the decoder remains active in the operating background. Of course, the decoder may be integrated into other applications, such as an operating system, software application, independent software module, device, system, etc., as discussed in assignee's Ser. No. 09/636,102 application. Such a decoder detects and reads an embedded watermark (or watermarks) from a signal suspected of containing the watermark. The watermark preferably includes additional data, such as a plural-bit message, payload and/or identification bits, which is extracted by the decoder.
[0039] Preferably, the user is prompted to position or to otherwise arrange the document 62 for image capture by input device 43 ( FIG. 4 ). The decoder examines a captured image (or images) and reads the digital watermark to extract the additional data. The additional data may include a document ID (P IDBK ) and a document type identifier (D T ). These identifiers may be concatenated strings or may be segmented within the additional data (or payload). (The symbol ∥ in the drawings represents concatenated data.). Of course, the data could be combined in another manner, such as in segments, packets or blocks. The document ID uniquely identifies the document and may optionally be associated with a user account (e.g., a credit or cash account). The length of the document identifier is preferably selected based on application and/or system requirements. In an illustrative embodiment, the document identifier includes 8-256 bits (e.g., 8, 32, 44, 64, 128, etc. bits). To provide further security, the document ID may be encrypted with a symmetric key (B K ) from the document's issuing institution (e.g., a bank). Preferably, only the issuing institution has possession of the symmetric key.
[0040] Software executing at user terminal 42 preferably computes a hash of each captured image. This software may be included as part of the watermark decoder, or may be a separate application or module. Each captured image will generally have a unique hash associated with it. Even images of the same document will have unique features respectively associated with them due to environmental changes (e.g., positioning of the document relative to the camera, background changes, orientation, lighting, etc.). Examples of common hashing algorithms include MD2, MD5, MD11, SHA, and SHA1. Of course, these and other hashing algorithms can be effectively used with the present invention. A computed hash is represented by I H in the figures.
[0041] As shown in FIG. 5 , the user terminal 42 contacts and establishes a secure communications channel with the central site 46 . The user terminal 42 passes a request to the central site 46 . The request preferably includes the encrypted document ID (P IDBK ), document type (D T ), unique image hash (I H ), the user terminal's IP address (C IP ), and a timestamp (TIMEc) of the request. Of course, the request could include more or less information depending on need and system implementation. Encrypting the request with a central site public key ( DKU ) provides additional security. In FIG. 5 the encrypted request is represented by:
[0000] [P IDBK ∥D T ∥I H ∥TIME C ∥C IP ] DKU .
[0000] The central site 46 has a corresponding private key to facilitate decryption of the request.
[0042] The user terminal 42 may obtain a timestamp in various ways. For example, a timestamp may be obtained by online synchronization of user terminal 42 with central site 46 . The user terminal 42 may alternatively maintain or gain access to (e.g., via the internet) an atomic clock.
[0043] The central site 46 decrypts a request using the corresponding private key. The central site 46 then has access to the request's components, including the encrypted document ID, document type, unique image hash, the user terminal's IP address, and timestamp. As discussed above, the document ID is preferably encrypted with the issuing financial institution's symmetric key, thus preventing the central site 46 from decrypting or otherwise accessing the document ID—providing a further level of security for system 40 .
[0044] If provided in a request, the hash (I H ) is used as an additional security measure. The central site 46 compares the hash against all other hashes received and stored from the user terminal 42 . For even further security, the hash is compared against all stored hashes, or a subset of the stored hashes. A match indicates that the hash was computed from an identical image. Such a match is a near impossibility for a legitimate request when considering background changes, orientation, position variations, etc. A match may suggest that an attack via capture and playback is being carried out. Accordingly, the request is preferably dropped (e.g., is not processed) if a match is found. As an alternative to dropping the request, the central site 46 could query the user for additional verification (e.g., a PIN, password, or instructions to recapture the image).
[0045] The timestamp can also be used as an additional security feature. The central site 46 checks whether the timestamp is within an acceptable time window. Preferably, the central site 46 will not process the request if the timestamp indicates that the request was stamped outside of the window. This technique also helps to prevent capture and playback by an unauthorized third party.
[0046] The central site 46 identifies corresponding information by using the document type identifier (D T ) as an index or reference. For example, the document type identifier is used to index into a database of URLs. These URLs respectively correspond to various financial institutions, which have issued watermarked documents. The central site 46 matches the document type identifier (D T ) with a URL (e.g., URL B ) corresponding to the document's issuing institution. In this example, the issuing institution is financial institution 48 .
[0047] The central site 46 provides a session ticket (T D ). The session ticket preferably includes the encrypted document ID (P IDBK ), a timestamp for the return ticket (TIME D ) and an IP address for the user terminal 42 . The session ticket is preferably encrypted with the financial institution's public key ( BKU ). Such encryption helps to prevent a malicious or unauthorized user of the user terminal 42 from interpreting and modifying the session ticket (T D ). The user's IP address may be verified at a later stage of the transaction process. Such IP address verification helps prevent misdirection of the session receipt. The session ticket and the URL of the financial institution (URL B ) are returned to the user terminal 42 (e.g., URL B ∥T D in FIG. 5 ).
[0048] With reference to FIG. 6 , upon receipt of the URL B and session ticket (T D ) the user's client (e.g., client software residing at user terminal 42 ) contacts financial institution 42 via the URL B . The client (via user terminal 42 ) passes the session ticket (T D ), merchant site URL (e.g., URL M ), and the transaction details to financial institution 48 . The transaction details preferably include the amount of the online purchase. The connection with the financial institution 48 is preferably secure (e.g., through a secure session internet protocol connection).
[0049] The financial institution 48 decrypts the session ticket with its corresponding private key. The user terminal IP address and return timestamp may be verified to determine any misdirection or playback attack. The financial institution 48 now has access to the encrypted document ID, which it decrypts with its symmetric key. The decrypted document ID is used to index or otherwise locate the user's account. In some cases, the document ID may include the user's account number. The user's corresponding account may be queried to determine if the user has sufficient funds (or credit) for the transaction amount. The financial institution may optionally prompt the user terminal 42 for a second form of identification (e.g., a PIN or password) before authoring the transaction. In an alternative embodiment, the PIN (or other verification) is collected and included in the session ticket, thus providing further efficiency for the system.
[0050] The financial institution 48 provides an authorization ticket (T B ) to the user terminal 42 upon authorization of a transaction ( FIG. 6 ). An authorization ticket preferably includes the document ID, a timestamp for the ticket, the user terminal's IP address, the merchant's URL, and the amount of the transaction. The authorizing ticket is used to help facilitate payment to the merchant. The authorization ticket is preferably encrypted using a symmetric key (B K ) associated with the financial institution. Since only the financial institution 48 knows the symmetrical key, encrypting the authorization ticket as such prevents a malicious user or merchant from interpreting or modifying the authorization ticket (I B ).
[0051] The user's client residing at terminal 42 passes the bank authorization ticket (T B ) to the merchant site 44 , as shown in FIG. 7 . The client may also pass additional information such as shipping and handling information. This information is optionally stored locally at the user terminal 42 , and submitted automatically to the merchant site 44 with the authorization ticket. The user may also be presented with a dialog screen, which allows entry and/or changes to shipping and handling requirements. Since the bank authorization ticket is encrypted with a symmetrical key, the authorization ticket cannot be meaningfully decrypted or altered by the user.
[0052] As shown in FIG. 8 , the merchant site 44 verifies the authorization of the credit/payment by passing the authorization ticket (T B ) back to the financial institution 48 , along with any other details of the transaction (e.g., merchant ID, user information, contract terms, etc.). The merchant site 44 may contact the financial institution 48 via the internet, or through secure, dedicated channels. The authorization ticket cannot be meaningfully decrypted or altered by the merchant. Accordingly, the financial institution can be assured that the ticket contains the original amount and merchant URL that was reported by the user terminal 42 . Also, the user is protected since her account details are never exposed to the merchant.
[0053] Existence of the authorization ticket signals to the financial institution 48 that a “PortalCard” purchase option was used for the transaction. After decrypting the authorization ticket, these details can be used to verify the transaction details. The ticket timestamp can also be used to prevent duplicate transaction submissions. The financial institution 48 confirms validity of the authorization ticket to the merchant site 44 . Optionally, the user then receives a confirmation from the Merchant site 44 that the transaction has been successfully completed.
[0054] The following discussion is presented to summarize some of the features and functionality of system 40 . A user begins an online purchase by accessing a merchant website. A decoder, residing on the user's site, reads (or identifies) a watermarked document. The client residing on a user terminal contacts a central site to obtain a URL for a financial institution's authentication server and to get a session ticket. The client contacts the financial institution's server via the URL and passes the session ticket to the bank to obtain an authorization ticket. The client then passes the authorization ticket to the merchant. The merchant includes the authorization ticket in its financial transaction with the financial institution. Preferably, these steps are seamlessly carried out by the user's computer (e.g., the client software), in conjunction with the merchant website, central site, and financial institution site.
[0055] System 40 offers many advantages. For example, system 40 provides a secure transaction system for online purchases via layers of message encryption and obtaining secure communication channels. According to one embodiment, a merchant is prevented from accessing user credit information (e.g., account or document ID). System 40 also prevents an unscrupulous user from changing price or transaction details, since the authorization ticket is securely encrypted. The above-described hash matching techniques also provide a unique feature of the present invention. The hash matching helps to prevent capture and playback attacks. These and other advantages are apparent from the detailed description.
ALTERNATIVE EMBODIMENTS
[0056] There are many variations and alternative arrangements of system 40 . Of course, such modifications fall within the scope of the present invention. For example, additional security measures may be taken in event that a user accesses the transaction system (e.g., merchant site 44 , central site 46 and financial institution 48 , etc.) through remote site 50 ( FIG. 4 ). For example, input device 51 and its link to a remote site 50 may include an encrypted link (or links), using a key negotiated by camera 51 and software resident on the remote site 50 . Secure encryption techniques may also be used for a link between remote site 52 and the system.
[0057] In another alternative arrangement, a watermark is not decoded by the user terminal 42 (e.g., a decoder operating on user terminal 42 ). Instead, the decoder determines whether a watermark is present within a captured image. If a watermark is present, a block of image data (e.g., all or some of the captured image) is passed as a request to central site 46 . Preferably, the request includes the image data (IB LOCK ), a timestamp (TIME C ), and the user terminal's IP address (C IP ). The request may be encrypted with a central site public key ( DKU ) for additional security. An encrypted request is represented in FIG. 5 as [IBLOCK∥TIME C ∥C IP ] DKU . The central site 46 decrypts the request and then extracts the watermark from the image data. Additional data (e.g., the encrypted document ID and document type identifier) can then be extracted from the watermark. This alternative arrangement shifts a majority of the decoding from the user terminal 42 to the central site 46 . Shifting the decoding away from the user terminal 42 may provide an advantage, particularly if a third party could intercept the data stream from the user terminal 42 to the central site 46 . In this alternative arrangement, the intercepted stream will not be in a decoded form—which significantly reduces the amount of revealed data. Also, since the decoding processes (or a majority of the processes) are maintained securely by central site 46 , there is less of the decoding algorithms (and/or software code) to attack at the user terminal 42 .
[0058] Upon receiving the image block, the central site 46 may optionally record the image data or a hash of the image data. The hash is then used to match against other hashes corresponding to the user terminal 42 , as discussed above.
[0059] A premise of these ideas also finds application beyond online purchases. One application is to verify permissions, add security to logins, and/or to facilitate account access (e.g., a bank account, credit account, access to restricted or hidden network layers, etc.). For example, a user establishes a link with the central site 46 via an embedded object to obtain a corresponding permission authenticator URL. The central site 46 generates a session ticket with appropriate data (identifiers, IP addresses, etc.). The user terminal 42 passes the session ticket to the authenticator (e.g., bank, corporation, etc.) for authorization. The authenticator authorizes access by providing an authorization ticket or other enabling data (corresponding password, new URL, etc.). Such modifications are within the scope of the present invention.
Additional Security Features
[0060] To deter use of precision photocopy apparatuses to reproduce document faces (while retaining the associated watermark), the face of the document can be provided with a reflective layer, e.g., in the form of an overlay or varnish. In the bright illumination of a photocopier, such layer mirrors the light back onto the photodetectors, preventing them from accurately reproducing the watermark pattern. In contrast, when presented to a web cam or other such imaging device, no bright illumination is typically present, so the photosensors are not overwhelmed and the document can be used for its intended authentication purpose.
Concluding Remarks
[0061] The foregoing are just exemplary implementations of secure online transaction systems. It will be recognized that there are a great number of variations on these basic themes. The foregoing illustrates but a few applications of the detailed technology. There are many others.
[0062] Consider, for example, the use of embedded watermark data in a document to allow access to a resource. A card may be used to grant physical access through a normally locked door. Or a card may be used to logon to a computer network—with directory privileges tied to the data decoded from the card.
[0063] Entry of a user's PIN code, or other identity check, may be desirable in certain contexts, e.g., to guard against granting access to a person who has found or stolen someone else's card. Security is further enhanced when a user possesses both i) a physical document, and ii) corresponding verification data (e.g., password, PIN, retinal scan, voice recognition, biometric verification data, etc). To illustrate, in order to gain system or network access (or to login), a user must demonstrate physical possession of document. A compliant reader reads and extracts embedded data from the document. The embedded data is used to index or otherwise identify corresponding verification data. The corresponding verification data is preferably predetermined and stored for comparison. The user is prompted to provide the verification data (e.g., to provide a PIN, yield to a fingerprint or retinal scan, etc.). (The user may be prompted to provide such verification data prior to, or after, presentment of the document). System access is granted only when the provided verification data correctly corresponds with the predetermined verification data. This multi-step security (e.g., physical possession and verification data) is valuable in many environments, including authentication to a network, access to a software application, verification of identity, verification of permissions, login security, restricted access management, etc. The basic system functionality as shown in FIG. 2 may be used to facilitate such. Of course, a link between a client and host also may be used to facilitate such a verification process.
[0064] In some cases, the data encoded in the card fully replicates certain information associated with the card (e.g., the bearer's last name or initials, or OCR printing, or mag-stripe data, etc.). Or the encoded data can be related to other information on the card in a known way (e.g., by a hash function based on the bearer's printed name, or the full-text card contents). Or the encoded data can be unrelated to other information on the card. In many embodiments, the data encoded in the card may serve as an index to a larger repository of associated data stored in a remote database, e.g., on computer 30 . Thus, for example, an index datum read from a passport may allow a passport inspector to access a database record corresponding to the encoded data. This record may include a reference photograph of the passport holder, and other personal and issuance data. If the data obtained from the database does not match the text or photograph included on the card, then the card has apparently been altered.
[0065] Whereas specific bit lengths and string names have been used for illustrative purposes, it will be appreciated that the present invention is not so limited. Instead, data of differing lengths and names may be used. Also, whereas specific components for the various tickets have been used for illustrative purposes, it will be appreciated by those skilled in the art that a ticket could include alternative components, so long as some form of identifying features remain.
[0066] To provide a comprehensive disclosure without unduly lengthening this specification, the above-detailed patent documents are incorporated herein by reference.
[0067] Having described and illustrated the principles of the invention with reference to illustrative embodiments, it should be recognized that the invention is not so limited.
[0068] As a further alternative, the embedded data may be infrared (IF) or ultraviolet (UV) sensitive. The embedding can be effected using IF or UV ink. For example, the CCD or CMOS detector of most cameras (under normal lighting) detects some of the UV spectrum. The effect can be enhanced by illuminating the object with black light in order to fluoresce the mark at the time of imaging—making the mark visible to the camera. Earlier disclosure relating to use of UV inks is provided in co-pending U.S. patent application Ser. No. 09/562,516, filed May 1, 2000, and 60/257,822, filed Dec. 21, 2000, each of which are hereby incorporated by reference.
[0069] The particular combinations of elements and features in the above-detailed embodiments are exemplary only; the interchanging and substitution of these teachings with other teachings in this and the incorporated-by-reference patent/applications are also contemplated.
[0070] The above-described methods and functionality can be facilitated with computer executable software stored on computer readable mediums, such as electronic memory circuits, RAM, ROM, magnetic media, optical media, removable media, etc. Such software may be stored on a user terminal, and/or distributed throughout a network. Data structures representing the various data strings may also be stored on such computer readable mediums.
[0071] In view of the wide variety of embodiments to which the principles and features discussed above can be applied, it should be apparent that the detailed embodiments are illustrative only and should not be taken as limiting the scope of the invention. Rather, we claim as our invention all such modifications as may come within the scope and spirit of the following claims and equivalents thereof. | A variety of systems and embodiments are disclosed. One embodiment provides a method including: maintaining a database including a plurality of records stored therein; obtaining first information derived from image or video data, the first information being derived remotely relative to performance of said method, the first information comprising a reduced-bit representation of the image or video data itself; determining whether the first information has been previously received with reference to at least the plurality of records stored in the database; and disregarding a request or action associated with the first information if the first information has been previously received. Of course, other combinations are provided and claimed as well. | 6 |
FIELD OF THE INVENTION
The invention relates to pump assemblies and pumping methods for internal combustion engines where the liquid pumped by the assembly is used to actuate hydraulically driven devices, typically fuel injectors, intake and exhaust valves, and engine brakes.
DESCRIPTION OF THE PRIOR ART
Diesel engines using hydraulically actuated devices including fuel injectors, intake and exhaust valves and engine brakes are well known. The hydraulically actuated devices each include an actuation solenoid, which, in response to a signal opens a valve for an interval to permit high-pressure liquid supplied to the device to extend a piston and actuate the device.
U.S. Pat. No. 6,460,510 discloses a pump assembly for a diesel engine with hydraulically actuated fuel injectors including a high-pressure pump for pumping high-pressure engine oil to the injectors, a hydraulic inlet throttle valve for controlling inlet flow of low-pressure engine oil to the pump and a hydraulic circuit for opening and closing the inlet throttle valve in response to signals from an engine control module (ECM) proportional to the difference between measured pump outlet pressure and desired outlet pressure as determined by the ECM.
The inlet throttle valve includes a spool and a spring that biases the spool toward a full open position. A piston on the spool forms one wall of a pressure chamber which is connected to an injection pressure regulator (IPR) valve and is also vented to the sump through a restriction. High-pressure output oil is flowed to the chamber by the IPR valve to shift the spool against the spring toward the closed position. The pressure drop across the restriction prevents pressurizing the chamber at full output pressure. Additionally, when the ECM determines the output pressure must be increased, the restriction prevents rapid flow of oil out from the pressure chamber and slows opening movement of the spool. Rapid opening and closing response of the inlet throttle valve to signals to increase or decrease output pressure is desirable.
The pump assembly of U.S. Pat. No. 4,460,510 is particularly adapted to controlling the output pressure of oil used to actuate fuel injectors for a diesel engine which is operated primarily at high engine speed, such as an engine in an over-the-road truck.
Accordingly, there is a need for an improved pump assembly with a hydraulic inlet throttle valve and method for flowing engine oil to a high-pressure pump for an internal combustion engine where the pump assembly responds rapidly and accurately to ECM signals, particularly when the engine is at low speed or idling and output pressure is low. The pump assembly should be capable of rapidly opening or closing the inlet throttle valve to increase or decrease the flow of low-pressure oil to the pump and rapidly increase or decrease the output pressure. The assembly should improve the stability of the inlet throttle valve by damping the effect of output pressure spikes on the inlet throttle valve. The inlet throttle valve should respond directly to full output pressure when a decrease in output pressure is required and should drain oil directly to the sump, without flow restriction, when increased output pressure is required. Operation of the inlet throttle valve by high output pressure oil should not damage the valve.
There is also a need for a pump assembly and method for an internal combustion engine with improved fuel efficiency, particularly when the engine is operating at low speed or idling.
SUMMARY OF THE INVENTION
The invention comprises a pump assembly and method for actuating a fuel injector, intake or exhaust valve, engine brake or other member in an internal combustion engine. The pump assembly has a high-pressure variable output pump and a hydraulically actuated inlet throttle valve for the pump. The inlet throttle valve has a valving spool that is biased toward an open position by a spring and by inlet pressure. The spool is biased toward a closed position by high-pressure oil from the pump.
The pump assembly includes a three-way valve responsive to a signal from the ECM to rapidly open or close the inlet throttle valve. The inlet throttle valve is rapidly closed by oil at full output pressure. The inlet throttle valve is rapidly opened by a spring and inlet pressure while draining oil in the valve directly to the sump.
Connection of the inlet throttle valve to oil at output pressure moves the valve spool in a closing direction responsive to the full output pressure, without pressure reduction due to flow of the oil to the sump through a restriction. The spool moves in an opening direction with direct drain to the sump, without flow through a restriction. In each case, response time for movement of the spool is reduced.
The inlet throttle valve includes a soft or hydraulic stop to prevent physical contact between the spool and the valve body when the valve is rapidly closed by flow from a full output pressure oil passage.
The three-way valve includes a spool having a valving land which moves across valving openings leading to the pressure chamber in the inlet throttle valve. When the inlet throttle valve is pressure balanced, the land is in a null position, overlies the valving openings and the valving openings are underlapped, permitting limited flow of high-pressure oil past the land and directly to sump. Underlapping damps spikes in output pressure by flowing oil directly to the sump and improves stability of the inlet throttle valve.
The pump assembly is designed for stable operation both at high engine speed with output pressure as high as 4,060 PSI and at low or idle engine speed where the output pressure may be as low as 360 PSI. This results in improved fuel economy, particularly in engines that frequently operate at low RPM or at idle.
Three embodiment pump assemblies are disclosed. In the first embodiment the three-way valve spool is biased against a spring and is shifted by hydraulic pressure. The hydraulic pressure is determined by flow through a solenoid controlled valve. In the second and third embodiments, the three-way valve spool is biased against a spring by a proportional solenoid. In all embodiments, the ECM sends a current signal to a solenoid that is influenced by the difference between the output pressure of the high-pressure pump and desired output pressure.
Other objects and features of the invention will become apparent as the description proceeds, especially when taken in conjunction with the accompanying drawings illustrating the invention.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram of the hydraulic circuitry of a first embodiment pump assembly;
FIG. 2 is a sectional view, partially broken away, of valve components of the pump assembly of FIG. 1;
FIG. 3 is a flattened view of an interior cylindrical surface of a valving bore in the assembly;
FIG. 4 is a sectional view through an inlet throttle valve; and
FIGS. 5 and 6 are diagrams of hydraulic circuitry of second and third embodiment pump assemblies.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
First embodiment pump assembly 10 is a component of an internal combustion engine, typically a diesel engine, and provides high-pressure liquid, typically engine oil, for actuating fuel injectors for the engine. The assembly may also provide high-pressure liquid for actuating mechanisms for intake and exhaust valves or for other devices.
My U.S. Pat. No. 6,460,510 discloses a diesel engine with a pump assembly for hydraulically actuated fuel injectors which is related to assembly 10 . The disclosure of U.S. Pat. No. 6,460,510 is incorporated herein by reference, in its entirety.
The diesel engine includes a low-pressure oil pump 12 which draws oil from sump 14 and flows the oil through low-pressure line 16 to engine bearings and cooling jets. The fuel injectors for the engine (not illustrated) are actuated by high-pressure engine oil supplied by assembly 10 through high-pressure outlet passage 18 .
Assembly 10 includes hydraulically actuated inlet throttle valve 20 and variable output high-pressure pump 22 . The pump may be identical to the pump disclosed in U.S. Pat. No. 6,460,510. Pump 22 is rotated by the engine. Branch low-pressure line 24 extends from line 16 to the inlet port of inlet throttle valve 20 . Inlet passage 26 extends from the outlet port of the inlet throttle valve to the inlet port of pump 22 . High-pressure outlet passage 18 is connected to the outlet port of pump 22 .
Inlet throttle valve 20 is illustrated in FIG. 4 . Valve 20 includes a body 28 , which may be part of the body of high-pressure pump 22 . Bore or passage 30 extends into body 28 to closed end 32 . Low-pressure line 24 extends to oil inlet port 34 at the open end of bore 30 . Inlet passage 26 extends to oil outlet port 36 which surrounds the bore 30 between the open and closed ends of the bore.
Hollow, cylindrical valving spool 38 has a close sliding fit in the bore permitting movement of the spool along the bore. Outer spool end 40 is open and inner piston end 42 is closed to form a piston. Cylindrical wall 44 extends between ends 40 and 42 . Spring 46 is confined between retainer sleeve 48 at the open end of the bore and the piston end 42 of the spool to bias the spool toward closed end 32 of the bore. Locating post 50 extends inwardly from the closed end of, the spool to prevent the spool end from bottoming on the end of the bore and to define a hydraulic chamber 52 between piston end 42 and bore end 32 . Chamber port 54 permits flow of oil into and from chamber 52 .
A number of flow openings 56 extend through cylindrical wall 44 . When the spool is in the full open position as shown in FIG. 4 the openings provide a large flow area communicating ports 34 and 36 for maximum flow of low-pressure oil to pump 22 . High-pressure oil flowed into chamber 52 , moves the spool away from closed end 32 , against spring 46 and the inlet pressure of pump 12 , and moves the flow openings past the oil outlet port to reduce the flow area through the inlet throttle valve and correspondingly reduce the volume of oil flowed to high-pressure pump 22 .
Drain port 58 extends through body 28 to bore 30 . When the spool is in the full open position, as shown in FIG. 4, wall 44 overlies port 58 and the piston end 42 is between the port and bore closed end 32 . As oil in chamber 52 moves the spool away from the full open position the piston uncovers port 58 prior to engagement of the spool outer end 40 against retainer 48 . When the piston uncovers the drain port the high-pressure oil in chamber 52 is flowed directly to sump 14 to stop closing movement of the spool and prevent contact between the spool end 40 and retainer 48 . In this way, rapid movement of the spool toward the closed position by the high-pressure oil in chamber 52 is automatically slowed and stopped to prevent mechanical engagement between the spool and retainer. The drain port 58 forms a hydraulic stop, rather than mechanical stop, to cushion closing movement of the spool and prevent damage to the inlet throttle valve because of mechanical engagement between the spool and the retainer.
Port 34 opens into the interior of spool 38 so that the pressure of inlet oil in line 24 cooperates with spring 46 to bias the spool toward the open position. When chamber 52 is connected to the sump the inlet oil pressure and the spring rapidly open the valve. The flow area of the inlet throttle valve, and consequently the volume of low-pressure inlet oil flowed through passage 26 to pump 22 , is determined by the position of spool 38 in bore 30 .
Regulator valve 60 includes pilot relief valve 62 and main stage, three-way valve 64 . High-pressure branch passage or line 66 extends from passage 18 through opening 68 of valve 60 to restriction 70 . Passage or line 72 extends from the restriction to one end of pilot relief valve 62 . Passage or line 74 extends from line 72 to the inlet port of valve 62 and to one end of main stage three-way valve 64 . The other end of valve 64 is connected to line 66 .
Valve 64 includes a high-pressure inlet port 76 connected to line 66 , a drain port 78 connected to sump 14 through line 80 and a work port 82 connected directly to hydraulic chamber 52 in inlet throttle valve 20 through line 84 . Drain port 58 in inlet throttle valve 20 is connected to sump 14 through lines 59 and 80 .
Valve 64 has a valving spool 86 ,moveable between first and second positions shown in FIG. 1 and an intermediate null position shown in FIG. 2 . In the first position work port 82 is connected to drain port 78 to vent hydraulic or pressure chamber 52 in inlet throttle valve 20 directly to the sump and inlet port 76 is closed. In the second position drain port 78 is closed and the inlet port 76 is connected to work port 82 to flow high-pressure oil from passage 18 directly to the pressure chamber in the inlet throttle valve. The full output pressure acts on the inlet throttle valve spool to shift the spool toward the closed position against spring 46 and inlet pressure.
Spring 88 and the pressure of oil in line 74 downstream of restriction 70 , bias spool 86 toward the first position, as indicated in FIG. 1 . High-pressure fluid in line 66 biases the spool toward the second position. Both ends of the spool have the same area so that when there is no pressure drop across restriction 70 , spring 88 holds the spool in the first position, chamber 52 is vented to sump and the inlet throttle valve is open. When the pressure in line 74 is reduced by opening valve 62 to flow fluid in line 74 to sump, there is a pressure drop across restriction 70 and the pressure in line 66 shifts spool 86 toward the second position.
Pilot relief valve 62 includes solenoid 90 which is actuated by a current signal from the ECM. The valve includes a spool or pin 92 that is acted upon by the pressure of oil in line 72 to open the valve. The solenoid, in response to the signal from the ECM, biases the spool toward a closed position as illustrated.
The regulator valve 60 includes inlet opening 68 in line 28 , drain opening 94 in drain line 80 leading to sump 14 , and work opening 96 in line 84 leading to the inlet throttle valve 20 .
Assembly 10 includes a conventional high-pressure mechanical relief valve 98 that opens in response to transient over pressure in passage 18 to flow high-pressure oil directly to sump 14 and reduce the over-pressure. The assembly also includes a conventional makeup check valve 100 . Valve 100 permits flow of makeup oil into the high-pressure passage when the engine is shut off and cools.
FIG. 2 is a sectional view through regulator valve 60 . The valve has a body 102 housing valves 62 and 64 . Body 102 has a stepped cylindrical recess 104 extending into one side of the body with the port end 106 of the recess communicating with inlet port 76 . Radial passage 108 extends from the recess to work port 82 and radial passage 110 extends from the recess to drain port 78 . Hollow, generally cylindrical body 112 is threaded into recess 104 .
Solenoid 90 is mounted on the outer end of body 102 , outside of body 112 . The solenoid includes coil 114 , which surrounds armature 115 . The armature engages rod 116 which is slideably mounted in solenoid insert 118 .
Valve insert 120 is mounted in recess 104 in body 102 and defines a cylindrical valving bore 122 extending from the port end 106 of the recess 104 to cap 124 confined between inserts 118 and 120 . The cap closes the end of bore 122 adjacent the solenoid. A small diameter valving passage 126 extends through cap 124 to communicate bore 122 with chamber 128 formed in solenoid insert 118 . Passage 130 communicates chamber 128 with cylindrical chamber 132 surrounding insert 120 and in flow communication with passage 110 leading to drain port 78 .
Cap 124 slideably supports spool or pin 92 of valve 62 . The pin is held between rod 116 and one end of valving passage 126 . The pin is larger than passage 126 . Energization of solenoid 90 by a current signal from the ECM biases the armature 115 against rod 116 and the rod against pin 92 to bias the pin toward the cap. The pressure of the oil in valving passage 122 biases the pin in the opposite direction.
Hollow cylindrical valve spool 86 is slideably fitted in bore 122 and includes an open end adjacent cap 124 and piston 134 adjacent port end 106 . Restriction or bleed opening 70 extends through piston 134 to the interior of the spool. The spool is located in bore 122 between cap 124 and the inner end of cylindrical stop 136 fitted in the end of bore 122 adjacent port 76 . Spring 88 is confined between cap 124 and an interior step in spool 86 to bias the spool toward stop 136 .
Narrow, cylindrical valving land 138 extends around the end of spool 86 at piston 134 . Land 138 extends from the piston to a circumferential recess 140 formed in the spool and has a close sliding fit in bore 122 . One or more openings 142 extend through insert 120 to communicate recess 140 with chamber 132 at all times.
Four like, small diameter cylindrical valving passages 144 a , 144 b , 144 c and 144 d extend through insert 120 and open into bore 122 a short distance outwardly from stop 136 . Passages 144 open into chamber 146 and passage 108 leading to work port 82 . The passages 144 are spaced apart 90 degrees from each other around the wall of bore 122 and are spaced axially or offset a short distance along the bore as illustrated in FIG. 3 . Flow passages 144 a and 144 c are diametrically opposed and in line with each other in bore 122 . Likewise, passages 144 b and 144 d are diametrically opposed and in line with each other. Passages 144 a and 144 c are axially offset from passages 144 b and 144 d in bore 122 .
The bore 122 may have a diameter of 0.250 inches with valving passages 144 having diameters of 0.047 inches. The centers of passages 144 a and 144 c are axially spaced from the centers of passages 144 b and 144 d by a distance 148 of 0.035 inches so that the passages 144 are located within a circumferential band 150 extending around bore 122 and having a width 152 of 0.082 inches. Valving land 138 on spool 86 has a width of 0.076 inches so that when the spool is in the null position shown in FIG. 2, the land overlies passages 144 with an underlap of approximately 0.0015 inches at passages 144 a and 144 c and an underlap of 0.0045 inches at passages 144 b and 144 d . When the spool in the null position, flow through underlapped passages 144 a and 144 c equals flow through underlapped passages 144 b and 144 d . Because the pressure drop across passages 144 a and 144 c on the high-pressure side of piston 134 is greater than the pressure drop across passages 144 b and 144 d on the low pressure side of piston 134 , passages 144 a and 144 c are underlapped less than passages 144 b and 144 d . The underlaps shown are for a null position at high output pressure. The null position for a reduced output pressure would have a larger underlap at passages 144 a and 144 c and a smaller underlap at passages 144 b and 144 d.
The small diameters of passages 144 means that the flow areas through the passages increases and decreases relatively slowly as an edge of the valving land 138 moves across the passages, thus providing relatively gradual increase of high-pressure flow through the passages to the inlet throttle valve 20 during opening. Slow opening of the passages improves the stability of inlet throttle valve. Large passages having a diameter equal to the full width of band 150 would increase and decrease the flow area undesirably rapidly as land 138 moves across the passages.
The pressure of oil on the high-pressure side of piston 134 may be as high as 4,060 pounds per square inch. When the valving spool is moved toward cap 124 against spring 88 and partially opens passages 144 , the oil exerts radial pressure on exposed portions of land 138 . Since the diametrically opposed passages 144 are in line with each other, radial forces are balanced. For instance, movement of spool 86 to the right of the position shown in FIG. 2 opens passages 144 a and 144 c and the high-pressure oil exerts equal and opposite forces on the portions of the valving land overlying the passages. Thus, there are insignificant radial forces acting on spool 86 , with minimum friction and spool/bore wear.
Land 138 underlaps passages 144 and substantially closes the passages when in the null position. In addition, passages 144 a and 144 c may be smaller in diameter that passages 144 b and 144 d to improve the gradual change of flow area from outlet pressure to work port 82 relative to gradual change of flow area from the work port 82 to sump. If desired, the land may have a width sufficient to completely cover the passages, so that the land completely closes the passages when in the null position.
The operation of pump assembly 10 will now be described.
Before startup of the engine main stage valve 64 is in the first position indicated in FIG. 1 with spring 88 holding spool 86 against stop 136 and passage 108 is connected to passage 110 . With the hydraulic chamber 52 of the inlet throttle valve connected to the sump through passages 108 and 110 , spring 46 holds the inlet throttle valve spool in the full open position for maximum flow of inlet oil to the high-pressure pump and rapid increase of pressure in outlet passage 18 .
When the engine has been started, the pressure in outlet passage 18 is typically less than the desired pressure in the passage so that the ECM sends a high current signal to solenoid 90 to bias pin 92 against passage 126 and close the passage. In the absence of flow through the passage, there is no flow through restriction 70 , no pressure drop across piston 134 and no force exerted on the piston to move spool 86 away from stop 136 . Spring 88 continues to hold spool 86 against the stop. Valving land 138 remains positioned to the left of passages 144 preventing flow of high-pressure outlet oil through the passages and to the inlet throttle valve. The inlet valve stays fully open and pressure in passage 18 rapidly increases.
As pressure builds in passage 18 the difference between the actual output pressure and the desired output pressure decreases and the ECM signal to solenoid 90 decreases, reducing the force exerted on pin 92 by the solenoid. The reduction of this force, together with the increase of pressure in bore 122 moves pin 92 away from cap 124 sufficiently to permit flow past the pin to passages 130 and 110 and to the sump. High-pressure fluid flows into the spool through restriction 70 in piston 134 . The pressure drop across the piston biases the piston to the right, as shown in FIG. 2, away from stop 136 against the force exerted by spring 88 . As land 138 moves away from stop 136 it gradually closes passages 144 . This occurs until the land is in the null position, the output pressure in passage 18 is equal to the desired pressure and the inlet throttle valve spool 38 has reached a pressure balance position.
When the pressure in passage 18 is greater than the desired pressure the ECM signal is decreased, further increasing flow through passage 126 and increasing the pressure on piston 134 to shift spool 86 away from stop 136 . Further movement of the spool moves land 138 past passages 144 to open the passages to flow of high-pressure oil directly from the output passage 18 to hydraulic chamber 52 in the inlet throttle valve, increase the pressure in the chamber and shift the inlet throttle valve spool 38 toward the partially closed position. Venting of the inlet throttle valve to sump is cut off.
As the pressure in passage 18 approaches the desired pressure, the signals to solenoid 52 either increase or decrease until the desired pressure is achieved, the inlet throttle valve spool has reached a pressure balance position and land 138 is in the null position shown in FIG. 2 to substantially or fully close passages 112 to the pressure chamber in the inlet throttle valve.
When desired output pressure changes, the ECM signal changes and the spools of valves 20 and 64 modulate with spool 86 returning to the null position and inlet throttle valve spool 38 stabilizing at a new equilibrium position.
Full output pressure in passage 18 is applied directly to the inlet throttle spool to shift the spool and close the valve. Applying full output pressure to the inlet throttle valve spool is important when the engine is operating at a rotational low speed and the full output pressure is relatively low, yet sufficiently high to rapidly shift the inlet throttle spool 92 against spring 46 and inlet pressure in response to signals received from the ECM. For instance, pump assembly 10 may be mounted on a diesel engine used in a light truck or a passenger vehicle where the rotational speed of the engine is rapidly and frequently increased and decreased through an operating range extending from idle to a high speed maximum and where the output pressure at low speed is considerably less than the output pressure at high speed. Regulator valve 60 utilizes available output pressure to close the inlet throttle valve spool quickly and stably. The hydraulic stop for spool 38 provided by drain port 58 prevents output pressure from moving the spool into contact with stop 136 . Valve 60 allows the inlet throttle valve spring and inlet pressure to shift the spool rapidly to the open position by directly venting the pressure chamber in the valve to the sump. Valve 60 permits rapid response of the inlet throttle valve to changes in the ECM signal over the RPM range of the engine and improves inlet throttle valve stability and fuel economy.
At the equilibrium or null position of valve 60 , shown in FIG. 2 and indicated in FIG. 3, land 138 is positioned over and underlaps the four valving passages 144 . Small portions of passages 144 a and 144 c on the high-pressure side of land 138 are open and small portions of passages 144 b and 144 d on the low-pressure side of land 138 are open. The underlap shown in FIG. 3 is exaggerated for purposes of illustration. The open portions of passages 144 a and 144 c may be 0.0015 inches wide and the open portions of passages 144 b and 144 c may be 0.0045 inches wide.
When the land 138 is in the null position the uncovered or untapped portions of passages 144 a and 144 c communicate with the small area untapped portions of passages 144 b and 144 d through chamber 146 . The untapped openings permit limited flow of high-pressure oil at output pressure from passage 18 through the untapped portions of passages 144 a and 144 c , chamber 146 , untapped portions of passages 144 b and 144 d , and to sump 14 . The small area underlap bleed passages desensitize inlet throttle valve spool 38 to pressure spikes in outlet passage 18 . The full force of the pressure spike is not transmitted to the inlet throttle valve. The bleed passages communicate port 76 to the sump to dampen pressure oscillation of the inlet throttle valve spool in response to pressure spikes and improve stability of the inlet throttle valve.
Regulator valve 60 does not respond to overpressures in passage 18 by dumping high-pressure oil directly to the sump with consequent energy loss when the oil is depressurized. Rather, an overpressure insufficient to open valve 98 shifts main stage valve 64 to flow high-pressure fluid through line 84 to the inlet throttle valve and shift the valve toward the closed position and reduce input to high-pressure pump 22 . Reduced input reduces the volume of oil pumped into passage 18 and reduces output pressure. Underlapping of openings 144 by valving land 138 provides limited direct flow to the sump to reduce instability of the inlet throttle valve.
Alternate connection of the inlet throttle valve chamber 52 directly to output pressure or to the sump permits rapid flow of oil into and out of the chamber to move the inlet throttle valve spool rapidly in response to signals from the ECM and reduces the time required to increase or decrease the pressure in the outlet passage 18 to match the desired output pressure as determined by the ECM. Rapid output pressure response is particularly valuable in diesel engines where the speed of the engine may quickly vary from idle, with a low output pressure of about 360 PSI to maximum engine speed with output pressure as great as 4,060 PSI.
FIG. 5 illustrates a second embodiment pump assembly 200 which is identical to assembly 10 except that the assembly uses a regulator valve 202 different from regulator valve 60 . Other components of pump assembly 200 are identical to the prior described components of assembly 10 and are identified in FIG. 5 by the same reference numbers used in FIG. 1 .
Regulator valve 202 includes a single solenoid three-way valve 204 having inlet port 206 , drain or exhaust port 208 and work port 210 . These ports are respectively connected to regulator valve inlet opening 212 , drain opening 214 and work opening 216 , corresponding to openings 68 , 94 and 96 of regulator valve 60 .
Valve 204 includes a valving spool (not illustrated) having a pressure piston with a cylindrical valving land moveable along a valving bore as in valve 38 . The piston is imperforate. Four cylindrical valving passages open into the bore and are arranged in opposed, spaced pairs, like passages 144 previously described. The valving land is underlapped with regard to the valving passages, as previously described. If desired, the land may completely cover the valving passages.
Spring 218 biases the spool toward a first position, previously described, where work port 210 is connected to drain port 208 and the pressure chamber 52 in inlet throttle valve 20 is connected to the sump through lines 84 , valve 204 and line 80 .
The valve has a second position, previously described, where the inlet port 206 is connected to work port 210 to flow high-pressure oil from passage 18 directly to the pressure chamber of the inlet throttle valve through line 84 .
Valve 204 has a null position, as previously described, with the spool land underlapping or closing the valving passages. The position is the same as indicated in FIG. 3 and previously described. The solenoid force biases the spool against the force of spring 218 to shift the spool in the valve bore relative to the small valving passages like passages 144 described previously.
The valve 204 includes a fast acting proportional solenoid 220 having an armature engaging the spool. The solenoid biases the spool toward the second position. The coil of solenoid 220 receives a steady state current signal from the engine ECM to maintain the spool in a null position. Current is increased or decreased proportional to the difference between the desired output pressure in line 18 , as calculated by the ECM, and the actual outlet pressure in line 18 . This signal generates a force biasing the spool toward the second valve position. When the solenoid force is greater than the spring force the spool shifts toward the second position and high-pressure oil from line 18 is flowed directly to the inlet throttle valve to rapidly move the inlet throttle valve toward the closed position. When the solenoid force is less than the spring force the spool shifts toward the first position and the inlet throttle valve opens.
In valve 204 , the spool has a central piston carrying the valving land and end pistons spaced to either side of the central piston. The outer ends of the valving bore are connected to sump 14 through passage 80 and are at the same low-pressure. Both ends of the spool have the same area. This assures that the movement of the spool along the valving bore is influenced by spring 218 and solenoid 220 and is not influenced by pressure differentials at the ends of the spool.
FIG. 6 illustrates a third embodiment pump assembly 300 which is identical to assembly 200 except that assembly 300 uses a regulator valve 302 different from regulator valve 202 . Other components of pump assembly 300 are identical to the prior described components of assembly 10 and are identified in FIG. 6 by the same reference numbers used in FIG. 1 .
Regulator valve 302 includes a single solenoid three-way valve 304 having inlet port 306 , drain or exhaust port 308 and work port 310 like ports 206 , 208 and 210 . These ports are respectively connected to regulator valve inlet opening 312 , drain opening 314 and work opening 316 , like openings 212 , 214 and 216 .
Valve 304 includes a valving spool (not illustrated) having a pressure piston with a cylindrical valving land moveable along a valve bore, as in valve 204 . The piston is imperforate. Four cylindrical valving passages open into the bore and are arranged in opposed, spaced pairs like passages 144 previously described. The valving land is underlapped with regard to the passages, as also previously described. If desired, the land may completely cover the valving passages.
Valve 304 includes a fast acting proportional solenoid 320 which engages the spool. Solenoid 320 is like solenoid 220 , previously described. The solenoid biases the spool toward a first position in which inlet port 306 is closed and work port 310 is connected to drain port 308 so that the spring of the inlet throttle valve 20 holds the inlet throttle valve in a full open position.
Spring 318 of valve 304 biases the spool toward a second position where work port 310 is connected to inlet port 306 and drain port 308 is closed. When the spool is in this position high-pressure oil from outlet passage 18 is flowed directly to inlet throttle valve 20 to close the inlet throttle valve and reduce inlet flow to pump 22 to minimum or idle flow.
Valve 304 has a null position in which the spool land underlaps or closes the valving passages. This position is the same as indicated in FIG. 3 and previously described.
In valve 304 the ends of the valving bore are connected to sump 14 through passage 80 and are at the same low pressure. The spool includes end pistons having the same area and assuring that movement of the spool along the valving bore is influenced by spring 318 and solenoid 320 and is not influenced by pressure differentials at the ends of the spool.
The coil of solenoid 320 receives a steady state current signal from the engine ECM to maintain the spool in a null position. Current is increased when the output pressure is lower than desired to shift valve 304 toward the first position and open the inlet throttle valve to increase flow to pump 22 and increase output pressure. Conversely, current is decreased when output pressure is greater than desired to shift valve 304 toward the second position, close valve 20 and increase output pressure.
The spool of valve 304 is moved to a null position when the output pressure equals the desired output pressure, as previously described and solenoid 320 holds the spool against the spring with the piston underlapping or closing the passages opening into the valving bore.
In the third embodiment of FIG. 6, failure of solenoid 320 allows spring 318 to shift the three-way valve spool to the second position and connect inlet port 306 to work port 310 . High-pressure output oil is supplied directly to the inlet throttle valve, shifting the valve to the closed position and reducing inlet flow to pump 22 to an idle level. Pump assembly 300 facilitates rapid shut down of the engine in the event the solenoid 320 fails.
In the embodiment shown in FIG. 6, spring 318 can be replaced by a piston acted upon by outlet pressure from passage 18 . The solenoid force biases the spool against the force of outlet pressure acting on the piston to shift the valve spool in the valve bore relative to the small valving passages like passages 144 described previously. In this case, outlet pressure is proportional to current to solenoid 320 . Current is increased or decreased proportional to the difference between the desired output pressure in line 18 , as calculated by the ECM, and the actual outlet pressure in line 18 .
While I have illustrated and described a preferred embodiment of my invention, it is understood that this is capable of modification, and I therefore do not wish to be limited to the precise details set forth, but desire to avail myself of such changes and alterations as fall within the purview of the following claims. | A pump assembly and method for an internal combustion engine includes a high-pressure pump for pressurizing oil used to actuate fuel injectors or other devices, a hydraulic inlet throttle valve, a three-way valve for alternatively connecting the inlet throttle valve to output pressure or to the sump and a solenoid responsive to signals from an electronic control module for shifting the three-way valve. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority under 35 U.S.C. § 119 to United States Provisional Application Ser. No. 60/596,523, filed Sep. 30, 2005, incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of Invention
[0003] The present invention relates generally to the field of oilfield exploration, production, and testing, and more specifically to protection of pump components used in such ventures.
[0004] 2, Related Art
[0005] Electrical submersible pumps (ESPs) are used for artificial lifting of fluid from a well or reservoir. An ESP typically comprises an electrical submersible motor, a seal section (sometimes referred to in the art as a protector) which functions to equalize the pressure between the inside of the system and the outside of the system and also acts as a reservoir for compensating the internal oil expansion from the motor; and a pump having one or more pump stages inside a housing. The protector may be formed of metal, as in a bellows device, or an elastomer, in which case the protector is sometimes referred to as a protector bag.
[0006] A variety of production fluids are pumped from subterranean environments. Different types of submersible pumping systems may be disposed in production fluid deposits at subterranean locations to pump the desired fluids to the surface of the earth. For example, in producing petroleum and other useful fluids from production wells, it is generally known to provide a submersible pumping system for raising the fluids collected in a well. Production fluids (e.g., petroleum) enter a wellbore drilled adjacent a production formation. Fluids contained in the formation collect in the wellbore and are raised by the submersible pumping system to a collection point at or above the surface of the earth.
[0007] In addition to motors, pump sections, and seals, a typical submersible pumping system may further comprise a variety of additional components, such as a connector used to connect the submersible pumping system to a deployment system. Conventional deployment systems include production tubing, cable and coiled tubing. Additionally, power is supplied to the submersible electric motor via a power cable that runs through or along the deployment system.
[0008] Often, the subterranean environment (specifically the well fluid) and fluids that are injected from the surface into the wellbore (such as acid treatments) contain corrosive compounds that may include carbon dioxide, hydrogen sulfide, and brine water. These corrosive agents can be detrimental to components of the submersible pumping system, particularly to internal electric motor components, such as copper windings and bronze bearings. Moreover, irrespective of whether or not the fluid is corrosive, if the fluid enters the motor and mixes with the motor oil, the fluid can degrade the dielectric properties of the motor oil and the insulating materials of the motor components. Accordingly, it is highly desirable to keep these external fluids out of the internal motor fluid and components of the motor.
[0009] Submersible electric motors are difficult to protect from corrosive agents and external fluids because of their design requirements that allow use in the subterranean environment. A typical submersible motor is internally filled with a fluid, such as a dielectric oil, that facilitates cooling and lubrication of the motor during operation. As the motor operates, however, heat is generated, which, in turn, heats the internal motor fluid causing expansion of the oil. Conversely, the motor cools and the motor fluid contracts when the submersible pumping system is not being used.
[0010] In many applications, submersible electric motors are subject to considerable temperature variations due to the subterranean environment, injected fluids, and other internal and external factors. These temperature variations may cause undesirable fluid expansion and contraction and damage to the motor components. For example, the high temperatures common to subterranean environments may cause the motor fluid to expand excessively and cause leakage and other mechanical damage to the motor components. These high temperatures also may destroy or weaken the seals, insulating materials, and other components of the submersible pumping system. Similarly, undesirable fluid expansion and motor damage can also result from the injection of high-temperature fluids, such as steam, into the submersible pumping system.
[0011] Accordingly, this type of submersible motor benefits from a motor fluid expansion system able to accommodate the expanding and contracting motor fluid. The internal pressure of the motor must be allowed to equalize or at least substantially equalize with the surrounding pressure found within the wellbore. As a result, it becomes difficult to prevent the ingress of external fluids into the motor fluid and internal motor components.
[0012] Numerous types of motor protectors have been designed and used in isolating submersible motors while permitting expansion and contraction of the internal motor fluid. A variety of elastomeric bladders alone or in combination with labyrinth sections have been used as a barrier between the well fluid and the motor fluid. For example, expandable elastomeric bags or bladders have been used in series to prevent mixing of wellbore fluid with motor fluid while permitting expansion and contraction of the motor fluid. Another type of protector employs a bellows, such as a one-piece annular bellows.
[0013] As may thus be seen, there remains a need in the natural resources exploration and production field for improving reliability and life of motor protectors. The present invention is directed at providing such protectors.
SUMMARY OF THE INVENTION
[0014] In accordance with the present invention, apparatus, systems and methods are described that reduce or overcome problems in previously known apparatus and systems.
[0015] A first aspect of the invention are apparatus comprising:
(a) a protector body comprising a material allowing expansion and contraction of an internal fluid, and serving as a barrier between fluids external of the protector body and the internal fluid, the protector body having first and second ends, at least one of the first and second ends adapted to connect the protector body to another pump component, the second end optionally adapted to connect the protector body to a motor seal; (b) the protector body further comprising structural features permitting facile cleanout and reuse of the protector body.
[0018] Various apparatus embodiments of the present invention may be employed in systems and methods for protecting a motor of a pump exposed to a subterranean environment, for example a submersible pumping system. Apparatus of the invention in these embodiments may be termed motor protectors. Apparatus of the invention may be used to protect motors and other components in any combination. As used herein the phrase “structural features permitting facile cleanout” means that in certain apparatus embodiments, the body comprises an assembly of two or more pieces that may be disassembled and cleaned without great difficulty, as compared with conventional single piece bellows apparatus. Certain multi-piece bellows assemblies of the invention may be dismantled and cleaned in a simpler fashion than one-piece bellows. For instance, the multiple-piece bellows may be cleaned with by steam cleaning, or other methods including but not limited to chemical cleaning, ultrasonic cleaning, baking, blasting, and combinations thereof to significantly reduce the cost for the bellows cleaning processes. When mentioning apparatus of the invention comprising an assembly of two or more pieces or components, the pieces or components may be arranged in any number of ways within the invention, such as concentric bellows (inner and outer bellows); one outer bellows and two inner bellows in series, each of shorter length than the outer bellows; one outer bellows and three shorter inner bellows in series, one bellows fastened to another component, and the like. Conventional apparatus may be used in combination with apparatus of the invention, for example in series or parallel. Apparatus of the invention, whether the same or different, may also be used in series or in parallel.
[0019] Apparatus of the invention may comprise materials able to withstand temperatures, pressures, temperature and pressure variations, and a variety of organic, inorganic and mixtures of inorganic and organic compositions. Suitable materials for the body and ends of apparatus of the invention include metals, such as Hastelloy C, an Inconel, a heat treated stainless steel, or titanium, combinations and composites of metals and polymeric materials, and layered and coated versions of metals, wherein individual layers and coatings may be the same or different in composition and thickness. Bellows assemblies may be constructed from suitable materials that are resistant (e.g., impermeable) to the hot and corrosive environment within the wellbore, such as Kalrez, Chemrez, or Inconel 625. If a polymeric material is used, the polymeric material may be a composite polymeric material, such as, but not limited to, polymeric materials having fillers, plasticizers, and fibers therein. The polymeric material may comprise one or more thermoplastic polymers, one or more thermoset polymers, one or more elastomers, and combinations thereof. Apparatus within the invention include those wherein the apparatus may or may not be integral with the motor. Each of these motor protectors also may have various moisture absorbents, filters, particle shedders and various conventional motor protector components.
[0020] Another aspect of the invention are pumping systems which may be used in natural resources exploration, production, and/or testing, one pumping system comprising:
(a) one or more pump components; and (b) one or more apparatus of the first aspect of the invention connected to the pump component.
[0023] Yet another aspect of the invention are methods of protecting pump components, for example during activities such as raising hydrocarbons from an underground or undersea reservoir, one method comprising:
(a) selecting one or more pumping systems of the invention; and (b) using the pumping system in an oilfield operation, the oilfield operation exposing the pumping system to a wellbore environment.
[0026] Methods of the invention may include, but are not limited to, running one or more oilfield tools into the wellbore prior to, during, or after using the pumping system. Methods of the invention also include those wherein the pumping system is used to raise a hydrocarbon from a reservoir, or circulate either a hydrocarbon or other composition in at least a portion of a well bore, and/or retrieve an oilfield element from the wellbore. The wellbore environment during any of these methods may stay substantially the same or vary during the oilfield operation.
[0027] The various aspects of the invention will become more apparent upon review of the brief description of the drawings, the detailed description of the invention, and the claims that follow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The manner in which the objectives of the invention and other desirable characteristics can be obtained is explained in the following description and attached drawings in which:
[0029] FIG. 1 is a front elevation view of a prior art electrical submersible pump disposed within a wellbore;
[0030] FIG. 2 is a schematic cross-section view through the longitudinal axis of a two-piece protector apparatus in accordance with the invention;
[0031] FIG. 3 is a schematic cross-section side elevation view through the longitudinal axis of a system of the invention having two of the two-piece protector apparatus of FIG. 2 installed therein; and
[0032] FIG. 4 is a more detailed schematic cross-sectional view of a portion of the system of FIG. 3 .
[0033] It is to be noted, however, that the appended drawings are not to scale and illustrate only typical embodiments of this invention, and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
DETAILED DESCRIPTION
[0034] In the following description, numerous details are set forth to provide an understanding of the present invention. However, it will be understood by those skilled in the art that the present invention may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.
[0035] All phrases, derivations, collocations and multiword expressions used herein, in particular in the claims that follow, are expressly not limited to nouns and verbs. It is apparent that meanings are not just expressed by nouns and verbs or single words. Languages use a variety of ways to express content. The existence of inventive concepts and the ways in which these are expressed varies in language-cultures. For example, many lexicalized compounds in Germanic languages are often expressed as adjective-noun combinations, noun-preposition-noun combinations or derivations in Romanic languages. The possibility to include phrases, derivations and collocations in the claims is essential for high-quality patents, making it possible to reduce expressions to their conceptual content, and all possible conceptual combinations of words that are compatible with such content (either within a language or across languages) are intended to be included in the used phrases.
[0036] The invention describes apparatus, systems incorporating same, and methods of using the apparatus and systems in oilfield applications, including exploration, testing, drilling, and production activities. As used herein the term “oilfield” includes land based (surface and sub-surface) and sub-seabed applications. The term “oilfield” as used herein includes hydrocarbon oil and gas reservoirs, and formations or portions of formations where hydrocarbon oil and gas are expected but may ultimately only contain water, brine, or some other composition. A typical use of apparatus and systems of the invention will be in wellbore applications, such as pumping fluids from or into wellbores.
[0037] Various apparatus embodiments of the present invention may be employed in systems and methods for protecting a motor of a pump exposed to a subterranean environment, for example a submersible pumping system. Apparatus of the invention in these embodiments may be termed motor protectors. Apparatus of the invention may be used to protect motors and other components in any combination. In certain apparatus embodiments, the body comprises an assembly of two or more pieces that may be disassembled and cleaned without great difficulty, as compared with conventional single piece bellows apparatus. Certain multi-piece bellows assemblies of the invention may be dismantled and cleaned in a simpler fashion than one-piece bellows. For instance, the multiple-piece bellows may be cleaned with a commercial steam cleaner, or other methods including but not limited to chemical cleaning and ultrasonic cleaning to significantly reduce the cost for the bellows cleaning processes. When mentioning apparatus of the invention comprising an assembly of two or more pieces or components, the pieces or components may be arranged in any number of ways within the invention, such as concentric bellows (inner and outer bellows); one outer bellows and two inner bellows in series, each of shorter length than the outer bellows; one outer bellows and three shorter inner bellows in series, and the like. Conventional apparatus may be used in combination with apparatus of the invention, for example in series or parallel. Apparatus of the invention, whether the same or different, may also be used in series or in parallel.
[0038] Apparatus of the invention may comprise materials able to withstand temperatures, pressures, temperature and pressure variations, and a variety of organic, inorganic and mixtures of inorganic and organic compositions expected or unexpected in a wellbore. A “wellbore” may be any type of well, including, but not limited to, a producing well, a non-producing well, an injection well, a fluid disposal well, an experimental well, an exploratory well, and the like. Wellbores may be vertical, horizontal, deviated some angle between vertical and horizontal, and combinations thereof, for example a vertical well with a non-vertical component. Suitable materials for the body and ends of apparatus of the invention include metals, polymeric apparatus selected from natural and synthetic polymers, combinations and composites of metals and polymeric materials, and layered and coated versions of polymers and metals, wherein individual layers and coatings may be the same or different in composition and thickness. If a polymeric material is used, the polymeric material may be a composite polymeric material, such as, but not limited to, polymeric materials having fillers, plasticizers, and fibers therein. Apparatus within the invention include those wherein the apparatus may or may not be integral with the motor. Using metal bellows extends temperature operating limits far beyond those of polymeric bag-type protectors in extreme temperatures. In the case of gassy wells, metal apparatus may prevent gas from migrating through the apparatus and displacing the motor oil. Metals that are resistant to H 2 S and impermeable to gas may be employed in wellbores having harsh environments, i.e., high temperature and H 2 S, as well as high hydrocarbon gas content.
[0039] Apparatus and systems of the invention may thus be especially useful in steam flood injection operations, such as steam-assisted gravity drainage (SAGD) projects. As is known, conventional oil production is declining in Canada, but oil production from tar sands and other heavy oil sources using SAGD is increasing. In the SAGD process, two parallel, horizontal wells are drilled, steam is injected in the upper well, which is approximately 5 meters above the lower, producing wellbore. The injected steam rises in the formation and heats the oil (having a gravity of less than 10° API), which flows down to the producing wellbore by gravity drainage. Formerly, gas-lift was used to produce the SAGD wells, however, gas-lift requires high power (for compression) and there may be problems with instability due to the horizontal wellbores. Using an ESP, production is controlled. The produced emulsion is produced to the treating plant. By using the ESP, the pump intake pressure, and thus the flowing bottom-hole pressure can be reduced. The lower reservoir pressure helps to optimize the steam coverage and use in the reservoir. The ESP may be that known under the trade designation “Hotline” 550, available from Schlumberger, Houston, Tex., rated for 218° C. (425° F.). Production rate presently ranges from about 300-1000 M3/Day, or 1900-6300 B/D. The pumps are landed in the horizontal portion of the wellbore, and experience a rapid temperature increase. The temperature at the surface may be very low. The wells produce approximately 1% sand. The ESP may use a variable speed drive. Challenges presented include the high temperature in the reservoir, sand, temperature cycles, setting the pump in the horizontal wellbore, and maintaining clean the dielectric motor oil. Despite the use of advanced insulation, all steel stators, high-temperature di-electric motor cooling oil, elastomers able to withstand up to 550° F., high temperature pothole, and metal bellows having seal and bellows sections, as taught in assignee's U.S. Pat. No. 6,688,860, the search for improvements remains an active area. One area in need of improvement is the ability to clean the motor protector in a timely and cost effective manner. The apparatus and systems of the present invention address this need.
[0040] Referring generally to FIG. 1 , an exemplary pumping system 10 , such as a submersible pumping system, is illustrated. Pumping system 10 may comprise a variety of components depending on the particular application or environment in which it is used. Typically, system 10 has at least a submersible pump 12 , a motor 14 , and a motor protector 16 . Motor 14 may comprise any electric motor or other motor that requires volume compensation based on, for instance, the thermal expansion and/or contraction of internal fluid. Submersible pump 12 may be of a variety of types, e.g. a centrifugal pump, an axial flow pump, or a combination thereof. System 10 may also comprise a gearbox, as is known in the art.
[0041] In the illustrated embodiment, pumping system 10 is designed for deployment in a well 18 within a geological formation 20 containing desirable production fluids, such as petroleum. In a typical application, a wellbore 22 is drilled and lined with a wellbore casing 24 . Wellbore casing 24 typically has a plurality of openings 26 (e.g. perforations) through which production fluids may flow into wellbore 22 . While FIG. 1 illustrates a system in vertical orientation, this is merely for convenience. As previously explained, in SAGD production the wellbore section would be illustrated as horizontal.
[0042] Pumping system 10 is deployed in wellbore 22 by a deployment system 28 that may have a variety of forms and configurations. For example, deployment system may comprise tubing 30 connected to pump 12 by a connector 32 . Power is provided to submersible motor 14 via a power cable 34 . Motor 14 , in turn, powers centrifugal pump 12 , which draws production fluid in through a pump intake 36 and pumps the production fluid to the surface via tubing 30 .
[0043] It should be noted that the illustrated submersible pumping system 10 is merely an exemplary embodiment. Other components can be added to the system, and other deployment systems may be implemented. Additionally, the production fluids may be pumped to the surface through tubing 30 or through the annulus formed between deployment system 28 and wellbore casing 24 . In any of these configurations of submersible pumping system 10 , it is desirable to attain maximum protection and life of the motor fluid, the motor 14 and the motor protector 16 in accordance with the present invention.
[0044] In embodiments of the present invention, system 10 may have multiple sections of the motor protector 16 disposed about the motor 14 . As illustrated, system 10 comprises the pump 12 , motor 14 , and various motor protection components disposed in a housing. Pump 12 is rotatably coupled to the motor 14 via a shaft, which extends lengthwise through the housing (e.g., one or more housing sections coupled together). System 10 and the shaft may have multiple sections, which can be intercoupled via couplings and flanges. For example, the shaft may have couplings and an intermediate shaft section disposed between pump 12 and motor 14 .
[0045] Generally, conventional bellows protectors use an annular bellows (or in some cases two layers of bellows, or alternatively a small bellows inside a big bellows) to allow the shaft to pass through the center of the bellows. At one end of the annular bellows, the big and small bellows may be welded to an end plate, but may otherwise be free. At the other end, both the big and small bellows may be welded to a flange for installing the bellows onto another part of the protector during assembly, such as a protector seal section. In the flange, there are several holes for fluid communication. Accordingly, if some wellbore debris gets into such a one-piece bellows, it may be very difficult to clean.
[0046] Some embodiments of systems of the invention employ a multi-piece bellows (e.g., a two-piece bellows, or a single bellows with another component) that can be dismantled and cleaned, so the cleaning process may be much easier and less expensive. Moreover, the quality of bellows cleaning may be significantly enhanced to provide more reliable operation of the bellows downhole.
[0047] The present invention encompasses various ways using multi-piece bellows in a protector assembly. For example, the bellows can be designed into one, two, or more pieces depending on the actual cost and manufacturing capability. FIG. 2 illustrates in cross-section an embodiment 50 having a bellows that is in two pieces. One piece is an external bellows 51 , and another piece is an internal bellows 53 . Both bellows have upper and lower flanges so that the two bellows can be connected together to form an annular bellows. External bellows 51 is welded to an upper flange 55 and a lower flange 59 , while internal bellows 53 is welded to an upper flange 57 and a lower flange 61 . In some embodiments, like the embodiment illustrated in FIG. 2 , o-rings 63 and 65 provide seals between each pair of the flanges to be connected together. Lower flange 61 of internal bellows 53 has one or more fluid communication ports 67 , and flange 61 may serve as a male portion fitting into a female seat of a protector seal body 17 ( FIG. 4 ). The bellows assembly can thus be installed onto seal body 17 of the protector. Bolts 69 , 71 , 73 , and 74 , hold the flanges together, and an opening for a motor shat is illustrated at 77 .
[0048] FIG. 3 illustrates a cross-sectional view of embodiment 100 of the invention, and FIG. 4 illustrates, also in cross-section, more details of the two piece bellows installation of embodiment 100 . Illustrated is a pump 12 and a motor 14 , with the protector in this embodiment being in multiple bellows sections 16 a and 16 b, each having external/internal bellows construction as in embodiment 50 of FIG.2 . A seal section 15 for bellows section 16 a and a seal section 17 for bellows section 16 b are illustrate, as well as dielectric motor oil 54 . A third seal section 19 is provided in this embodiment. Pump shaft 11 is illustrated. Note that the construction as detailed in FIG. 4 allows easier disassembly than previously known apparatus and systems by virtue of multiple pieces: external bellows 51 may be detached from internal bellows 53 by simply unscrewing bolts 69 , 71 , 73 , and 75 .
[0049] Referring now to the operation of the bellows assembly illustrated by FIGS. 2, 3 and 4 , motor fluid 54 expands and contracts as motor 14 is activated and deactivated and as other temperature fluctuations affect the fluid volume. If motor fluid 54 expands, then bellows 51 and 53 expand accordingly. If motor fluid 54 contracts, then bellows 51 and 53 also contract. The spring force of the bellows ensures that motor fluid 54 is positively pressurized relative to the well fluid, regardless of whether motor fluid 54 has expanded or contracted (e.g., 10 psi, 25 psi, 50 psi or higher pressure differential). During or after submerging the systems of the invention, the system may release or inject oil in the motor to maintain the pressure of motor fluid 54 within a certain pressure range. Accordingly, external fluids (i.e., the well fluids) are continuously pressured away from the motor fluid of motor 14 to prevent undesirable corruption of the internal fluids and components of motor 14 . The foregoing pressure ensures that if leakage occurs, the leakage is directed outwardly from motor fluid 54 to the well fluid, rather than inwardly from the well fluid into motor fluid 54 (i.e., the typical undesirable leakage/corruption of motor fluid 54 ). The positive internal pressure generally provides a better environment for the system 10 . The positive pressure of motor fluid 54 provided by the bellows also may be used to periodically flush fluids through the bearings and seals to ensure that the bearings and seals are clean and operable.
[0050] Throughout the life of apparatus and systems of the invention, motor fluid tends to leak outwardly through the shaft seals and into the external fluids. By itself, this gradual leakage tends to decrease the pressure of motor fluid 54 . However, the bellows compensate for the leakage to maintain a certain positive pressure range within motor fluid 54 . In the embodiments illustrated in FIGS. 2, 3 , and 4 the bellows compensate by contracting (due to the spring force). In other embodiments, the bellows may compensate by expanding (also due to the spring force).
[0051] The bellows also may have various protection elements to extend their life and to ensure continuous protection of motor 14 . For example, a filter may be disposed between ports and the exterior of the bellows to filter out undesirable fluid elements and particulates in the well fluid prior to fluid communication with the exterior. A filter also may be provided adjacent the interior of the bellows to filter out motor shavings and particulates. If used, the filter may be positioned adjacent a moisture absorbent assembly between a motor cavity and the interior of the bellows. Accordingly, the filter may prevent solids from entering or otherwise interfering with the bellows, thereby ensuring that the bellows is able to expand and contract along with volume variations in the fluids.
[0052] A plurality of expansion and contraction stops also may be disposed about bellows 51 , 53 to prevent over and under extension and to prolong the life of the bellows. For example, a contraction stop may be disposed within the interior of either bellows to contact an end section and limit contraction of the bellows. An expansion stop also may be provided. Contraction and expansion stops may have various configurations depending on the material utilized for the apparatus and also depending on the pressures of motor fluid 54 and the well fluid. A housing 21 also may be disposed about the exterior of external bellows 51 to guide the bellows during contraction and expansion and to provide overall protection.
[0053] As discussed above, motor fluid 54 may be pressurized significantly prior to submersing the system 10 . As system 10 is submersed and activated in the downhole environment, the internal pressure of motor fluid 54 may rise and/or fall due to temperature changes, such as those provided by the activation and deactivation of motor 14 . Accordingly, various valves may be disposed within housing 21 to control the pressurization of motor fluid 54 and to maintain a suitable positive pressure range for motor fluid 54 . For example, a valve may be provided to release motor fluid 54 when the pressurization exceeds a maximum pressure threshold. In addition, another valve may be provided to input additional motor fluid when the pressurization falls below a minimum pressure threshold. Accordingly, the valves maintain the desired pressurization and undesirable fluid elements are repelled from the motor cavity at the shaft seals.
[0054] System 10 also may have a wiring assembly extending through housing 21 to a component adjacent a bellows. For example, a variety of monitoring components may be disposed near one of the bellows to improve the overall operation of system 10 . Exemplary monitoring components comprise temperature gauges, pressure gauges, and various other instruments, as should be appreciated by those skilled in the art.
[0055] As discussed above, apparatus of the invention may have various configurations. For example, certain apparatus and systems of the invention may comprise a motor protector 16 that comprises a seal section 17 and a bellows section 51 , 53 ( FIG. 4 ). As illustrated in embodiment 100 of FIG. 3 , seal section 17 may be disposed between pump 12 and motor 14 , while a protector 16 a is disposed adjacent motor 14 , and another protector 16 b is disposed on an opposite side of seal section 17 . System 100 may also have an optional monitoring system disposed adjacent one of protectors 16 a and/or 16 b. If additional sealing and motor protection is desired, then a plurality of seal and bellows sections may be disposed about the motor 14 in desired locations. For example, certain systems of the invention may have multiple bellows sections disposed sequentially and/or on opposite sides of motor 14 , such as a bellows section having two bellows assemblies in series.
[0056] Seal sections of a motor protector may have various seal and protection elements disposed about shaft 11 within housing 21 . These elements may be provided to protect motor 14 from undesirable fluid elements in pump 12 and wellbore. Accordingly, the seal section may have a plurality of shaft seals disposed about shaft 11 to seal and isolate motor fluid 54 from the undesirable fluids (e.g., the well fluid, or injected fluid). Seal sections may also have a thrust bearing disposed about shaft 11 to accommodate and support the thrust load from pump 12 . A moisture absorbent assembly also may be disposed about shaft 11 to remove undesirable fluids from the internal fluid (i.e., motor fluid 54 within housing 21 ).
[0057] As discussed above, the internal fluid of systems of the invention may be positively pressurized to prevent in-flow of the undesirable fluids through the shaft seals. In a section between shaft seals, a relief valve may be provided to release internal fluid from the system when the internal pressure exceeds the maximum pressure threshold. According to these embodiments, the technique maintains the internal fluid within a certain positively pressurized pressure range to prevent in-flow of undesirable fluids through the shaft seals, while also allowing a pressure release when the internal pressure exceeds the maximum pressure threshold. This technique ensures that fluid is repelled and ejected under pressure rather than allowing the undesirable fluids to slowly migrate into the system, such as in a pressure balanced system. However, the apparatus and systems of the present invention also may utilize various pressure balancing assemblies to complement the seal and bellows sections. For example, a seal section may include a labyrinth or bag assembly between shaft seals.
[0058] The bellows sections of the motor protectors 16 a and 16 b have the bellows disposed in a housing 21 , which may be coupled to motor 14 at a coupling section and to another component at a different coupling section. Inside housing 21 , bellows 51 and 53 are oriented such that an interior is in fluid communication with the well fluid through various ports, as is known in the art. An external filter assembly may be disposed about the ports to filter out undesirable elements within the well fluid. The exterior of bellows 51 and 53 are in fluid communication with motor fluid 54 . The bellows may also have a filter disposed between the bellows and motor 14 . For example, a filter assembly may be disposed at an expansion stop 79 of housing 21 to filter out motor shavings and other harmful elements. Accordingly, the filter assemblies filter out undesirable elements from motor fluid 54 and the well fluid to protect the bellows. In this configuration, motor fluid 54 contracts bellows 51 and 53 as it is injected into motor 14 , while the well fluid acts against the bellows as the system is submersed into the well.
[0059] As discussed above, the bellows may be movably disposed within a housing. As motor fluid 54 expands and contracts due to temperature changes, bellows 51 and 53 contract or expand to a new resting position, where the internal motor pressure is balanced against the well pressure plus the spring force of the bellows. If motor fluid 54 expands, the bellows of this embodiment contracts accordingly. If motor fluid 54 contracts, the bellows of this embodiment expands accordingly. Motor fluid 54 in this embodiment, therefore, remains positively pressurized in relation to well fluids, regardless of whether or not it has been expanded or contracted due to temperature variations.
[0060] The bellows also may utilize various spring assemblies and other biasing structures to facilitate pressurization of motor fluid 54 . For example, a spring assembly may be incorporated into the bellows assembly to complement the resistance of the bellows and increase the stroke of the bellows (thereby increasing the time and range in which the bellows will maintain a positive pressure on motor fluid 54 ). The orientation of the bellows also may be varied to accommodate a particular pumping system and application.
[0061] Moreover, as discussed in further detail below, apparatus of the present invention may be used alone or separate, in duplicate, in series, in parallel, or in any suitable configuration to provide optimal protection for motor 14 . For example, as illustrated in FIG. 3 , a plurality of protector bellows 16 a and 16 b may be disposed in series. Alternatively, the protector bellows may be arranged longitudinally adjacent one another in a bellows section, each bellows having a longitudinally adjacent set of ports and filters for fluid communication with the well fluid. The opposite side of each bellows assembly is then in fluid communication with motor fluid 54 .
[0062] Systems of the invention may also comprise a variety of conventional motor protector components, such as a bag assembly and a labyrinth assembly, for example, system 100 may have pump 12 , seal section 17 , motor 14 and bellows section sequentially intercoupled. The bellows section may have the bellows oriented such that the interior is in fluid communication with the well fluid, while the exterior is in fluid communication with motor fluid 54 . Although FIGS. 3 and 4 do not illustrate the various filters and other protection elements for the bellows, the bellows sections may include a variety of filters, seals, moisture absorbent assemblies, housings, bellow stops, and other desired bellows protection elements configured to prolong the life of the bellows assembly, as previously described. The seal section will have shaft seals disposed about respective chambers which have a bag assembly and a labyrinth assembly disposed therein to provide pressure balancing between the shaft seals. The seal section also may utilize a variety of other pressure balancing components, such as conventional bag assemblies, conventional labyrinth assemblies, and various bellows and labyrinth assemblies of the present technique. A plurality of pressure check valves may also be disposed in the seal section to control the positively pressurized fluid within system 100 . For example, a valve (not shown) may be configured to monitor the pressure and to trigger a backup oil supply when the pressure falls below the minimum pressure threshold in motor 14 (e.g., 5 psi). For example, if the bellows fails to expand or contract as in normal operation, then the valve acts as a backup to ensure a desired pressure range for motor fluid. The valve may be configured to monitor the pressure and to release the positively pressurized motor fluid 54 within motor 14 when the internal pressure exceeds the maximum pressure threshold. Accordingly, the valve ensures that the O-ring seals in the pothead, the joints, and various other components in the seal section are protected from excessive pressure differentials.
[0063] Alternate configurations of the seal and bellow sections are possible. In certain embodiments the seal section and the bellows section may be sequentially disposed between pump 12 and motor 14 . These systems may also have an optional monitoring system disposed adjacent motor 14 and opposite bellows 51 , 53 . In certain other embodiments, the seal section and the bellows section may be sequentially disposed between pump 12 and motor 14 . However, an additional bellows section may be disposed below motor 14 to complement bellows section disposed above motor 14 . Systems of the invention may also have an optional monitoring system disposed below the relatively lower bellows section. Accordingly, the seal and bellows sections may be oriented at various locations relative to pump 12 and motor 14 , while also including a plurality of seal and bellows sections to improve the effectiveness of the overall motor protection technique. It also should be noted that the seal sections may include conventional motor protection components.
[0064] As discussed briefly, one problem has been the difficulty in cleaning the bellows in a timely and cost effective manner, in particular the annular region between bellows 51 and 53 . Apparatus and systems of the invention address this problem by providing multi-piece protectors, such as previously described in reference to FIG. 2 , a non-limiting embodiment. Apparatus of the invention may be used to protect motors and other components in any combination. In certain apparatus embodiments, the body comprises an assembly of two or more pieces that may be disassembled and cleaned without great difficulty, as compared with conventional single piece annular bellows apparatus. Certain multi-piece bellows assemblies of the invention may be dismantled and cleaned in a simpler fashion than one-piece bellows. For instance, the multiple-piece bellows may be cleaned with a commercial steam cleaner, or other methods including but not limited to chemical cleaning and ultrasonic cleaning to significantly reduce the cost for the bellows cleaning processes. Bolts 69 , 71 , 73 , and 75 in embodiment 50 of FIG. 2 allow this facile cleaning. Other connectors may be employed with similar results.
[0065] Systems of the invention also may have a variety of alternate configurations of the apparatus for positioning the bellows about the shaft 11 . For example, the bellows may embody an annular or ring-shaped enclosure, which may be fixed at one or both ends to provide a fixed seal and an expandable/contractible volume. Accordingly, the bellows avoids use of sliding seals, which typically cause leakage into the motor fluid. In this embodiment, the fluid pressures on opposite sides of the bellows may be relatively balanced rather than providing a significant pressure differential between the fluids. However, it is understood that a slight pressure differential, such as 5 psi, may be provided in this pressure-balanced configuration of the bellows assembly. Another protector component (e.g., a bellows assembly, a bag assembly, a labyrinth assembly, etc.) may be coupled to the section. Alternatively, if a labyrinth assembly is coupled to the section, then the interior of the annulus or ring-shaped enclosure may be in fluid communication with a desired isolation fluid configured to facilitate separation from the well fluid in the labyrinth assembly. In either configuration, a filter assembly may be disposed adjacent the port to filter out undesirable elements within the well fluid or the desired isolation fluid. The exterior of external bellows 51 is in fluid communication with motor fluid 54 via ports. Alternatively, the exterior may be in fluid communication with a second isolation fluid for a second labyrinth assembly, a bag assembly, or any other desired fluid separation assembly. As described in detail above, the bellows also may include a variety of bellows protection elements, such as guides, seals, filters and absorbent packs (e.g., moisture absorbent packs). The bellows also may comprise one or more shaft seals, thrust bearings, and various other seals and bearings. For example, the bellows may have shaft seals disposed about the shaft 11 on opposite sides of the bellows. A thrust bearing may also be disposed about shaft 11 .
[0066] As discussed above, the bellows may be balanced pressure bellows rather than a positively pressurized bellows. In operation of balanced pressure bellows, injection and expansion of motor fluid in motor 14 (or other isolation fluid) and the exterior causes the bellows to contract. In contrast, the pressure of the well fluid (or other isolation fluid) causes the bellows assembly to expand. As motor fluid expands and contracts due to temperature changes, the bellows contracts or expands to a new resting position, where the internal motor pressure is balanced against the well pressure plus any resistance of the bellows. If motor fluid (or other isolation fluid) expands, the bellows of this embodiment contracts accordingly. If the motor fluid (or other isolation fluid) contracts, the bellows of this embodiment expands accordingly. Accordingly, bellows substantially balances the pressures between the motor fluid and the well fluid under a wide range of operating conditions, which include both expansion and contraction of motor fluid 54 . If a positive pressure differential is desired in the bellows, then a spring assembly can be incorporated into the bellows to prevent inward leakage of undesirable elements such as the well fluid.
[0067] As noted above, the bellows may be fixed at one or both ends. Embodiment 100 illustrated in FIGS. 3 and 4 has the bellows protector 16 a and 16 b fixed to a seal section 15 and 17 , while an opposite end is free to expand and contract within housing 21 . The particular length and spring stiffness of the bellows may be configured for any desired operating conditions and well environments. Additional bellows also may be incorporated into the bellows sections 16 a and 16 b to provide additional protection for motor 14 .
[0068] The bellows also may have one or more stepped sections, which provide a fluid interface to facilitate expansion and contraction of the bellows. In these embodiments, the bellows is fixed at both ends, while the stepped section is movable as the well and motor fluids expand and contract. The stepped section acts as a fluid interface between large diameter and small diameter bellows sections. The particular lengths and spring stiffness of the bellows sections may be configured for any desired operating conditions and well environments.
[0069] The apparatus and systems of the invention may also include one or more labyrinth assemblies, bag or bladder assemblies, or other conventional motor protector assemblies to protect both motor 14 and the bellows 51 and 53 . Moreover, the systems may comprise both a positively pressured bellows assembly along with a balanced pressure bellows assembly.
[0070] Additionally, the motor protectors 16 of system 100 may comprise a multi-orientable labyrinth assembly (i.e., operable in multiple orientations), which may be used alone or in combination with the bellows or other components. The multi-orientable labyrinth assembly has one or more conduits that extend in multiple directions to ensure fluid paths having peaks and valleys in multiple orientations of the multi-orientable labyrinth assembly. Accordingly, the peaks and valleys in these various orientations ensure continuous fluid separation in all orientations of the multi-orientable labyrinth assembly based on differences in specific gravity. Systems of the invention may have a multi-orientable labyrinth assembly disposed between pump 12 and motor 14 . As described in other embodiments of the system 10 , a variety of seals, couplings, bearings, filters, absorbents, and protection devices may be provided to protect and prolong the life of motor 14 . Accordingly, system 100 may include couplings, a thrust bearing, and a solids processor. An exemplary solids processor may be disposed in a chamber between pump 12 and motor protector 16 to prevent solids from entering the multi-orientable labyrinth assembly and from generally corrupting the motor protection devices in the motor protector(s) 16 . A suitable solids processor may include a variety of solids separators, such as shedder and shroud, which prevent solids from settling on and damaging bearings and seals such as shaft seals. The solids separator throws or sheds solids outwardly from the shaft 11 and shaft seal. The shroud, which may embody an extended length shedder in a deviated orientation, also prevents solids from settling near shaft 11 and damaging shaft seals. The solids processor may also include one or more flow ports that allow solids to escape into the wellbore. The multi-orientable labyrinth assembly may comprises a multi-directional winding of tubing, which is fluidly coupled to the motor and well fluids (or other isolation fluids) at its ends. The ends may be positioned in respective opposite ends of the motor protector 16 . One end may be coupled to a port extending to motor 14 , while the other end may be positioned openly within motor protector 16 . The ends may also include a filter to prevent solids and other undesirable elements from entering the multi-orientable labyrinth assembly. The well fluid enters the motor protector 16 via a conduit, which also can include one or more filters to prevent the inflow of solids into the motor protector 16 . In operation, a multi-directional winding of a multi-orientable labyrinth assembly maintains fluid separation of the motor and well fluids by using the differences in specific gravity of the fluids and multidirectional windings. A multi-orientable labyrinth assembly may have a plurality of crisscrossing and zigzagging tubing paths, which extend in multiple orientations (e.g., 2-D, 3-D, or any number of directions) to ensure that the fluids go through upward and downward movement regardless of the orientation of the system. For example, a multi-orientable labyrinth assembly may be operable in a vertical wellbore, a horizontal wellbore, or any angled wellbore. A multi-orientable labyrinth assembly may also be disposed in a variety of submersible pumping systems, including those illustrated in FIGS. 3 and 4 . Moreover, a plurality of multi-orientable labyrinth assemblies may be disposed in series or in parallel in various locations within the system.
[0071] In one system configuration, a multi-orientable labyrinth assembly may be disposed in a chamber between the bellows and the well fluid to protect the bellows. In the foregoing system configuration, pump 12 and motor 14 may be positioned side by side, while the bellows and multi-orientable labyrinth assembly may be disposed adjacent motor 14 . In contrast, in another embodiment the multi-orientable labyrinth assembly may be configured for positioning about shaft 11 in a central protector configuration. In this central configuration, the multi-orientable labyrinth assembly has an annular or ring-shaped geometry, which provides an inner conduit for shaft 11 . In both embodiments, the multi-orientable labyrinth assembly may include one or more continuous tubes, which are interwoven in zigzagging and multi-directional patterns terminating at opposite ends of the labyrinth assembly. Moreover, the dimensions of the tubing, the density of the windings, and other geometrical features may be tailored to the specific system and downhole environment. A multi-orientable labyrinth assembly may also have an additional feature, as compared to conventional two-dimensional labyrinths. In two-dimensional labyrinths, the oil/well fluid interface occurs within the labyrinth chamber and not within one of the labyrinth tubes. In multi-orientable labyrinth assemblies, the interface may occur in the relevant chamber, but it may also occur within the multi-oriented tube thereby enabling the assembly to be used in any orientation (as previously discussed).
[0072] In another exemplary embodiment of systems of the invention, a plurality of the foregoing motor protector and seal devices may be disposed in parallel or in series within the system.
[0073] Accordingly, the present invention may embody a variety of system configurations and motor protectors 16 and corresponding devices, such as the bellows 51 and 53 and multi-orientable labyrinth assembly. As described above, the bellows may embody either a positively pressurized system or a balanced pressure system. The foregoing motor protectors 16 and corresponding devices may be used alone or together in any configuration, including multiples of each device and conventional motor protectors. Moreover, one or more of the motor protectors 16 can be disposed above, between or below pump 12 and motor 14 . For example, if a balanced pressure bellows is disposed above motor 14 or between pump 12 and motor 14 , then a positively pressurized bellows may be disposed below motor 14 in fluid communication with the well fluid. Moreover, any of the foregoing motor protectors 16 and corresponding devices may be functionally combined in series or in parallel, or any combination thereof.
[0074] Exemplary materials of construction for apparatus and systems of the invention comprise a metal selected from metals chemically compatible with expected environmental conditions, heat treated metals, corrosion resistant metals, high strength metals, and metals having two or more of these properties. Hastelloy “C” is a good choice for most pumps because of its chemical compatibility, but it may not be thick enough for a Hastelloy “C” pump. Most bellows convolutions are only 0.004 inches (0.10 mm) thick and one definition of “corrosion resistant” is that the material can corrode up to 0.002 inches (0.05 mm) per year. The 300 series of stainless steel, while high in strength, may cause chloride stress corrosion problems. One heat treatable form of stainless steel is type AM350, which has been used successfully for many years in high temperature and cryogenic seal applications. Heat-treated materials tend to retain their strength and spring rate at elevated temperatures expected in wellbores. Inconel 718 is a metal that has good corrosion resistant properties in an annealed form and retains some of the corrosion resistant properties after heat testament. It has become the favorite of oil refinery people because of corrosion problems they have experienced with type AM350 stainless steel after five or six years of service. Titanium, 17-4 PH and variety of other materials have been used as bellows seals.
[0075] Metal apparatus of the invention may have coatings, including polymeric coatings. “Coating” as used herein as a noun, means a condensed phase formed by any one or more processes. The coating may be conformal (i.e., the coating conforms to the surfaces of the inventive apparatus), although this may not be necessary in all oilfield applications or all apparatus, or on all surfaces of the apparatus. Conformal coatings based on urethane, acrylic, silicone, and epoxy chemistries are known, primarily in the electronics and computer industries (printed circuit boards, for example). Another useful conformal coating includes those formed by vaporization or sublimation of, and subsequent pyrolization and condensation of monomers or dimers and polymerized to form a continuous polymer film, such as the class of polymeric coatings based on poly (p-xylylene), commonly known as Parylene. Thermoplastic elastomers, which may be another type of polymeric coating, are generally the reaction product of a low equivalent molecular weight polyfunctional monomer and a high equivalent molecular weight polyfunctional monomer, wherein the low equivalent weight polyfunctional monomer is capable, on polymerization, of forming a hard segment (and, in conjunction with other hard segments, crystalline hard regions or domains) and the high equivalent weight polyfunctional monomer is capable, on polymerization, of producing soft, flexible chains connecting the hard regions or domains. Another class of useful polymeric coatings are thermally curable coatings derived from coatable, thermally curable coating precursor solutions, such a those described in U.S. Pat. No. 5,178,646, incorporated by reference herein. Two other classes of useful coatings are condensation curable and addition polymerizable resins, wherein the addition polymerizable resins are derived from a polymer precursor which polymerizes upon exposure to a non-thermal energy source which aids in the initiation of the polymerization or curing process. Examples of non-thermal energy sources include electron beam, ultraviolet light, visible light, and other non-thermal radiation. Examples of useful organic resins to form these classes of polymeric coating include methylol-containing resins such as phenolic resins, urea-formaldehyde resins, and melamine formaldehyde resins; acrylated urethanes; acrylated epoxies; ethylenically unsaturated compounds; aminoplast derivatives having pendant unsaturated carbonyl groups; isocyanurate derivatives having at least one pendant acrylate group; isocyanate derivatives having at least one pendant acrylate group; vinyl ethers; epoxy resins; and mixtures and combinations thereof. The term “acrylate” encompasses acrylates and methacrylates.
[0076] For embodiments wherein a better bond between the polymeric coating and the metal portions of the apparatus is desired, mechanical and/or chemical adhesion promotion (priming) techniques may used. The term “primer” as used in this context is meant to include both mechanical and chemical type primers or priming processes. Examples of mechanical priming processes include, but are not limited to, corona treatment and scuffing, both of which increase the surface area of the apparatus. An example of a preferred chemical primer is a colloidal dispersion of, for example, polyurethane, acetone, isopropanol, water, and a colloidal oxide of silicon, as taught by U.S. Pat. No. 4,906,523, which is incorporated herein by reference.
[0077] As may be seen by the exemplary embodiments illustrated in FIGS. 2-4 there are many possible uses of apparatus and systems of the invention. Alternatives are numerous. For example, certain electrical submersible pumps, which are modified versions of a pumping system known under the trade designation Axia™, available from Schlumberger Technology Corporation, may feature a simplified two-component pump-motor configuration. Pumps of this nature generally have two stages inside a housing, and a combined motor and protector, which may comprised an apparatus of the invention. This type of pump may be built with integral intakes and discharge heads. Fewer mechanical connections may contribute to faster installation and higher reliability of this embodiment. The combined motor and protector assembly is known under the trade designation ProMotor™, and may be prefilled in a controlled environment. The pump may include integral instrumentation that measures downhole temperatures and pressures.
[0078] Other alternative electrical submersible pump configurations that may benefit from apparatus of the invention include an ESP deployed on cable, an ESP deployed on coiled tubing with power cable strapped to the outside of the coiled tubing (the tubing acts as the producing medium), and more recently a system known under the trade designation REDACoil™, having a power cable deployed internally in coiled tubing. Certain pumps may have “on top” motors that drive separate pump stages, all pump stages enclosed in a housing. A separate protector may be provided, as well as an optional pressure/temperature gauge. Also provided in this embodiment may be a sub-surface safety valve (SSSV) and a chemical injection mandrel. A lower connector may be employed, which may be hydraulically releasable with the power cable, and may include a control line and instrument wire feedthrough. A control line set packer may be included in this embodiment. The technology of bottom intake ESPs (with motor on the top) has been established over a period of years. It is important to securely install pump stages, motors, and protector within coiled tubing, enabling quicker installation and retrieval times plus cable protection and the opportunity to strip in and out of a live well. This may be accomplished using a deployment cable, which may be a cable known under the trade designation REDACoil™, including a power cable and flat pack with instrument wire and one or more, typically three hydraulic control lines, one each for operating the lower connector release, SSSV, and packer setting/chemical injection.
[0079] Systems of the invention may include many optional items. One optional feature may be one or more sensors located at the protector to detect the presence of hydrocarbons (or other chemicals of interest) in the internal motor lubricant fluid. The chemical indicator may communicate its signal to the surface over a fiber optic line, wire line, wireless transmission, and the like. When a certain chemical is detected that would present a safety hazard or possibly damage a motor if allowed to reach the motor, the pump may be shut down long before the chemical creates a problem.
[0080] Although only a few exemplary embodiments of this invention have been described in detail above, those skilled in the art will readily appreciate that many modifications are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of this invention. Accordingly, all such modifications are intended to be included within the scope of this invention as defined in the following claims. In the claims, no clauses are intended to be in the means-plus-function format allowed by 35 U.S.C. § 112, paragraph 6 unless “means for” is explicitly recited together with an associated function. “Means for” clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. | Apparatus and pumping systems including the apparatus are described, the apparatus including a protector body comprising a material allowing expansion and contraction of an internal fluid, the body serving as a barrier between fluids external of the body and the internal fluid. The body has first and second ends, at least one end adapted to connect the body to other components, the protector body further comprising structural features permitting facile cleanout and reuse of the protector body. Methods of use of the apparatus and systems are described, particularly in oilfield exploration, testing, and production. This abstract allows a searcher or other reader to quickly ascertain the subject matter of the disclosure. It will not be used to interpret or limit the scope or meaning of the claims. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present patent application claims the benefits of priority of commonly assigned Canadian Patent No. 2,674,106, entitled “Extendable Clothes Dryer” and filed at the Canadian Patent Office on Aug. 4, 2009.
FIELD OF THE INVENTION
[0002] The present invention generally relates to clothes dryers and, more particularly, to a novel open air extendable clothes dryer.
BACKGROUND OF THE INVENTION
[0003] Even if sophisticated automatic cloth dryers exist, there is still demand for open air dryers from which any clothes or laundry can be laid flat or hung to dry.
[0004] Many reasons exist to justify the high demand for this type of dryers. First, clothes manufacturers often recommend to hang clothes or to lay flat to dry them instead of using automatic clothes dryers in order to avoid damages to some types of fabrics. Second, as the price of energy is escalating, many are those who are avoiding the use of energy-consuming sophisticated automatic clothes dryers to use open air clothes dryers. Third, in some areas, such as high density populated regions, clothes-lines are often unavailable, impossible to be installed or the coldness of the winter prevents clothes to be hung on the exterior clothes lines. Finally, the advent of front load washing and drying appliances has left empty and often unused space between the said appliances and either the ceiling or the cabinets usually installed over the appliances.
[0005] In some situation, those advantages are eclipsed by inherent disadvantages such as the space required to store and use these apparatus. As many open air dryers can be folded or collapsed in order to be stored out of sight, their usage still require considerable space. Those living in apartments and even homeowners have generally a limited area to use for clothes drying. These types of dryers are generally made of a structure of rigid material such as plastic, metal or wood and are designed to be placed on the floor. As a consequence, these apparatuses require much space when used to dry clothes. There is therefore a need for an extendable open air dryer which can be easily installed and stored in some unused areas of an apartment or a house and more particularly in the space located between the washer and dryer appliances and either the ceiling or the cabinets usually installed over the appliances. Also, it should be easy to manipulate and to be cleaned. Such a clothes dryer should preferably be simple and inexpensive to manufacture.
[0006] Other and further objects and advantages of the present invention will be obvious upon an understanding of the illustrative embodiments about to be described or will be indicated in the appended claims, and various advantages not referred to herein will occur to one skilled in the art upon employment of the invention in practise.
SUMMARY OF THE INVENTION
[0007] The present invention is generally providing a clothes dryer adjustable in length and in tension to be fixed on and between at least a pair of substantially parallel wall structures or the like extending substantially vertically, and the adjustable clothes dryer may be installed between walls having variable distance between them, the dryer comprising at least one layer adjustable in length, the layer comprising a first support bar and a second support bar extending substantially horizontally, and a laundry support mesh extending between the support bars, wherein the laundry support mesh is removable from the support bars; a supporting structure comprising retaining members, the retaining members securely fixed to the walls; retainers fixed to the retaining members, the retainers being configured to receive the support bars, wherein the length of each of the layer is adjustable in length in order to fit variable distance between the walls by rolling the laundry support mesh over at least one of the support bars to adjust the length of the layer to the width between the walls.
[0008] In a further embodiment, the clothes dryer further comprises at least one supplementary retaining member extending substantially parallel to the parallel walls, the supplementary retaining member being secured to a further wall perpendicular to the parallel walls.
[0009] In a further embodiment the first support bar and the second support bar are parallel to the parallel walls.
[0010] In a further embodiment the first support bar and the second support bar are perpendicular to the parallel walls.
[0011] In a further embodiment, the retainer is a hook.
[0012] The features of the present invention which are believed to be novel are set forth with particularity in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The above and other objects, features and advantages of the invention will become more readily apparent from the following description, reference being made to the accompanying drawings in which:
[0014] FIG. 1 is a perspective view of a dryer in accordance with the invention installed with many layers.
[0015] FIG. 2 is a perspective view of a dryer in accordance with the invention installed with one layer.
[0016] FIG. 3 is a perspective view of the unassembled dryer of FIG. 1 showing the hooks portion of the dryer.
[0017] FIG. 4A is a front view of another embodiment of a dryer in accordance with the invention installed over a top loading washer and dryer appliances.
[0018] FIG. 4B is a side view of the supplementary retaining member shown in FIG. 4A .
[0019] FIG. 4C is a perspective view of the supplementary retaining member shown in FIG. 4A .
[0020] FIG. 5A is a perspective view of another embodiment of the dryer, showing the hooks portion and supplementary retaining bars.
[0021] FIGS. 5B to 5E are perspective views of the dryer of FIG. 5 , showing different ways to install the dryer by folding or not a layer over the supplementary retaining bars.
[0022] FIG. 6A is a front view of another embodiment of the dryer in accordance with the present invention.
[0023] FIG. 6B is a top view of the embodiment shown in FIG. 6A .
[0024] FIG. 6C is a side view showing an embodiment of the supplementary retaining member shown in FIG. 6A .
[0025] FIG. 6D is a perspective view showing another embodiment of the retaining member shown in FIG. 6A .
[0026] FIG. 6E is a perspective view showing another embodiment of the retaining member shown in FIG. 6A .
[0027] FIG. 7A is a front view of a further embodiment of the dryer in accordance with the present invention.
[0028] FIG. 7B is a top view of the embodiment shown in FIG. 7A .
[0029] FIG. 8 is a front view showing a possible way to store the dryer.
[0030] FIG. 9 is a front view of another way to install the dryer in accordance with the present invention, using the available space over the appliances.
[0031] FIG. 10 a front view of a further way to install the dryer in accordance with the present invention, using the available space beside appliances mounted one over the other.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] A novel extendable clothes dryer will be described hereinafter. Although the invention is described in terms of specific illustrative embodiment(s), it is to be understood that the embodiment(s) described herein are by way of example only and that the scope of the invention is not intended to be limited thereby.
[0033] Referring to FIG. 3 , the extendable clothes dryer of the present invention is generally indicated at 10 . The dryer 10 generally comprises one or a plurality of layers 100 and at least two retaining members 200 that each retains one longitudinal extremity of the layer 100 . Each layer 100 comprises at least two support bars 110 and a laundry support mesh 120 . Each support bar 110 is made of rigid material such as wood, plastic or metal and in the embodiment shown is generally shaped as a rectangular cuboid but could also have another shape such as a circular rod, a hexagonal prism or an octagonal prism. The laundry support mesh 120 has a generally rectangular shape and is typically made of any breathable fabric or net. The skilled addresses will note that breathable fabric is used to allow air to circulate through the laundry support mesh 120 in order to accelerate the drying of the laundry.
[0034] The laundry support mesh 120 is secured to the support bars 110 through attaching means 115 . The skilled addressee will note that the use of non-permanent attaching means 115 such as, but not limited to, snap fasteners, hook and loop fasteners, buttons or zipper is preferred to permanent attaching means such as glue, nails or staples to facilitate the cleaning of the laundry support mesh 120 . The attaching means 115 are generally secured to the support bars 110 with nails, screws, staples or glue. The skilled addressee will note that the attaching means 115 are strong enough to provide the required tension to hold the laundry items laid down on the laundry support mesh 120 .
[0035] Referring now to FIG. 1 , each retaining member 200 embodies one or many supporting structures 210 comprising at least one hook 220 used to retain one end of a layer 100 . In the present embodiment, a hook 220 can be made of a folded sheet of metal or plastic which forms a square angle. Each hook is secured at a selected height of the supporting structure 210 using fasteners (not shown). Typically, permanent fasteners such as nails or screws are used but any other non permanent attaching means could be used instead. The hooks 220 can also be integral with the retaining member 200 . The hooks 220 could also be attached directly to the wall or other support structure. In the present invention, the hooks 220 can be replaced by other holding means such as hook and loop fasteners, or clips located on the supporting bar 110 which engage with attaching means such as apertures located on the retaining member 200 .
[0036] In the embodiment shown, each retaining member 200 comprises a supporting structure 210 generally shaped as bars made of metal, plastic or any other rigid material. Even if the present embodiment shows the use of two supporting structures 210 at each end of the dryer, other embodiments of the present invention could comprise one or many said supporting structures 210 at each end. Each supporting structure 210 is secured to any external structure such as walls, a dryer, a washer or other appropriate self-supporting structure. The supporting structure 210 is secured to the external structure using fasteners (not shown) generally through apertures 230 located in the supporting structure 210 . The supporting structure 210 is secured to a dryer or a washer using appropriate means such as a support or a rack adapted to the dryer or the washer. The skilled addressee will note that the supporting structures 210 facilitate the installation of the dryer 10 and could be replaced by hooks or other retainer devices directly secured in any such external structure.
[0037] Referring now to FIG. 1 to 3 , to hold the weight of the laundry items laid down on the support mesh 120 , any of the support bars 110 must be first downwardly engaged with one or many hooks 220 of any retaining member 200 and then the opposite support bar 110 must be downwardly pushed into engagement with one or many of the aligned hooks 220 of the opposite retaining member 200 while stretching the laundry supporting mesh. The skilled addressee will note that the length of the laundry supporting mesh 120 must be adjusted to the width of the opposite retaining members 200 to maintain a sufficient tension to hold the laundry items laid down on supporting mesh 120 . The length and the tension of the laundry supporting mesh 120 are generally adjusted by rolling the said mesh 120 around one or all the support bars 110 . Once layer 100 is installed, the previous steps may be repeated to install identical layers 100 to increase the drying surface as shown in FIG. 3 .
[0038] To store the dryer, one must simply upwardly displace any support bar 110 of any layer 100 installed to get it out of the hook 220 . The skilled addressee will note that one may generally either engage the removed support bar 110 with the opposite set of hooks so to leave the laundry supporting mesh 120 dangling underneath as shown in FIG. 8 , or roll the laundry supporting mesh 120 around the removed support bar 110 before engaging it with the opposite set of hooks 220 . Alternatively, both support bars may be disengaged from the hooks and the supporting mesh 120 may be wrapped around one or both of the support bars.
[0039] Referring now to FIG. 4A to 4C , in a second embodiment 300 , an extendable clothes dryer 10 is generally installed over a top loading washing machine 400 and an automatic cloth dryer 410 . The skilled addressee will note that, in the present embodiment, the space located between the washer and dryer appliances and either the ceiling or the cabinets usually installed over the appliances is limited by the top loading washing machine which require a higher clearance to open the door.
[0040] In the second embodiment, the extendable clothes dryer 10 comprises at least two retaining member 200 fixed to any external structure 320 on each end of the dryer using fasteners (not shown), one or many supplementary retaining member 310 fixed to any external structure 330 positioned perpendicularly to the external structures 320 using fasteners (not shown) and one or a plurality of layers 100 supporting the laundry laid down to dry. The supplementary retaining member 310 typically comprises one or many supporting bars 311 and one or many supporting structure 312 , as shown in FIGS. 4B and 4C . A supporting bar is generally made of plastic, metal or any other rigid material and is secured to the supporting structure 312 using fasteners such as nails, screws or any other securing means. The supporting bar 311 can also be integral with the supporting structure 320 .
[0041] To hold the weight of the laundry items laid down on the support mesh 120 , one of the layer support bars 110 must be first downwardly engaged with one or many hooks 220 of one of the retaining members 200 . Then the opposite layer support bar 110 must moved over a first supporting bar 311 . Next, the said layer support bar 110 must be moved over another supporting bar 311 , located over or under the first supporting bar 311 . Finally, such opposite support bar 110 must be engaged with one or many of the aligned hooks 220 of the opposite retaining member 200 while stretching the laundry supporting mesh 120 . The skilled addressee will note that the length of the laundry supporting mesh 120 must be adjusted to maintain a sufficient tension to hold the laundry items laid down on supporting mesh 120 . This second embodiment allows one supporting mesh 120 to be configured as at least two levels of drying layers.
[0042] FIGS. 5A to 5E show that a layer 100 may be folded over supplementary retaining bar 310 to create smaller drying sections.
[0043] FIGS. 6A and 6B shows an embodiment of the present invention wherein the layers are extended in a different direction due to the orientation of the hooks. In this case, the layers are extended from the rear to the front of the appliances or vice versa instead of from a side to another side. To hold the weight of the laundry items laid down on the support mesh 120 , one of the layer support bars 110 must be first downwardly engaged with one or many hooks 520 of one of the first retaining members 500 . Then the opposite layer support bar 110 must moved over a supporting bar 511 . Finally, such opposite support bar 110 must be engaged with one or many of the aligned hooks 560 of the second retaining member 550 while stretching the laundry supporting mesh 120 . It is to be noted that the layers may be extended from front to rear also.
[0044] FIGS. 7A and 7B shows an embodiment similar to the one disclosed in FIGS. 6A and 6B , the layer having a larger width.
[0045] FIG. 6C shows another embodiment of a supplementary retaining member 510 comprising one or many supporting bars 511 and one or many supporting structure 512 . FIG. 6D shows another embodiment of a retaining member 550 having hooks 560 . FIG. 6E shows another embodiment of a retaining member 500 having hooks 520 .
[0046] FIG. 9 discloses an installation wherein there are no storage over the appliances and all the available space is used to hang on clothes using the dryer in accordance with the present invention. FIG. 10 shows another installation wherein the dryer is installed beside appliances mounted one over the other. It is to be noted that the user may adapt the dryer to the available space he has by using different length of layers.
[0047] It is to be noted that the support bars could be retained by other means than the hooks without departing from the present invention. For example, the support bars could be retained by clip connected to the retaining members. The support bars could also be retained by extensions such as a pins cooperating with hole in the support bars. The support bars could also be retained in a receiving hole having a shape complementary to the shape of the support bars.
[0048] While illustrative and presently preferred embodiment(s) of the invention have been described in detail hereinabove, it is to be understood that the inventive concepts may be otherwise variously embodied and employed and that the appended claims are intended to be construed to include such variations except insofar as limited by the prior art. | The present invention discloses an open air dryer having one or more layers of flexible clothes dryers. Each clothes dryer is made of at least one generally rectangular piece of breathable fabric or net like material mounted on two parallel support bars made of a rigid material. The length of each layer is fully adjustable. Each support bar is held by at least one hook and preferably two hooks to any external structures such as walls, dryer, washer or other self-supporting structure. | 3 |
FIELD OF THE INVENTION
The present invention relates to an electrolytic cell for use in the practice of an ion exchange membrane electrolysis method, and more particularly, to an electrolytic cell suitable for the production of halogen and alkali metal hydroxide by electrolyzing an aqueous solution of alkali metal halides.
BACKGROUND OF THE INVENTION
Heretofore, in the electrolysis of brine, a diaphragm method utilizing an electrolytic cell comprising an anode compartment and a cathode compartment separated from each other by a porous neutral diaphragm made of asbestos or the like has been used in place of the mercury method. This diaphragm method, however, has the disadvantage that high purity alkali metal hydroxide cannot be obtained. Thus, an ion exchange membrane method using a cation exchange membrane has been developed for the production of high purity alkali metal hydroxides.
SUMMARY OF THE INVENTION
An object of the invention is to provide an electrolytic cell suitable for use in the ion exchange membrane method, which can be produced by remodeling an electrolytic cell which has heretofore been used in the diaphragm method.
Another object of the invention is to provide an electrolytic cell which can be assembled by utilizing equipment used in the electrolytic cell for the diaphragm method, and which is free from the danger of liquid leakage and permits production of high concentration alkali metal hydroxide and maintenance of cell voltage at a low level.
The present invention, therefore, relates to an electrolytic cell for the ion exchange membrane method, comprising:
(a) an electrolytic cell main body;
(b) a plurality of porous and tubular cathodes disposed in the interior of the electrolytic cell main body;
(c) an electrolytic cell bottom plate having therein a plurality of apertures;
(d) a plurality of electrically conductive bars provided with a flange at a lower portion thereof, which are each inserted through the aperture of the electrolytic cell bottom plate into the interior of the electrolytic cell main body and secured to the electrolytic cell bottom plate by the flange;
(e) a plurality of porous anodes which are each connected to the electrically conductive bar and placed vertically in a face-to-face relation to the cathode, and which are disposed alone or in combination with each other between the cathodes;
(f) a plurality of bag-shaped molds, at least the portion facing the anodes and the cathodes being formed by a cation exchange membrane, which are each provided at the bottom thereof with an aperture through which the electrically conductive bar can be passed, and are open at the top;
(g) a partition plate which is provided on the top of the electrolytic cell main body, and which has a plurality of openings at the positions corresponding to the top openings of the bag-shaped molds; and
(h) a plurality of lid members each of which covers the opening of the bag-shaped mold,
wherein
the bag-shaped mold accommodates one or more anodes;
the bottom of the bag-shaped mold is secured to the electrolytic cell bottom plate together with the electrically conductive bar extending through the aperture of the bottom of the bag-shaped mold by the flange so that an anode compartment is defined inside the bag-shaped mold; and
the top opening edge of the bag-shaped mold is secured at the opening of the partition plate by the lid member.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmental, longitudinal-sectional view of an embodiment of the electrolytic cell according to the invention.
FIG. 2 is a partially cutaway perspective view of an anode portion.
FIG. 3 is a perspective view of the electrolytic cell.
FIGS. 4 to 6 are each a perspective view of a bag-shaped mold as used in the invention.
FIG. 7 is a partially enlarged view of the top of the electrolytic cell, illustrating a method of securing the lid member to the top of the anode compartments.
DETAILED DESCRIPTION OF THE INVENTION
The invention will hereinafter be explained with reference to the accompanying drawings wherein:
FIG. 1 is a fragmentally longitudinal-sectional side view of an embodiment of the electrolytic cell for the ion exchange membrane method according to the invention;
FIG. 2 is a partially cutaway perspective view of an anode portion; and
FIG. 3 is a perspective view of the electrolytic cell.
In an electrolytic cell main body 1, a plurality of porous and hollow tubular cathodes 2 are disposed so that they extend from one inner side wall of the electrolytic cell main body 1 to the opposite inner side wall thereof. An electrolytic cell bottom plate 3 comprises an electricity-supply plate 4 and an anticorrosion sheet 5 provided on the plate 4, and has a plurality of apertures 7. Each of the apertures is positioned at a location just intermediate between two adjacent cathodes 2, and through which an electrically conductive bar 6 can be extended. The electrically conductive bar 6 extends through an aperture 7 of the electrolytic cell bottom plate 3 into the interior of the electrolytic cell main body 1 and has a flange 8 at a lower portion thereof. This electrically conductive bar is secured to the electrolytic cell bottom plate 3 with the flange 8 by fastening nut 9. A porous anode 10 is connected to the electrically conductive bar 6 at an upper portion thereof, vertically supported in a face-to-face relation to the cathode 2, and is disposed at a location intermediate two adjacent cathodes 3.
A mold 11 is formed by a cation exchange membrane at least at portions facing the anode and cathode and is designed in a bag-like form so that it can accommodate one or more anodes 10, and the top of the bag-shaped mold 11 is open. The bag-shaped mold 11 is provided at a location corresponding to the aperture 7 of the electrolytic cell bottom plate 3 with an aperture through which the electrically conductive bar 6 can be extended. The bag-shaped mold 11 accommodates therein one or more anodes 10 in a close contact relationship with the portion defined by the cation exchange membrane of the bag-shaped mold 11, and it is secured to the electrolytic cell bottom plate 3 together with the electrically conductive bar 6 extending through the aperture of the bottom of the bag-shaped mold 11 by the flange 8. In this way, an anode compartment 12 is defined in the bag-shaped mold 11.
On the top of the electrolytic cell main body 1 is provided a partition plate 13 having an opening at a location corresponding to the upper opening of the bag-shaped mold 11, and a sheet 14 made of elastic material such as rubber is interposed between the partition 13 and the upper opening of the bag-shaped mold. An anode compartment upper lid member 15 is provided at an upper portion of each anode compartment 12, covering the upper opening of the bag-shaped mold 11, and the upper opening of the bag-shaped mold 11 is secured to the lid member at each opening of the partition plate 13. A sheet 16 made of elastic material such as rubber, is interposed between the anode compartment upper lid member 15 and the upper opening end of the bag-shaped mold 11. This sheet 16 serves to protect the bag-shaped mold 11 and also acts as a packing material.
The bag-shaped mold 11 and the anode 10 are preferably brought in contact with each other as closely as possible, and it is preferred to employ an anode of the structure that permits extension of the anode in the cathode direction. An example of anodes which can be extended in the cathode direction is described in, for example, Japanese Patent Publication No. 35031/75 (corresponding to U.S. Pat. No. 3,674,676). If necessary, a spacer 17 is interposed between the bag-shaped mold 11 and the cathode 2. It is preferred for the width of the space defined between the bag-shaped mold 11 and the cathode 2 by the interposition of the spacer to be maintained within the range of about 1 to 3 mm.
In order to protect the bag-shaped mold 11 from being broken at a lower portion of the anode by the pressure exerted from the cathode side to the anode side during electrolysis, it is desirable to provide a protective frame 18 to enclose the anode lower portion. The protective frame 18 is made of a corrosion-resistant material such as a fluorine resin, and its shape is not critical as long as it encloses the anode lower portion and holds the form of the bag-shaped mold.
Referring to FIG. 3, a manifold 19 for supplying an anolyte is shown. The manifold 19 has a plurality of small-diameter pipes 20 for supplying an anolyte, these small-diameter pipes extending to each anode compartment upper lid member 15, and the anolyte is introduced through each small-diameter pipe 20 into each anode compartment. In order to control the flow rate of the anolyte, the small-diameter pipe 20 is designed in a spiral form, or is provided with an orifice meter. The anode compartment upper lid member 15 is provided with a discharge small-diameter pipe 21 at a side portion thereof so that the liquid and gas from the anode compartment can overflow through the discharge small-diameter pipe 21. Also there is provided a manifold 22 to which a plurality of discharge small-diameter pipes 21 are connected. The liquid and gas discharged from the anode compartment are introduced into the manifold 22 where they are separated from each other, and the liquid is withdrawn from an outlet 23 and the gas from an outlet 24.
A cathode compartment 25 is defined outside of the bag-shaped mold 11 in the electrolytic cell main body 1, and dilute alkali or water is introduced through a catholyte-supplying pipe 26 into the cathode compartment. The liquid and gas from the cathode compartment, overflowing from the top of the electrolytic cell main body 1, are withdrawn through outlets 27 and 28, respectively.
The bag-shaped mold 11 as used herein is designed so that at least the portions facing the anode and cathode are made of a cation exchange membrane. Various embodiments are included in the invention, including an embodiment as shown in FIG. 4 wherein the entire mold is made of a cation exchange membrane 29; an embodiment as shown in FIG. 5 wherein the bottom of a mold which is secured to the electrolytic cell bottom plate, and the upper portion of the mold which is held in position between the partition plate 13 and the anode upper lid member 15 are formed of a corrosion-resistant material 30, e.g., a fluorine resin, and the central portions facing the anode and cathode are made of a cation exchange membrane 29; and an embodiment as shown in FIG. 6 wherein only the portions facing the anode and cathode are formed of a cation exchange membrane 29, and the frame is made of a corrosion-resistant material. The invention is not limited to the above-described embodiments, and it is sufficient for the bag-shaped mold to be made of a cation exchange membrane at least at the portions facing the cathode and anode. The other portions may be made of a corrosion-resistant material and can be designed in various forms depending on the structure of each electrode. When a cation exchange membrane and a corrosion-resistant material are used to form a bag-shaped mold, they are bonded together by, for example, heat-sealing. When the entire mold is formed of a cation exchange membrane, portions coming into contact with the lower end portion of the anode are readily damaged and, therefore, the above-described protective frame 18 for protecting the mold becomes important.
FIG. 7 is a partially enlarged view of the top portion of an electrolytic cell illustrating a method of securing the anode compartment lid member 15. Referring to FIG. 7, each anode compartment upper lid member 15 is secured to a lid member-fixing member 31 by a clamp bolt 32, and both ends of the lid member-fixing member 31 are secured to projections 33 provided at each side of the electrolytic cell main body 1 by fastening with a bolt.
The electrolytic cell of the invention has a structure that is suitable for remodeling an electrolytic cell heretofore used in the diaphragm method into an electrolytic cell for the ion exchange membrane method. In the usual electrolytic cell for use in the diaphragm method in which a neutral diaphragm comprising asbestos is used, a porous and hollow tubular cathode is covered by the asbestos diaphragm to thereby form a cathode compartment, and an anode supported on an electrically conductive bar is disposed between the cathodes covered with the diaphragm. In accordance with the invention, by utilizing parts of the electrolytic cell for the diaphragm method, such as the electrolytic cell main body, the lid member, cathodes, and anodes, an electrolytic cell having an excellent structure for use in the ion exchange membrane method can be produced.
In the electrolytic cell of the invention, an anode is surrounded by a bag-shaped mold in which at least portions facing the anode and cathode are made of a cation exchange membrane; the bottom of the bag-shaped mold is secured to an electrolytic cell bottom plate by a flange of an electrically conductive bar; and the upper open end of the mold is secured to an anode compartment upper lid member at an opening of a partition plate provided at an upper portion of the electrolytic cell main body. Thus, the cation exchange membrane can be held in position in a closed condition with no relaxation, and as the anode can be brought into close contact with the cation exchange membrane by utilizing an anode having the structure that allows the anode-acting surface to extend in the cathode direction, the invention is advantageous as an excellent structure for the ion exchange membrane method.
By forming the upper and lower portions of the bag-shaped mold using a corrosion-resistant material, the cation exchange membrane can be prevented from being damaged by sharp parts of the anode end portion and, furthermore, the bag-shaped mold can be protected by surrounding the lower end portion of the anode with a protective frame.
In the structure of the present electrolytic cell, there is no danger of explosion due to the mixing of anode side gas and cathode side gas even if a gas leakage occurs between the partition plate of the electrolytic cell main body upper portion and the open end of the bag-shaped mold, or between the anode compartment upper lid member and the open end of the bag-shaped mold, because the outside is open to the air.
While the invention has been particularly shown and described with reference to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. | An electrolytic cell having a plurality of porous and tubular cathodes, a plurality of porous anodes and a plurality of bag-shaped molds being formed by a cation exchange membrane in at least the portions facing and between the vertical faces of the anode and cathodes. The anode accommodating bag-shaped molds have apertures at the bottom through which anode connected electroconductive bars extend, said bars being inserted through and secured at corresponding cell bottom plate apertures by flanges. A partition plate, on the top of the cell main body, has a plurality of openings which correspond to the open tops of the bag-shaped molds. The open top edges of the bag-shaped molds are secured to the partition plate openings by a plurality of lid members. | 2 |
CROSS REFERENCE TO A RELATED APPLICATION
This application is based upon Applicants' Provisional Applications Ser. Nos. 60/596,093 filed Aug. 31, 2005 and 60/767,207 filed Mar. 10, 2006.
BACKGROUND OF THE INVENTION
This invention is directed toward a wall forming system and more particularly a wall forming system that requires less concrete.
Wall forming systems are well known in the art. Generally, a wall forming system has a pair of vertical panels that are held in spaced relation by a tie rail or furring strip assemblies. The space between these panels creates a generally uniform cavity where concrete is formed. The problem with such wall systems is that they require more concrete due to the cavity formed which adds to expense, and the amount of insulation provided by the panels is likewise limited. Excess concrete additionally increases fluid pressures that create blow outs, bowing and snaking of walls and ultimately contribute to poor quality of finished product of typical ICF systems. Therefore, a need exists in the art for an improved wall system.
An object of this invention is to provide a wall system that requires less concrete.
Another object of the present invention is to provide a wall system that provides greater insulation.
A still further object of this invention is to provide a wall system that is easier to assemble.
BRIEF SUMMARY OF THE INVENTION
A wall forming system having a pair of panels that are positioned in spaced relation from one another to form a cavity having a web section and a column section. There is at least one furring strip assembly secured to the pair of panels to hold the panels in spaced relation wherein the furring strip assemblies have retaining flanges with a web section that spans between the flanges. A retainer is then disposed within the furring strip assembly and within the cavity contacting the panels to hold the panels in place.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an elevation view of a concrete structure formed within the wall forming system;
FIG. 2 is a plan top view of a concrete structure formed within a wall forming system;
FIG. 3 is a top plan view of a wall forming system;
FIG. 4 is a plan side view of a furring assembly;
FIG. 5 is a plan side view of panels of a wall forming system;
FIG. 6 is a side plan view of a furring assembly;
FIG. 7 is a top plan view of a corner of a wall forming system;
FIG. 8 is a side plan view of a retainer for a wall forming system; and
FIG. 9 is a top plan view of a wall forming system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the FIGS. 1-3 , the wall forming system 10 includes a pair of panels 12 having an outer surface 14 and an inner surface 16 . The panels have an outer section 18 that extends longitudinally the length of the outer surface 14 and an inner section 20 that extends inwardly from and has a length less than the outer section 18 . A channel or conduit 21 may be cut through the outer section 18 for receiving electrical wires and the like. Specifically the conduit 21 is pre-cut for ease of installation of the electrical wires or preferably cut on-sight. The panels 12 are made of a material having a relatively high insulating value.
When assembled, two panels 12 are positioned in spaced relation where inner surfaces 16 face one another and form a cavity 22 having a web section 24 and a column section 26 . The cavity 22 receives poured concrete or other hardenable materials. When hardened, the hardenable materials form a wall structure.
The panels 12 are held in position relative to one another, and relative to adjacent pairs of panels 12 by a furring assembly 28 . While the furring strip assembly 28 may have any shape, as shown in FIGS. 4 and 6 , preferred is a strip 28 having retaining flanges 30 and one or more webs or connectors 32 that span the distance between the flanges 30 . The webs 32 may include one or more slots 34 to hold conventional reinforcing bars (not shown). Such reinforcing bars are provided to strengthen and increase the durability of the poured, cured, and hardened final wall structure.
Cut out of the furring assembly 28 in alignment with conduit 21 is one or more openings 36 . The openings allow wires to extend from the conduit 21 of one panel 12 to the conduit 21 of an adjacent panel 12 through the opening 36 .
Disposed within the connector 32 of the furring strip assembly 28 are a plurality of retaining slots 38 . One of the retaining slots may be offset in relation to the other slots so that the retainer 40 may be installed one way and is not reversible. The retaining slots 38 can be of any shape. A retainer 40 is inserted through slots 38 to hold panels 12 in place. Preferably a retainer is positioned at the top and bottom of the furring strip assembly. The retainer can be of many shapes (e.g. FIGS. 3 , 8 , etc.). In one embodiment ( FIG. 3 ) the retainer 40 has a longitudinal section 42 with supporting flanges 44 connected to the ends. The longitudinal section 42 has at least one vertical rebar holder 46 and the flanges 44 have generally arcuate ends 48 that engage inner surface 26 . The generally arcuate ends 48 allow for easy insertion of panels 12 and provide a spring type action to hold the panels in place.
In another embodiment ( FIG. 8 ) the retainer 40 has a longitudinal section 42 with supporting flanges 44 and having first and second vertical rebar holders 46 a and 46 b . The flanges 44 have flange sections 49 that extend outwardly from the longitudinal section 42 to ends 48 a that extend in an opposite direction to the flange sections 49 . The flanges 44 are flexible and fit through retaining slots 38 . Further, the flange sections 49 have angled longitudinal prongs 49 b that hold the panels 12 in place.
Alternatively, the furring strip assembly 28 is received in grooves 41 cut within the panels 14 as shown by example in FIG. 9 so that the outer surface 18 of panel 14 more readily receives stucco or EISS material.
To assemble, the ends 48 , 48 a of flanges 44 of the retainer 40 are inserted through retaining slots 38 and frictionally held in place. The outer section 18 of the panel is then inserted between flange 30 and 44 . The arcuate shape facilitates insertion of the panel 12 . Vertical and horizontal rebar (not shown) are added as needed to holders 46 , 46 a , 46 b and 34 respectively. Concrete is then poured into cavity 22 and allowed to harden.
In an alternative embodiment, as shown in FIG. 5 , the inner section 20 of the panel 12 is spaced from the top edge 50 of the panel 12 to form a shelf 52 that defines a beam 54 . Preferably, the shelf has a tapered or angled surface 56 that extends from the panel 12 toward the cavity 22 . The tapered surface 56 facilitates flow of a hardening material from the beam 54 to the web section 24 .
Also, the furring strip assembly 28 , alternatively, has a plurality of slots 34 for receiving reinforcement bars. By having a plurality of slots 34 , flexibility is provided to place horizontal reinforcement bars such that they do not intersect with vertical reinforcement bars. This is particularly a problem with above grade construction where vertical rebar is typically centered.
To further assist with this problem, a retainer 40 having multiple vertical rebar holders 46 (A & B) is used. Such a retainer 40 allows for use below grade (off-set rebar holder 46 B) which provides a gain of approximately 50% in strength, and above grade (centered rebar holder 46 A). To better secure the retainer to the furring strip assembly 28 a locking device 57 such as a spring clip extends transversely from the longitudinal section 42 , preferably from the point where the vertical rebar holders 46 A and B intersect. The spring clip (not shown) is inserted through a retaining slot 38 and expands outwardly to engage the connector 32 holding the retainer in place. In another embodiment, the locking device 57 ( FIG. 8 ) is a pin that is offset to insure that the pin 57 is installed in the correct position. Accordingly, rebar will not be installed in the wrong location in a below grade application where rebar is installed on the opposite sides of the lateral forces (opposite backfill). The furring strip assembly 28 and retainers 40 are used with conventional straight panels or with panels 12 having an inner section 20 that forms a web section 24 and/or a beam 54 .
The wall forming system 10 also has a corner section 58 shown in FIG. 7 . The corner section has an outer panel 60 and an inner panel 62 . The outer panel 60 and inner panel 62 both have an outer section 64 and an inner section 66 , with the inner sections 66 facing one another. In one embodiment, the inner section 66 is spaced from the top edge 50 of the panels 60 and 62 to form a shelf 52 that defines an area for a beam 54 . The shelf 52 may have an angled surface 56 to facilitate flow of hardening material.
The inner and outer panels 60 and 62 are held in place by furring strip assemblies 28 that are transverse to one another. In most situations the furring strip assemblies 28 are at a 45° angle in relation to one another, but, depending upon the construction specifications, other angles are contemplated.
Positioned between the outer panel 60 and the furring strip assembly 28 , is a support member 68 . The support member 68 surrounds the outer surface 16 of outer panel 60 to provide support, as well as a surface upon which materials, including exterior finish materials such as aluminum siding or the like, may be mounted. The support member 68 is made of any rigid material such as polycarbonate, wood, or metal, and may be formed as a single piece or in multiple pieces.
The corner section may be pre-made, or modified to be bent to any angle on job sites using templates for particular specifications which is helpful when the corner angle is not standard.
Thus, a system 10 is provided that reduces the amount of needed concrete, increases the amount of insulation provided and is easy to assemble. This reduced concrete causes a decrease in fluid pressures thus minimizing blow outs, bowing and snaking of walls. Thus, the system creates a high quality concrete wall that is straighter, taller, and more easily made with a user friendly system than previous concrete walls. Therefore, at the very least, all of the stated objectives have been met.
It will be appreciated by those skilled in the art that other various modifications could be made to the device without the parting from the spirit in scope of this invention. All such modifications and changes fall within the scope of the claims and are intended to be covered thereby. | A wall forming system that uses a pair of panels in combination with a furring strip assembly and retainer The pair of panels are placed in spaced relation using the combination of the furring strip assembly and the retainer wherein the furring strip assembly holds the exterior of the panels while the retainer is disposed between the panels to hold them at a predetermined distance. By holding the panels at a predetermined distance concrete is poured within the cavity formed between the panels to create a wall. | 4 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.