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This application is a Continuation in Part of U.S. patent application Ser. No. 08/512,367 as filed Aug. 8, 1995, now U.S. Pat. No. 5,666,880, entitled Integrally Driven and Balanced Line Printer.
BACKGROUND OF THE INVENTION
1. FIELD OF THE INVENTION
The field of this invention lies within the printer art. More particularly, it lies within the art of dot matrix printing wherein numerous dots are printed on a print media such as a sheet of paper to provide for an alpha numeric representation thereon. It specifically relates to the field wherein line printers are driven for movement across a print media in order to impress a number of dots thereon as the printer moves reciprocally across the print media.
2. PRIOR ART AND IMPROVEMENTS THEREOVER
The prior art with regard to dot matrix printers encompasses multiple printers of various configurations. Such configurations use various wheels and hammers of various types to impress a dot on a print media. One particular type of printer which is known in the art is a line printer.
Line printers generally have a series of hammers. The series of hammers are implaced on a hammerbank which reciprocally moves across a print media. The print media is advanced across the hammers and is printed thereon by an inked ribbon.
Such hammers are supported on a hammerbank. The hammers are often held in place by a permanent magnet until released or fired. The release or firing takes place by the permanent magnetism holding the print hammers being overcome. The permanent magnetism is overcome by means of coils which receive a drive current to overcome the magnetism of the permanent magnets.
The foregoing action releases the hammers at a given time and causes them to move toward a print ribbon moving across their face. When the print ribbon is impressed by the hammers, it moves against an underlying print media which has the dots printed thereon. The hammers are released and controlled by electronic drivers which cause the coils to function.
The drivers are provided with logic consistent with the particular configuration of the print to be impressed on the print media. The logic can be in the form of local logic control in conjunction with a host and a central and data processing unit integral to the printer.
In the past, it has been known to place a drive motor at an offset location from the hammers of a hammerbank and drive the hammerbank reciprocally by a crank or a connector. The movement is such wherein the crank or connector must move the hammerbank in a reciprocal manner in a sufficiently rapid manner so as to provide high speed printing. To help to accomplish this, a sufficiently strong and reliable connection is provided between the drive means such as the motor and the hammerbank. During reciprocal movement of the hammerbank, it moves in such a manner as to reciprocate and terminate this movement at various positions with regard to the desired effect on the print media. During its course of movement, when considering the mass of the hammerbank and the speed, it has been customary to counterbalance the hammerbank.
The foregoing counterbalances have been placed in a manner so that they can offset the movement of the hammerbank at different portions of its stroke or movement. Such offset relationships have not always been desirable because of the fact that they were offset and not in a compact and tightly oriented relationship to the hammerbank. In effect, the counterbalance although helping to balance the hammerbank was offset to a degree wherein it created forces which caused the printer to vibrate. Various methods have been used to dampen such vibrational forces. However, in most cases, the vibrational forces could only be dampened and not significantly offset in a consistent and balanced manner.
Another problem of the prior art is that the motor's flywheel was not always consistent and balanced with regard to a configuration to provide for smooth and compact mechanical movement. This creates a situation wherein the flywheel was not always such where it provided for a smooth balanced operation between the connecting rod and the hammerbank and counterbalance.
Another drawback of the prior art was that the capability of driving the hammerbank in a reciprocal manner was not accomplished to the extent where the various forces of movement could be readily dampened. In the alternative they could not be driven in such a manner so as to provide for integrated movement wherein one force offset the other as to the counterbalance and hammerbank and/or the connecting rods and the motor.
The prior art incorporated motor drives for the shuttle which had multiple sensors associated with them. Sometimes, the multiple sensors were also placed on the hammerbank. More recently, it has been common to place multiple sensors on the motor in the form of Hall sensors.
Such motors, in the prior art are commonly brushless motors because of their high reliability and efficiency. These motors require sensing devices to detect the position of the rotor of the motor so that the stator can be driven properly. A common sensor that is used is a Hall sensor that is mounted inside the motor in multiple locations. This increases the cost of the motor and is not as effective as this invention.
In other systems, the shuttle or hammerbank required a second sensor to detect the position of the shuttle during the stroke to determine when the hammers needed to be fired.
It is an object of this invention to remove the Hall sensors where those sensors are on or in the brushless D.C. motor. Another object of this invention is to provide for a rotor position by using a low cost shuttle position sensor.
It is another object of this invention to overcome the problems of the prior art by having a flywheel which is integral to the motor. The motor is an inside out motor wherein the stator is on the inside. With the flywheel being on the outside, the inertia is enhanced to maintain the angular velocity of the motor and flywheel once it is up to speed and of course the mechanical elements connected thereto.
The integral motor is enhanced by a ferrite permanent magnet to enhance efficiency. The flywheel is a sintered metal flywheel having a high density without having to machine the flywheel. The permanent magnet is a sintered barium ferrite material formed as a ring with substantial qualities to enable the motor to function over a highly efficient range.
Another object of the invention and a most important consideration is the fact that the motor is directly connected to the connecting rods of the hammerbank and the counterbalance. This connection is through an integrated motor shaft connected to the flywheel. This relationship thereby transmits the inertia of the flywheel directly to the shaft and the connectors. The connectors are each connected to the respective portions of the integrated hammerbank and counterbalance for reciprocal movement thereof. This is accomplished by eccentrically driven connector rods that move 180° degrees in opposite relationship with the eccentrics being formed as part of the motor shaft, and 180° apart from each other.
Another object of the invention is to dynamically balance the system so that the flywheel, eccentrics, and connector rods are all dynamically balanced during their movement. This serves to minimize vibrations and unwanted forces throughout the cyclical movement of the printer.
A further and substantially important object of the invention is to provide for an integral hammerbank with an overlying and surrounding counterbalance. The relationship of the hammerbank and the counterbalance with its overlying relationship allows the structure to be compatibly and integrally balanced between the two respective members namely the hammerbank and the counterbalance. This overlying relationship causes a dynamically coordinated and balanced relationship to be established between them when connected to the connector rods. The invention further establishes close proximity of the hammerbank and counterbalance to the connector rods as an integral unit, for smoother operation. As can be appreciated the more distal an object is driven, the greater the forces are required and thereby greater dampening and other efforts must be undertaken to prevent unwanted forces to be applied to the dynamic system. This invention tends to eliminate such problems.
This invention provides for the integrated hammerbank and counterbalance to be connected with connector rods or drive rods which are in close proximity to each other. The rods drive a dynamically moving system comprised of the hammerbank and counterbalance. This is done in as close a proximity as practical with respect to the drive shaft emanating from the motor. This particular relationship enhances the dynamics so that less vibration and various forces are encountered. The result is to create a dynamically balanced system driven by the motor and connecting rods as an entire integrally formed and balanced system.
Another object of this invention which is significant and important is that the motor, counterbalance and hammerbank are keyed or linked for operation after being placed in a closed loop relationship. This effectively allows an electrically locked position between the motor and the hammerbank. This is effectuated by means of a low cost single sensor that merely senses the position of the rotor of the motor that is in turn keyed to the position of the hammerbank.
For these reasons, the invention is a substantial step over the prior art and enhances line printer functions as well as smoothness of operation, speed of operation, and provides longevity and finer printing for a line printer than had previously been capable in the art.
SUMMARY OF THE INVENTION
In summation, this invention comprises a line printer having an integral hammerbank and an overlying or surrounding counterbalance with a motor and a single sensor, having a flywheel and rotor integrally oriented with it, that drives a motor shaft having integral eccentrics respectively connected to the connector rods for the counterbalance and the hammerbank.
More particularly, the invention comprises an improved line printer having an integral hammerbank with an overlying or surrounding counterbalance interconnected thereto. The counterbalance and the hammerbank are respectively supported for reciprocal movement 180° apart from each other. The respective hammerbank and counterbalance overlie each other so that they move in such a manner wherein one moves within the other in direct underlying and overlying axially aligned relationship. In particular, the counterbalance is formed such that it overlies and surrounds the hammerbank in part which moves reciprocally and axially therein in a position 180° apart from the movement of the counterbalance. This particular movement is such wherein the counterbalance and the hammerbank are integrated for dynamic reciprocally axially aligned movement to prevent offsets and forces being applied thereto which can disturb the dynamic movement of each one respectively.
An integrated motor and flywheel are provided to the invention. The flywheel is on the outside of a circular magnetic ring which overlies a stator for causing the flywheel to move on an integrated basis with the motor shaft connected thereto through the stator. The motor shaft is interconnected to a drive shaft. The drive shaft is provided with two eccentrics thereon.
The two eccentrics on the drive shaft are oriented so that they are 180° out of phase from each other. These eccentrics are connected to bearings within two connector rods.
The two connector rods are each respectively connected to the hammerbank and the counterbalance for reciprocal movement thereof 180° apart. This effectively allows for the drive shaft to turn the connector rods 180° apart from each other and drive the respective hammerbank and counterbalance.
The invention is further enhanced by balancing the counterbalance and the hammerbank on a pair of bearing surfaces and flexures. The bearing surfaces and flexures allow for reciprocal movement on flexible spring connectors while at the same time providing for a smooth bearing operation during lateral movement as the hammerbank and its accompanying counterbalance reciprocate.
This invention in reference to the movement of the motor eliminates redundant sensors. The sensors are eliminated from both the hammerbank as well as in multiple relationship within the motor itself. The elimination of the multiple sensors in the motor itself eliminates the expensive Hall sensors and the need for multiple sensors.
The invention eliminates the use of expensive Hall sensors and multiple sensors by detecting the rotor position using a low cost magnetic position sensor. This sensor can also be in the form of other magnetic, optical, or other types of sensors that sense the position of the rotor of the motor.
In order to enhance the use of a single sensor, extreme accuracy is maintained and orientation of the sensed pulses that are a direct correlation to the position of the rotor as it is connected to the hammerbank. In turn, the hammerbank must be in position with respect to the motor so that the sensor that sends signals as to the position of the rotor of the motor is directly correlated and orientated with the position of the hammerbank.
The entire system is controlled by a host and a central processing unit through detecting movements of the motor rotor as correlated to the hammerbank, causing the system to respond thereto so that the integral unit moves in a smooth, accurately positioned, and low vibration printing movement.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of the integrally driven and balanced line printer of this invention with its shuttle frame to be mounted on a mechanical base.
FIG. 2 shows a perspective view of the integrally driven and balanced line printer looking at the opposite side from that shown in FIG. 1, and wherein a fragmented portion of the hammerbank cover and ribbon cover have been removed to expose the hammers of the hammerbank.
FIG. 3 shows an exploded view of the components of the integrally driven and balanced line printer shown in the same direction as that of FIG. 1.
FIG. 4 shows a side elevation view of the connecting rods for respectively driving the hammerbank and counterbalance.
FIG. 5 shows a side elevation view of the respective hammerbank and counterbalance connecting rods driven 90° from the position shown in FIG. 4.
FIG. 6 shows a view of the drive shaft with the eccentrics and bearings thereof as sectioned along line 6--6 of FIG. 4.
FIG. 7 shows a side sectional view of the linear bearings, shafts and connectors related to the hammerbank as seen in the direction of line 7--7 of FIG. 4.
FIG. 8 comprises a top plan view looking downwardly at the printer of this invention.
FIG. 9 shows an exploded view of the integrated motor and flywheel of this invention.
FIG. 10 shows a view of the relative placement of the magnetic portions of the circular magnet of the motor as to the north and south orientation of the magnetized portions of the ring.
FIGS. 11A through 11D show the electrical connections for the various coils of the stator of the motor of this invention.
FIGS. 12A and 12B show a trace of the output of the magnetic sensor sensing the position of the rotor of the motor of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Looking more particularly at FIGS. 1 and 2, it can be seen that a base 10 or shuttle frame has been shown. The base 10 or shuttle frame is attached to a mechanical base by means of various attachments. The mechanical base can form a large portion of a cabinet such as a stand alone printer cabinet or a printer mechanical base that can be portable or placed on a surface such as a table.
The shuttle frame or base 10 which attaches to the mechanical base, which is not shown in this case is formed from a die cast alloy. It can be in the form of an aluminum zinc alloy or any other suitable material which will form a firmly fixed and rigid base upon which the printer movement will not be torqued, moved, or unduly provided with forces which will disorient it.
Underlying the shuttle frame or base 10, are a series of cross members in a pattern to provide reinforcement. The entire base 10 can be concave with struts and structures crisscrossing and rigidifying the entire shuttle frame or base 10.
The shuttle frame or base 10 is mounted to a mechanical base by means of mounting or support member shafts 12 and 14. The mounting or support member shafts are held such that they can be rotated on the mechanical base. This allows the entire printer structure formed on the base or shuttle frame 10 to be rotated such that the hammers can be adjusted with respect to a platen or other surface against which they impinge. The two mounting or support member shafts 12 and 14 comprise two portions of a three part mounting.
The third portion of the mounting is a bracket 16 which extends from the shuttle frame or base 10. The bracket 16 is integrally formed with the shuttle frame or base 10 the bracket 16 forms a strong component thereto for maintaining it in rigid relationship with a mounting screw 18 having an allen head 20. The mounting screw 18 threads downwardly against the mechanical base which is not shown to which the entire printer is mounted.
In effect, the base 10 is mounted by the three mountings including the support member shafts 12 and 14 as well as the bracket 16. Thus, adjustment around the rotational axis of mounting or support member shafts 12 and 14 allow for the base to be moved inwardly and outwardly as to the hammerbank's position this adjustment can be made by raising and lowering and adjusting the mounting screw 18.
FIG. 1 shows a hammerbank 22 of this invention from the back thereof. FIG. 2 shows the hammerbank 22 with the hammers exposed. In particular, hammers 24 are formed and supported in this case in a series of three, on frets 26 which are screwed to the hammerbank 22. Such frets 26 can have hammers 24 in multiple numbers significantly higher than the three on fret 26 shown here.
Each hammer 24 as is known in the art comprises a hammer supported and formed on the fret 26 which extends upwardly and provides a pin like member 64. The pin like member 64 impacts against a ribbon which is driven across the face of the hammers 24 to be printed against an underlying print media such as paper.
The ribbon which is impacted and impressed by the hammers 24 passes between a ribbon mask 30 and a hammerbank cover 32. The hammerbank cover 32 and the ribbon mask 30 are held together and joined at the bottom thereof namely at bottom interface 34. In order to secure the combination ribbon mask 30 and the hammerbank cover 32, four magnets, one of which is shown as magnet 38 pull the respective hammerbank cover 32 and ribbon mask 30 against the magnet 38 for securement. This allows for easy removal of the ribbon mask 30 and hammerbank cover 32 for cleaning and access to the hammers 24.
The hammerbank 22 is formed with a permanent magnet therein for holding the hammers 24 until released by coils which are not seen that are activated in part by drivers on an integrated hammerbank circuit board 42. The circuit board 42 has a plurality of electronic components thereon which electrically drive the hammers 24. The circuit board 42 is connected to a flex cable or connection 44 that is in turn connected to a terminator board 46. The terminator board 46 interconnects to a central and data processing unit or other means for driving the printer which in turn is connected to a host as is known in the art.
A power connection through a connector is provided through terminals seen in a terminal block 50, while a logic connection is provided through a logic connector 52.
The circuit board 42 of the hammerbank 22 can be formed in any particular manner provided with local logic, drivers, and various other electronic conditioning means for amply allowing the hammers 24 to fire when necessary in a well timed and readily functioning manner. As previously stated, the hammerbank 22 moves reciprocally across the print media in order to release the hammers and effect printing by the ribbon against the underlying print media.
Looking again more particularly at FIG. 7, it can be seen that the hammerbank 22 incorporates the frets 26 and hammers 24. Each hammer 24 has a narrow neck portion 60 that terminates in an enlarged portion 62 with a tip 64 at the end thereof. The hammerbank 22 is further provided with a printed circuit board 42 which terminates at the flex cable or connection 44 to provide the logic to the components on the printed circuit board 42. These components as previously mentioned allow the hammers 24 to be fired with respect to their being fired through the release of the permanent magnetism drawing them inwardly toward the hammerbank 22.
The hammerbank 22 is secured for driving purposes to two lugs. These two respective lugs are referred to as the driving lug 72 and the trailing lug 74. The respective driving lug 72 and trailing lug 74 are each respectively connected to a concave portion 76 of the hammerbank 22 by means of a high strength glue. The driving lug 72 and trailing lug 74 of course can be attached in any other suitable manner.
Attached to the driving lug 72 is a block driver 80. The block driver 80 is formed and secured to the driving lug 72 by means of the driving lug 72 having a flat portion 84 which is formed as a portion of the driving lug. The driving lug 72 can be seen more effectively in FIGS. 4 and 5 with the block driver 80 secured thereon. Securement of the block driver 80 to the lug flat 84 can be in any suitable manner such as by a bolt attachment or other suitable means.
The respective driving lug 72 and trailing lug 74 each have a shaft 90 and 92 passing therethrough. These shafts 90 and 92 each allow the hammerbank 22 to move reciprocally backwardly and forwardly on the shafts. Each shaft 90 and 92 supports the driving lug 72 and trailing lug 74 respectively with a linear bearing 94 which can be seen such as the linear bearing shown in FIG. 7. The linear bearing 94 is supported within the driving lug 72 in a manner whereby it allows reciprocal movement of the shaft 90. In like manner, the shaft 92 and trailing lug 74 reciprocate with respect to each other on a similar linear bearing 94.
The shafts 90 and 92 are secured to the shuttle frame or base 10 by means of four respective clamps 104, 106, 108 and 110. Each clamp as can be seen in greater detail in FIG. 3 incorporates a rounded concave interior surface 114 to receive the outer circumference of a portion of the respective shafts 90 and 92. They serve to clamp the shafts 90 and 92 against flats which again can be seen in FIG. 4 namely flats 116. These flats 116 allow the shafts 90 and 92 to be held tightly against the shuttle frame or base 10 and to be secured by the respective screws and a washer such as screws 118 securing each respective clamp 104, 106, 108 and 110 and its attendant shaft.
Both the hammerbank 22 and the counterbalance 130 as will be described hereinafter effectively rely upon a system to drive them reciprocally which shall be described hereinafter in greater detail.
Looking more particularly at the counterbalance to the hammerbank 22, it can be seen that a general rectangular configuration in the form of counterbalance 130 has been shown overlying and surrounding in part the hammerbank 22. This counterbalance 130 moves reciprocally and in opposite direction to the hammerbank 22. The counterbalance 130 is aligned for parallel movement with the hammerbank 22 in close proximate relationship. The hammerbank 22 and counterbalance 130 can be collectively referred to as the shuttle since they comprise the oscillating units that move across the platen for printing purposes.
The counterbalance 130 is a die cast aluminum alloy which forms a frame with an upper member 132 and a lower member 134 which overlies the hammerbank 22. The ends of the counterbalance 130 are provided with upright portions 136 and 138 which roughly define a rectangular opening 140 in which the hammerbank 22 moves backwardly and forwardly.
The counterbalance 130 is supported on the shuttle frame or base 10 by means of flexures, flexural support or spring leaves 144 and 146.
Each support flexure or spring leaf 144 and 146 is secured respectively to the shuttle frame or base 10 by means of clamps 150 and 152. The clamps 150 and 152 have screws with allen heads threaded into openings within the upper portion of the counterbalance 130. Clamps 154 and 156 which can be seen in the reverse view from FIGS. 1 and 3 in FIG. 2 support and counterbalance 130 at the lower position where it is attached to the frame 10.
The support or spring leaves 144 and 146 allow for reciprocal movement backwardly and forwardly of the counterbalance 130. In this manner they provide for not only strong vertical support, but movement in the direction of the length of the counterbalance 130. The flex supported movement of the counterbalance 130 can be seen in FIGS. 4 and 5 wherein the counterbalance 130 support leaves are shown flexed in FIG. 4 in their driving motion.
Returning now to the hammerbank 22 and the way it is driven in reciprocal movement with the counterbalance 130, it can be seen that a first shaft, connector, or drive rod, namely shaft 170 is shown on a connecting rod or crank arm 172. The crank arm or connecting rod 172 has a ball bearing 174 pressed fit with lock tight into an opening 176 provided by a circular loop or opening 180 forming a portion of the crank arm or connecting rod 172.
The connecting rod 172 terminates at a rod spring flexure 190 which can be seen screwed to the end of the connecting rod or crank arm 172 into the top of the block driver 80.
In FIG. 4, it can be seen that the movement is such wherein it is in a relatively aligned position with the axis of the connecting rod 172, while in FIG. 5 it is shown flexed during its drive movement.
The crank arm or connecting rod 172 serves to reciprocate the hammerbank 22 in response to the movement of the motor drive shaft as shall be detailed hereinafter.
Looking at the counterbalance 130 it can be seen that a second crank arm or connecting rod 200 is shown having an elongated connection portion 202 with a looped opening 204. The looped opening 204 contains a ball bearing 206. The connecting rod 200 terminates in a rod flexure spring member 212 which is secured by screws to the counterbalance 130 at a clamp 220 held again by screws.
In order to drive the hammerbank 22 with its associated counterbalance 130, the crank arms or connecting rods respectively 172 and 200 are driven in a relationship wherein they are 180° offset from each other as to their reciprocal movement. This is accomplished by a crank or shaft 230 having two integral offset eccentric circular portions. Eccentric 232 is associated with the connector rod 200 and eccentric 234 is associated with crank arm or connector rod 172. These two respective eccentrics 232 and 234 move within the respective ball bearings 206 and 174.
In order to support the crank or shaft 230, a front support plate 240 is utilized having a bearing 242 inserted within an opening 244 for rotational movement. The crank or shaft 230 rotates around an axis established by the center of the crank or shaft 230 thereby causing the eccentric circular portions 232 and 234 to drive respectively crank arms or connecting rod 172 and 200 in a reciprocating manner 180° offset from each other.
The foregoing movement can be seen in FIGS. 4 and 5 wherein the crank arms or connecting rods 172 and 200 are displaced from each at the farthest point of drive to the right, in FIG. 4. In FIG. 5 movement is such wherein the crank or shaft 230 has moved 90° so that the eccentric circular portions 232 and 234 are respectively directly overlying each other.
As can be seen in FIG. 5, the rod spring flexures 190 and 212 have been bent to provide for this eccentric movement of the crank arms or connecting rods 172 and 200 and their respective loop portions 180 and 204 in displaced relationship from each other.
It is now seen that the hammerbank 22 moves reciprocally backwardly and forwardly along the shafts 90 and 92 as supported by the driving lug 72 and the trailing lug 74 within their respective linear bearings. As reciprocal movement is encountered, it can be seen that the hammerbank 22 can rotate around the axis of the shafts 90 and 92 to some extent. In order to prevent this rotation, an anti-rotation plate 300 is utilized. The anti-rotation plate 300 is secured to the hammerbank 22 by two screws on the inset portion 302. The anti-rotation plate 300 provides a surface which can be held tightly in secured relationship against a button disk, or seating surface 304.
The button disk, or seating surface 304 is a disk like member having a rounded or convex portion or surface 306 and a flat portion or surface 308. The rounded portion or surface 306 is seated within an anti-rotation boss member 310. The boss member 310 has a convex rounded cup like seat to receive the rounded portion or disk surface 306 therein. This allows for the disk like member 304 to adjust its flat surface in relationship to the anti-rotation plate 300 so that the two flats are against each other. This provides for various disorientation of positioning while at the same time allowing the plate to move reciprocally across the flat portion or surface 308. The engaged relationship maintains the third portion of the planar orientation of the hammerbank 22.
The hammerbank 22 is biased against the anti-rotational plate 300 by a coil spring 320. The spring 320 is secured to a pin 322 on the shuttle frame or base 10 and through an opening 324 within the anti-rotational plate 300.
In order to rotate the crank or shaft 230, a brushless D.C. motor is utilized that is emplaced within a round or circular housing 350. The circular housing 350 receives the brushless D.C. motor with a portion exposed.
The brushless D.C. motor is driven by three wire leads 352 connected to a circuit board 354 with terminals for the motor. The circuit board 354 has a series of terminals or connectors in order to distribute power to a stator 356. The stator 356 has a number of stator coils 358 that are connected to the circuit board terminals 354. In this manner stepped pulses can be provided for causing the motor to rotate in a stepped relationship.
The motor is an inside out type of motor with a ferrite magnetic ring 360 having north south polarities oriented in the manner shown in FIG. 10. The polarization of the ferrite material is through six sections that are sixty degrees (60°) apart giving a north south orientation so that the motor can be driven with the magnetic ring 360 pulsed to move depending on the output of the stator coils 358 connected to the wire leads 352. This allows for the pulsing of the motor on a continuum when started with a great degree of accuracy and precision. The particular method of start-up and related aspects thereto will be detailed hereinafter and are a substantial portion of this invention.
The motor includes a flywheel portion 364. The flywheel 364 is connected to the motor by means of emplacing it in any suitable manner on the magnetic ring 360. The magnetic ring 360 and the flywheel 364 are referred to collectively as the rotor, and one element can be combined with the other. For instance, the flywheel 364 with the magnetic ring 360 can be combined as one element with the other portions of the flywheel being formed therewith forming a unitary rotor.
The flywheel 364 has a flywheel shaft 366 with an opening 368. The opening 368 receives the crank or shaft 230 passing therethrough and is seated within an opening 370 of the shuttle frame or base 10. The opening 370 has a retainer 372 and a bearing (not seen) which supports the flywheel shaft 366 in order to turn the crank or shaft 230.
The flywheel 364 is made of a sintered material of high density without the requirement of machining. The magnetic material of the magnetic ring 360 is of barium ferrite, to provide high density and strong magnetic properties to the magnetic ring.
The flywheel 364 has a plurality of teeth, notches, or lands and grooves respectively 380, and 382 around the surface thereof. These lands and grooves can be formed on a unitary rotor incorporating the flywheel 364 and ring 360 as a single piece. The lands 380 and grooves 382 are equally spaced around the outer circumference thereof except where an enlarged space or groove 386 can be seen in FIG. 1. This enlarged space or groove 386 can comprise the equivalent of two grooves 382 as placed between the respective lands 380. This is a spacing that is effectually twice as great as a single gap or grove 283. The enlarged space or groove 386 allows for a detection of non-continuity of the lands and grooves 380 and 382. This permits telemetry of the orientation and speed of the flywheel 364 and the shaft with the attendantly oriented hammerbank 22 and counterbalance 130 (the shuttle).
As an alternative the orientations and effect of the enlarged groove 386 can be substituted by an expanded land. The expanded land could have about twice the width of the lands so as to differentiate the pulse as to its width. This in turn can serve to indicate the orientation of the motor in the same manner as the expanded groove 386.
The lands and grooves 380 and 382 provide for detection of movement and orientation by a magnetic detector that is shown in dotted outline form in FIG. 8. Namely, a detector 390 having a permanent magnet 392 connected to leads 394 detects the rotational movement of the flywheel 364. Every time a land 380 passes, the magnetic orientation between a permanent magnet 392 and a coil 391 causes a signal to be generated on leads 394. These signals or pulses are then directed toward the logic of the system in order to determine where the flywheel 364, forming the rotor and attendant portions of the crank or shaft 230 attached to the hammerbank to 22 are oriented. This function will be explained in greater detail hereinafter.
Although, a magnetic sensor 390 has been shown with a coil 391 and permanent magnet 392, it should be appreciated that other types of sensors can be utilized. Such sensors can incorporate Hall effect sensors, optical pickups, laser telemetry, RF sensors, and various reflective or wave oriented sensors with regard to movement of the flywheel 364 of the rotor. Also, it should be appreciated that the orientation of the flywheel 364 and rotor at the outside is particularly advantageous in this respect, in that it allows for the stator 356 to be emplaced therein with the magnetic ring 360 surrounding it.
The initial start-up of the printer with the shaft 230 turned by the motor causes it to rotate to approximately 250 to 300 rpm afterwhich the pickup pulse by the sensor 390 becomes more stable. The pickup pulse orients the flywheel 364 and drive with regard to the enlarged space, gap or groove 386. Detection by the logic of the circuit determines where the orientation of the printer is as to the crank or shaft 230 and of course attendant relationships of the hammers 24 on the hammerbank 22. This will be detailed as to the motor and its start-up procedures, and logic control.
The flywheel 364 and the remaining portions of the rotor are dynamically balanced. This is done by compensating for the lesser material in the gap or groove 386 being offset by removing material from the flywheel at a point opposite from where the gap 386 is.
The motor as shown in FIGS. 9, 10, and 11 operates on an open loop basis until the proper timing is sensed. It then operates on a completely closed loop basis so that it moves in correspondence to the printing duty requirements in order to move the hammerbank 22 to release the respective hammers 24 at the appropriate point so that impact upon the part of the print tips 64 is at the right location with regard to the underlying print media.
When considering the fact that the motor is directly connected to the shaft 230 which is in turn directly connected by a mechanical linkage through the cams 232 and 234 to the respective drive shafts, it can be seen that the hammerbank 22 is in directly driven relationship to the orientation of the motor. When the hammerbank 22 is positioned at a particular position and the motor is keyed thereto by its direct mechanical connections, it can be seen that if a sensing of where the motor is determined, that an exact sensing of the placement of the respective hammers of the hammerbank 22 can be determined. This in turn allows for the hammers 24 to fire correctly if a particular orientation of the motor can be established. With this assumption of the particular direct linkage, if one knows the orientation of the rotor, one will then know respectively the orientation of the hammers 24.
Taking this particular supposition, the orientation of the motor can now be seen to be tied to the position of the hammerbank through the direct mechanical linkage.
In order to position the hammerbank 22 and the motor in a relatively known starting position, the hammerbank is initially held and retained in a central position. This central position is achieved by means of the spring 320 and the leaf springs at either end namely springs 144 and 146 positioning the hammerbank 22 in a relatively central position or at least in the position in which the springs 320 and the leaf springs 144 and 146 bias it to. With this known biased position, the motor can then be started. Based thereon, that particular position can then be oriented correctly with response to the particular motor position.
Looking more specifically at FIGS. 9, 10, 11, 12, and 13, it can be seen that the motor is shown with its respective functioning elements and logic control.
When looking at the magnetic ring 360 of FIG. 10, it can be seen that it is divided into six magnetically oriented segments. Starting at the twelve o'clock position or point 600, it can be seen that a south north orientation of the magnetic ring is positioned there. Within sixty degrees (60°) clockwise, the polarity changes from the outside to the inside to north south at position 602 which is approximately sixty degrees (60°), from the point 600.
Going around the ring 360, it can be seen that the orientation then changes every sixty degrees (60°) from south north to north south in polarity until the twelve o'clock position or top position is seen at point 600.
These particular south north to north south positions are such wherein they cause the magnetic ring 360 which is attached to the outer portion of the rotor 364 which is characterized as a flywheel to move when the coils 356 are excited.
Coils 356 are excited in a manner so that they respectively are tied together through their connections as seen in FIG. 11. In particular, the coils 358 can be seen as a first coil 606 connected with a second coil 608 one hundred and eighty degrees (180°) therefrom. A third coil 610 is connected to a fourth coil 612 that is in turn one hundred and eighty degrees (180°) from the coil 610. Finally, a fifth coil 614 and a sixth coil 616 are connected one hundred and eighty degrees (180°) apart. These respective connections can be seen as the connections, terminals or lines 618, 620, and 622 that comprise those connected to or forming lines 352.
Coils 606 through 616 can also be connected as pairs of coils shown in FIG. 11 as to the Y or Delta connections. The Y configuration is shown with the equivalent coils connected to lines A, B, and C of the motor which are equivalent to lines 618, 620 and 622 of the enlarged stator of FIG. 11. It should be appreciated that when referring to coils in this specification, the term is inclusive of motor windings. The Delta connection would also be connected through terminals A, B, and C equivalent to terminals 618, 620 and 622.
When lines or terminals 618, 620, and 622 are energized, they impart power to the respective coils which they are connected to. This allows for three particular energy pulses to direct six respective coils for improved smoothness and sensitivity and torque for driving the motor that comprises the ring 360 and outer rotor or flywheel portion 364. In this manner, when energy is applied to connection or terminal 618 it energizes coils 606 and 608. When energy is applied to line or terminal 620 it energizes coils 610 and 612. When energy is applied to line or terminal 622 it energizes coils 614 and 616. These particular lines are connected as previously stated to a circuit board 354 that serves as a connection for the coils 358 on lines 352 which represent those lines connected to lines or terminals 618, 620, and 622 as shown in FIG. 9.
Since the sensor 390 is a variable reluctance magnetic sensor, it requires that the motor be moving at a rate of about 250 to 300 revolutions per minute (rpm). This is in order for the sensor 390 to be able to fully detect the speed of the rotor from the flywheel 364. This in turn is indicative of the movement of the hammerbank 22 and allows for the motor to make a complete revolution to detect the position of the shuttle.
The mechanical movement of the hammerbank 22 with its counterbalance 130 (the shuttle) is such where it creates a difficult analytical variable from the standpoint of the loading of the motor since it is continuously changing. In effect, the shuttle drive comprising the motor and the remaining linkages have to be able to start the hammerbank 22 and counterbalance 130 (the shuttle) without discretely knowing the position of the components.
Generally stated, in order to effectuate controlled movement, the drive at the time of starting provides for a large amount of current through one of the motor coils, for example one of the pairs, such as pair 606 and 608 with the other pairs connected respectively to lines 620 and 622. This causes the motor to rotate to a known position and stop. The shorting of the other two pairs of coils causes the motion to be dampened and helps remove oscillations. This is particularly important inasmuch as the hammerbank 22 and counterbalance 130 are placed in a sprung mode so that they can oscillate to some degree. After holding the motor still for an instant, the current is driven through the next pair of coils, causing the motor to rotate and bend the springs holding the counterbalance namely those springs seen as springs 144 and 146. When the motor has turned one quarter turn, the springs are fully bent and start to spring back thereby accelerating the shuttle.
The stator in the form of the coils 356 also shown in FIG. 10 commutate after startup at a faster rate until the motor is moving fast enough for the sensor 390 to detect the motor speed and long enough for the sensor to detect the motor position. After the sensor 390 detects both the appropriate speed and position, then the drive changes from an open loop mode to a closed loop mode. A micro-controller or digital hardware then uses the information from the sensor 390 to drive the motor in an efficient manner.
Looking more specifically at the way this is carried out, it can be seen that FIG. 12 shows a trace of the pulses or relative voltage outputs from the sensor 390. At start-up, the pulses as seen on trace 640 are relatively weak as measured with respect to velocity (v) of the rotor flywheel 364 from start-up. These pulses 640 tend to get larger based upon the magnetic output due to the lands 380 of the rotor flywheel 364 going faster thereby creating a larger change of flux through the magnetic sensor 390. In effect, the coils of the magnetic sensor 391, as energized by the relative change in the magnetic flux through the magnet 392 as the lands 380 pass, increases the voltage or pulsed output with the increasing higher speed of the motor. The increased higher motor speed also increases the frequency of the pulses from the lower frequencies of magnetic changes to the higher magnetic frequency changes as the motor speeds up.
Upon sufficient velocity (v) of the motor to the point where it puts out a high enough detectable signal beyond the point of zero voltage, the signal can then be properly read. Generally, this is in the neighborhood, with the magnetic sensor, of being 250 to 300 rpm for the rotor or flywheel 364. This peak voltage (P) can be seen as shown on trace 640. It should also be noted that the signal trace 640 increases from a low frequency and low amplitude to a high frequency and higher amplitude signal as the motor speed (RPM) increases.
When trace 640 of the voltage pulses are sufficiently high at the point (P), the pulses are then utilized as signals 642 as shown in the lower trace. At such time, the position of where the gap 386 is read shows the particular position of the rotor with flywheel 364 of the motor. This gap is shown as the gap 386A of the usable voltage or pulses 642. This indicates the position of the motor and of course the relative position of the hammerbank 22 with the hammers 24 thereof. Gap 386A has a positive and negative amplitude because of the nature of the variable reluctance magnetic sensor 390 imparting a signal with a wave form being an analog sinusoid.
The wave form of the variable reluctance magnetic sensor 390 is squared up with a voltage comparator to provide a square wave form 643 having highs and lows that somewhat correlate to the zero crossing of the wave form 642. The output 645 of the voltage comparator as to the missing tooth or enlarged groove 386 is shown with respect to the wave form 642. This allows the signal to be digitized in a usable format.
The time domain is shown for the wave form 642 in the form of the time line trace 647 wherein the timing of the output based upon the enlarged gap or groove 386 is twice that of the remaining lands and grooves.
The foregoing outputs can then be reviewed such that when the hammerbank 22 and counterbalance 130 (the shuttle) are in a known position at power-up of the printer, the process for orienting the hammers 24 can begin. This is based upon the known position derived from the spring bias due to springs 320 and leaf springs 144 and 146. At this point, the respective coils connected to connections or terminals 618, 620, and 622 are driven to cause the motor to move.
For instance if those coils 606 and 608 connected to terminal or line 618 are first started, then those coils 610 and 612 connected to connection or terminal 620 are energized thereafter to cause the rotor 364 and ring 360 to begin to turn. They then move in a predictable manner because of the fact that the position is known based upon the characteristics of the electrical and mechanical elements all being linked together.
In the subsequent step, the next coils 614 and 616 are driven as connected to connection or terminal 622. Based upon the mechanism, the inertia, and the motor torque accelerating, the motor then reaches a theoretical speed. This theoretical speed is fast enough to give valid pulses out of the magnetic sensor pickup unit 390.
At this time, it is then determined whether or not the pulse is at a proper peak (P) for reliable signals. As the pulses reach the peak point (P) of the trace 640 they can then reliably determine the position of the gap 386A through the gapped pulses or expanded low orientation of the double lack of a pulse or gapped trace 386A.
Thereafter, the pulses are counted to determine the rotor placement based upon the long or skipped pulse 386A. The coils on terminals or lines 618, 620, and 622 are then driven in a closed loop mode based upon the rotor position.
Looking more specifically at FIG. 13, it can be seen wherein the logic of the system is shown.
In the previous example, the printer is started up. Thereafter, the first coil such as those coils 606 and 608 are driven in their connected relationship to line 618. A delay is then set. Thereafter, a determination of the time equaling the delay is determined. If time equals time minus one, the system proceeds. If the respective outcome of this step is such where time equals zero, the next coil is driven such as those coils connected to line 620, namely coils 610 and 612. If not, the system starts back at the time delay.
If the delay is correct, the system will then go forward to measure the frequency of the magnetic pickup unit or sensor 390. If the signal is not correct it will then go back to a starting mode because of the fact that the motor is out of sequence as to the respective portion of the pickup 390. Assuming it is correct, it then goes on to look for the long pulse or double gapped pulse 386A. If it finds the long pulse, it then continues on into a closed loop mode driving the coils connected to lines 618, 620, and 622 based upon the rotor position detected by the magnetic pickup unit or sensor 390.
The foregoing establishes through the controller of the printer the position of the rotor with the flywheel 364 and the magnetic ring 360. Since the drive is a direct drive, a determination can be made of the position of each respective hammer 24 based upon the position of the rotor in its positioning with the magnetic pickup unit or sensor 390. This enhances the functions of the overall system and unit to the point where the magnetic pickup unit or sensor 390 can take on the function of providing for the exact location and orientation of the hammerbank 22 as keyed to the motor with respect to the double pulse or gap 386A.
The integral motor shaft and flywheel 364 create a situation wherein dynamic forces are reduced significantly. Of particular consequence is the fact that the center of gravity of the hammerbank 22 and the counterbalance 130 (the shuttle) is placed at the position of the axis of the crank or shaft 230 such wherein the center of gravity is at approximately point 400. This causes dynamic forces to be diminished from the standpoint of the counterbalance and hammerbank orientation of the unit.
Another point to note is that the assembly is dynamically balanced so that the weight of the flywheel 364 is placed to optimize inertia while at the same time allowing smooth overlying operation of the hammerbank 22 and the counterbalance 130 (the shuttle). The particular relationship of the integral hammerbank 22 with the overlying counterbalance and the movement of the center of gravity at point 400 as closely as possible to the shaft 230 axis improves the overall performance. Furthermore, with the rotor comprising ring 360 and flywheel 364 integral to the inside out motor, a substantial amount of inertia is maintained to enhance the angular velocity and smoothness.
It should be specifically noted that the connecting rods 172 and 200 are in as close proximity as practical with regard to the spacing and adjacent relationship to the combined hammerbank 22 and counterbalance 130 (the shuttle). This close proximate spacing and orientation of the center of gravity 400 allows for a smooth operation and avoids the placement of the connector rods 172 and 200 outside of the balanced reciprocal orientation in which they are connected to the respective hammerbank 22 and counterbalance 130 (the shuttle).
From the foregoing, it can be seen that the invention hereof is a substantial step in the art to provide significant improvement over those printers known in the art and particularly with regard to the line printer art. Accordingly, the invention should be accorded the scope of the following claims as set forth hereinafter. | A dot matrix printer having a plurality of hammers forming in part a hammerbank, with a motor for driving the hammerbank, and a controller for releasing the hammers for printing on a print media. A counterbalance is mechanically linked to the hammerbank for balancing it during movement. Lands and grooves are connected for rotation with the motor. A sensor sends pulses corresponding to the lands and grooves for controlling the hammerbank movement. The hammerbank is linked to the position of the lands and grooves as mechanically connected to the motor. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to new and useful improvements in machines for degerming webs of packing foil. More particularly, the invention relates to means for generating UV-rays along or within which is advanced the web of packing foil discharged from a supply reel for sterilizing purposes to be then fed to a packing machine for further processing thereof while keeping the same sterile, with the term “processing” conveying, for example, molding, loading, closing and separating packings from a strip of packing foil.
2. Description of the Prior Art
The use of UV-radiators for germ reduction also in webs of packing foil corresponding exposed, sterilized and advanced in a so-called disinfecting tube to be subsequently passed through molding, loading and sealing stations of a packing machine, are generally known in the art.
Conventional UV-based degermers for webs of packing foil operate on so-called radiator cassettes linearly arranged along the strip of packing foil, wherein the rear side of the housing accommodating the UV-radiator, for achieving enhanced ray utilization, must be silvered and of a reflector-type design. To insure the required degree of exposure, in addition, either special cassettes of a great width or length are employed or a plurality of smaller-sized cassettes are to be successively arranged along the conveyor track of the web of packing foil equally involving large space-requirements. In view of the operating life of UV-radiators which is limited, as a rule, to about 2000 hours, high replacement costs are involved, in addition, especially high costs are incurred by assembly, maintenance and cleaning operations as well as by the stoppage times involved.
Conventional UV-radiators, in addition, result in considerable ozone generation and, beyond that are likely to have a negative influence on the packing material (pollutant migration).
Water-cooled radiator systems that are also known in the art tend to form condensate once the dew point is fallen below which is likely to result in a direct reduction of the UV-exposure of the packings and also in an indirect reduction of exposure as a consequence of corrosive effects on the reflector faces.
SUMMARY OF THE INVENTION
It is the object of the invention to provide a means for degerming webs of packing foil by employing a UV-radiator requiring no radiation reflectors, with the said means involving low space requirements despite a relatively large exposure surface of the web of packing foil, with the surface exposed being adapted to be well protected and enclosed, thereby insuring a uniform intensity of exposure of the web of packing foil advanced therealong, at the same time maintaining a high density and enabling, in an extremely simple way, the “bare” radiator free from a cassette or housing to be associated to the web of packing foil to be exposed and, hence, permitting worn-out radiators to be easily and quickly replaced by new ones.
These requirements, in the practice of the invention, are complied with by a degermer in that a UV-radiator of rod-type design is centrally arranged between guiding elements for the web of packing foil disposed at an equidistant radial distance about the UV-ray generator, with web deflecting members being associated at the inlet and/or outlet sides to the web supply track of a substantially circular configuration as defined by the said elements, with the web deflecting members feeding the web of packing foil into or out of the circular supply track.
The “and/or”-options (yet to be explained in closer detail hereinafter) merely result from different alternatives of feeding or introducing the web of packing foil into or out of the track of exposure. Thanks to the configuration of the degermer according to the invention a highly constricted yet relatively extended track of exposure is provided to which the centrally located UV-radiator held in an easy-to-mount way on one end only, without any reflectors, will radially and circumferentially release its rays with full and uniform density.
Basically, in the practice of the invention, initially, only one side of the web of packing foil is exposed to radiation, namely the side which, subsequently, gets into contact, in the packing machine, with the material to be loaded. The reason for this resides in that webs of packing foil also are advanced and processed in sterile semi-cylindrical tubes in the adjoining packing machine so that the other side of the strip of foil need not be sterile. Semi-cylindrical tubes of this type held sterile are being used, in particular, in deep-drawing machines.
However, as packing machines having sterile full-cylindrical tubes, i.e. sterile tubes completely enclosing the web of packing foil passing therethrough, involve less structural efforts, an advantageous and preferred embodiment of the device of the invention resides in that associated to the circular track of supply and exposure is another circular supply track, with one of the said tracks being provided with feed-in deflection elements and the other of said tracks being provided with discharge deflection elements. In other words, this constitutes a quasi S-type guidance of the packing foil to be degermed on both sides, wherein the strip of packing foil discharged from the first supply track and degermed on one side, with the side not yet degermed, now faces the UV-radiator in the following exposure track, in order to be fed into the directly following supply track in which the UV-radiator equally arranged centrally will act upon the side of the web of packing foil not yet degermed.
Apart from this directly neighbored association of two such circular tracks of supply and exposure to be successively passed by the web of packing foil it will be readily possible (yet to be explained hereinafter in greater detail) to provide two or more of such pairs of supply tracks in successive relationship should this be necessary, depending on the desired or required degree of sterilization.
The guiding elements defining the circular guidance of the web of packing foil can be made of rod-type rolling members; alternatively, they can be in the form of a cylinder of UV-permeable material.
Other objects and advantages of the invention will appear more fully hereinafter as the description proceeds, with reference to the accompany drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the principle of the circular guidance of the web of packing foil within a sterile casing about a centrally arranged UV-radiator;
FIG. 2 is a view corresponding to the one of FIG. 1 wherein the guiding elements are of different designs;
FIG. 3 schematically shows a combination of the assemblies according to FIGS. 1, 2 ;
FIG. 4 schematically shows a plan view of the embodiment according to FIG. 3;
FIGS. 5A to 5 E schematically show, omitting the sterile housing, different inlet and outlet guides of the web of packing foil leading into and out of the circular tracks of supply and exposure;
FIG. 6 schematically shows the arrangement of the invention in connection and association with a packing machine shown, by way of example, in contours only.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The arrangement of the invention for degerming webs of packing foil PB comprises means 1 for the generation of UV-rays and guiding elements 2 for advancing the webs of packing foil PB along a UV-radiator 4 . The guiding elements 2 and the UV-radiator 4 are accommodated within a sterile casing 20 provided with inlet and outlet ports 21 , 22 and being under a slight excess pressure of a gaseous sterile agent, such as sterile air, to prevent the ingress of germs from the atmosphere from occurring.
Now, it is of importance to an arrangement of the afore-described type that the UV-radiator 4 of rod-shaped configuration be centrally arranged between the guiding elements 2 located at an equidistant radial distance about the UV radiator 4 . Associated with the circular supply track 6 conveying the web of packing foil defined by the guiding elements 2 , at the inlet and/or outlet, are packing web deflecting elements 5 leading the web of packing foil BP into and out of the circular track of supply. In the embodiment according to FIG. 1 the guiding elements 2 are formed of rod-shaped rollers 2 ′ of small diameters rotably arranged within the walls 23 of the sterile casing 20 , whereas in the embodiment according to FIG. 2 they comprise a cylinder “ 2 made of UV-permeable material. The cylinder 2 ” may be rotably arranged although this is not imperative.
As shown in FIGS. 1, 2 , only one side F of the web of packing foil BP is exposed to radiation, namely the one which subsequently gets into contact, within the packing machine, with the item to be loaded. The sterile casing 20 preferably is provided with a wall portion 24 to be opened which, in the opening position, is shown in broken lines in FIGS. 1 to 3 , with the latter figure showing it on both sides of the casing 20 ′. With the wall portions 24 opened, the web of packing foil PB readily can be placed by hand about the guiding elements 2 to be then drawn into the adjoining packing machine. The wall section 24 may be, as opposed to the illustration, in the form of a simple lid removable from the casing 20 .
In the embodiment according to FIG. 3, the two arrangements according to FIGS. 1, 2 are combined with one another in order to enable the two sides F, F′ of the web of packing foil to be exposed to radiation; this will not require any closer explanation as it is readily understood from the illustrated guidance of the web of packing foil. It should be noted that such an association in pairs of assemblies within a common casing 20 ′ is also possible by employing two assemblies of the type as shown in FIGS. 1 or 2 .
FIG. 4 schematically shows a sectional view of the embodiment according to FIG. 3 also revealing the rod-type configuration of the UV-radiator 4 the length L of which substantially corresponds to the width B of the web of packing foil BP.
The radiators 4 , which can also be cooling radiators, are suitably arranged within one of the side walls 23 of the sterile housing 20 and are mounted on holding elements 19 in a replaceable way, i.e. they are easy to mount and easy to replace once their operating life has ended. No power connectors have been illustrated as they are known in the art.
A large variety of options are available for feeding the web of packing foil into the assembly of the invention and for passing the same from the assembly to the adjoining packing machine. Some of them are shown in FIGS. 5A to 5 E Among these options special reference is made to the one of FIG. 5B in which the elements 5 deflecting the web of packing foil are arranged substantially along a straight line 7 contacting the circular track 6 . However, virtually, this will be determined by the design at the inlet side of the packing machine coupled to the arrangement.
In the examples showing the guidance of the web of packing foil according to FIGS. 1, 2 and 5 A through 5 C, the web of packing foil PB passing along the substantially circular supply track 6 only on one side is exposed to UV-radiation; the exposed face F then forms, in the packing machine, the face of the packing foil on the side of the material to be loaded, i.e. the side to be degermed.
However, for the reasons set out in the afore-going it is preferred to expose both sides of the web of packing foil PB to radiation and sterilization. In reference to FIGS. 3 , 4 and 5 D, 5 E, another circular track 6 ′ is associated to the circular supply track 6 , with the latter being provided with feed-in elements 8 and track 6 ′ being provided with discharge deflecting elements 9 .
In case of need, also multiple pairs of associated supply tracks 6 , 6 ′ along the track feeding the web of packing foil to the packing machine will be possible as shown by FIG. 6 illustrating an example of double pairing and showing, at the same time, an example of associating the arrangement to the degermed and cylindrical tube 3 of a packing machine otherwise only schematically shown, which in the present instance is a machine for making tubular bags. In that form of embodiment, a sterile air generator 25 is arranged above the casing 20 of the degermer of the invention. The said sterile air generator 25 , hence, not only supplies sterile air, under a slight excess pressure, to the arrangement but also to the cylindrical tube 3 of the packing machine which, as shown, is directly connected to the outlet port 22 of the sterile casing 20 .
A deep-drawing packing machine, the supply track and, hence, the web of packing foil of which is held sterile only on one side at the top thereof by a semi-cylindrical tube has not been illustrated. In respect of such a machine, assemblies of the type as shown in FIGS. 1 , 2 will be used, i.e. devices provided with guides for guiding the web of packing foil as shown in FIGS. 5A through 5C, because in semi-cylindrical tubes the non-sterilized side of the web of packing foil BP is not directed to the interior of the semi-cylindrical tube.
No separate conveyor elements are required by the web of packing foil PB in the assembly of the invention as the web of packing foil PB to be degermed is drawn by the conveyor elements within the adjoining packing machine through the assembly at the operating cycle of the packing machine.
Any changes may be made to the construction of the device and the arrangement of parts from those described without departing from the spirit of the invention, provided, however, that such changes fall within the scope of the claims appended hereto: | An arrangement for sterilizing a flat web of a packing foil, which comprises a sterile casing having an inlet and an outlet, a rod-shaped UV radiator disposed in the sterile casing, a guide for guiding the web in a circular path around the UV radiator, the UV radiator being centrally arranged within the circular path and the guide being radially equidistantly spaced from the UV radiator, and deflecting elements at the inlet and the outlet of the sterile casing for deflecting the web into the circular path at the inlet and out of the circular path at the outlet. | 1 |
FIELD OF THE INVENTION
This invention relates to a unique system and method for performing a post-production operation upon a web subsequent to its output from a image transfer device.
BACKGROUND OF THE INVENTION
It is often desirable in a printing process involving a continuous stream of images laid down upon a moving paper web to incorporate other post-production processes to the web downstream of the printing process. These post-production processes may include, for example, page or job separation, hole punching, color logo application or folding operations. The problem with performing such post-production processes or operations is that the web transferred between the image and the post-production machines may not contain standard length pages or may otherwise have pages in locations upon the web that are difficult to gauge. Thus, the post-processing device must have some means for accurately locating each page presented to it, and furthermore, once each page location is found, must have a means of distinguishing between each individual page sent to it to determine which page must include a given post-production operation.
An additional problem with keeping track o processed pages as they are transferred to a post-production device is that the two devices may run at unsynchronized speeds, especially where they are discrete and separate units. As such, slack may develop in the transfer loop of web between the two devices, resulting in more images en route than expected and potential misapplication of the post-production operation.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a unique system and method for allowing post-production operations to be performed on a moving web containing images wherein the image production element and the post-production device may not be synchronized in their feeding of the web.
It is another object of this invention to provide a system and method for incorporating post-production operations that accurately locate the point upon the web at which the post production operation is to be applied.
It is another object of this invention to provide a system and method for incorporating post-production operations that allows the tracking of various locations upon a moving web to accurately perform a multiplicity of types of post-production operations at these various locations.
It is yet another object of this invention to provide a system and method for incorporating post-production operations that allows the tracking of pages and images placed upon a moving web wherein the pages and images are of variable length.
This invention provides a system for incorporation, in the production of continuous stream of images by an image transfer device upon a moving web, post-production operations upon the web at various web locations. There are means for tracking locations of a web, having a plurality of images placed thereon, output from an image transfer device. There are post-production means to perform a specific operation at locations of the web upon its passing through the post-production means. There are also means for directing the web from the image transfer device to the post-production means. There are means, responsive to the means for tracking, for determining when the location has entered the post-production means, and there are also means responsive to these determining mean for commanding the post-production means to perform its specific operation at the location.
In a preferred embodiment, the means for tracking also includes means for generating a pulse each time an interval of web is output from the image transfer device. This means for generating may include means for combining a plurality of pulses to indicate the output from the image transfer device of a page length of web. The post-production means may include means for creating an electronic mark each time one of the intervals of the web passes through the post-production means. This means for creating may include page identification means that indicates, by means of counting the electronic marks, the passing of the page length or certain image of the web through the post-production means.
The determining means may further include counter means that increments a stored value for each page indicated by the means for combining, and decrements the stored value for each page indicated by the page identification means. This stored value is a total length value equaling the number of page lengths upon the web disposed between the image transfer device and the post-production means when the web is pulled taut with relatively no slack thereon. The determining means may further include a register means, responsive to the counter means, to store first through last data blocks equal in number to at least a current value contained in the counter means. Each of the data blocks directly corresponds to a page length disposed between the image transfer device and the post-production means and each of the data blocks contains a data value representative of a post-production operation to be performed upon the web at the page length. The last of the data blocks contains a data value corresponding to the page length increment currently entering the post-production means. The register means may include a shifting means that adds a new data value. deletes a data value, or moves values in data blocks to correspond directly to the movement of each page length increment upon the web from the image transfer device to the post-production means.
In an alternative embodiment, the determining means may including storage register means having a number of storage locations to each store a data value corresponding to the number of intervals between each of the locations upon which the specific post-production operation is to be performed. This storage register means may also include means for monitoring the total number of intervals of the web currently disposed between the image transfer device and the post-production means.
In yet another embodiment, a storage register means may also have a number of storage locations to consecutively store first through last data values corresponding to the number of page length increments between each of the locations upon which a specific post-production operation is to be performed. This storage register may also include a means for structuring a number of storage locations equal to the maximum number of page lengths upon the web that may be disposed between the image transfer device and the post-production means. This storage register may further include a means for comparing a last data value stored in the storage register to the number of pages successively indicated by the page identification means. This allows the means for comparing to indicate when a correct location has entered the post-production means. There may be a means for moving data values, in response to the comparing means, within the storage register means to add a new data value to the storage register and to delete last data values from the storage register. This means for structuring may include a means for calculating the number of page lengths on the web currently disposed between the image transfer device and the post-production means.
The post-production means may generally include, among other devices, a folder, job separator, printing device, hole punching device, or web cutting device. Additionally, the image transfer device may include among its elements an electronic printer such as a laser, impact or other type capable of the production of variable page length images.
A method for incorporating, in the production of a continuous stream of images by an image transfer device upon a moving continuous web, post-production operations upon the web at various locations is also provided. Such a method would generally include the steps of tracking the locations of a web, having a plurality of images placed thereon, output from the image transfer device. There would also be provided a step of performing, with a post-production means, a specific operation at each of the locations on the web upon its passing through the post production means. In another step, the web is then directed from the image transfer device to the post production means. In response to the tracking step, the time when a correct location has entered the post-production mean is then determined. The method further includes the step of commanding the post-production means, in response to the determination of the point when the correct location has entered the post-production means to perform its specific operation at the correct location.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing objects and advantages of the present invention will be more clearly understood in connection with the accompanying drawings in which:
FIG. 1 is a schematic diagram of a system for incorporating post-production operations to a printed web according to this invention;
FIG. 2 is a block diagram showing the calculation of the number of pages in the intermediate loop for the post-production page pass through determination system of FIG. 1;
FIG. 3 is a somewhat schematic diagram of a shifting operation for the shift register used in the post-production page pass through determination system of FIG. 1;
FIG. 4 is a block diagram of the shifting control process for the shift register of FIG. 3;
FIG. 5 is a somewhat schematic diagram of an alternative incremental distance storage register system for use with the post-production page pass through determination system of FIG. 1.;
FIG. 6 is a somewhat schematic diagram of an alternative absolute distance storage register for use with the post-production page pass through determination system of FIG. 1;
FIG. 7 is a schematic diagram of the electronic interval detector in the image transfer device of FIG. 1; and
FIG. 8 is a schematic diagram of the electronic interval detector of the post-production device of FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A system for incorporating a post production operation to a printed web is depicted in FIG. 1. The system consists of a source of web 20 that is, for example, a paper material upon which printing is to be transferred. The web is thus fed to an image transfer device 40 that performs the printing process. A loop of web material 74 exits the image transfer device and enters a desired post production device 48. This post-production device 48 performs an operation upon the web at various locations. This specific operation may be, for example, one of folding, cutting, application of further printing or hole punching. The length of web, when disposed tautly between the image transfer device and the post-production device, is known as the taut distance 50. This taut distance can be characterized in terms of predetermined intervals 72 of length as small as 1/8", or in terms of a given number of page lengths 70. Each page length generally corresponds to a given number of intervals 72.
The image transfer device 40 contains a distance measurement device 200, as shown in FIG. 7, that measures the intervals 72 of length passing out of the image transfer device. These intervals of length are converted into corresponding electronic pulses or marks that are transmitted to a mark combiner 42. This mark combiner translates the marks into a quantifiable increment, generally the length of a page, and outputs data 54 indicating a page each time enough marks are combined to designate a page length of web passing through the image transfer device 40. The system quantifies measurements to page size to lessen the effects of rounding and truncation errors potentially resulting from discrete interval measurements.
After the web is fed from the image transfer device, it is carried over an intermediate loop 74 before again travelling into and out of the post-production device 48. Thus, a means for "hand-shaking" or synchronizing the operation of the image transfer device and the post-production device must be utilized if a page from the image transfer device is to be accurately processed by the post-production device. This hand-shake means is the system symbolized by the post-production pass through determination block 44 in FIG. 1. In general, a "hand-shake" is a two-way exchange of communication between devices. The determination block accomplishes such a hand-shake. This determination system 44 is fed data 52 indicating which page should contain a post-production operation. The data 52 may be synchronized with data 53 controlling the image transfer device 40. When a page passes through the image transfer device 40 and a simultaneous signal for post-production 52 is sent to the determination system 44, the system 44 internally flags that page for a post-production operation.
The post-production device also reads pages passing through itself, as shown by the distance measuring element 220 in FIG. 8. The determination system 44 has the taut distance 50 programmed into it, so it determines how many pages must pass through the post-production device 48 for the flagged page from the image transfer device to reach the post-production device. It then counts off pages passing through the post-production device, using the post-production output indicator signal 56, to determine when the flagged page is present at the post-production device. At this point, the determination device transfers a post production command 76 to the post-production device 48 to instruct the post-production device operational element 194, as shown in FIG. 8 to perform its operation.
As illustrated, one important variable that must be known for the determination system 44 to accurately command an operation is the number of pages in the intermediate loop 74. If the image transfer device 40 and the post-production device 48 are initiated with a loop that is relatively taut and with both running at synchronized rates of web transfer, then the number of page lengths in the loop remain equal to the taut distance 50. However, it is sometimes the case, especially where independent and removable post-production units are utilized, that the two devices will run at slightly offset speeds. To account for this, FIG. 2 depicts a counter unit 82 that receives the taut distance value 80 and continually increments 88 or decrements 90 this initial value 80 based, respectively, upon each time a page is output by the image transfer device 84 or passed through the post-production device 86. In this way, an ongoing realtime calculation of total pages in the loop 92 is achieved.
Using this loop page number figure, the determination system 44 accurately gauges when a page arrives at the post-production device.
The actual storage of post-production signals for pages disposed in the intermediate loop is depicted in three time frames in FIG. 3. The storage means consists of a shift register shown in a relative starting time frame 94. The shift register contains a number of shift locations equal to the number of pages in the loop 100. In the starting state 115, this number of pages 100 should equal the taut distance. In a simple embodiment, where one post-production device is utilized, each page in order of its appearance in the left-to-right loop from the image transfer device to the post production device contains a number equal to either zero or one. Zero may represent no operation by the post-production device for that page location, while one represents that a post-production operation is to be performed.
The register below 96 depicts the second time frame for the shift register in which a new page 116 has been added to the loop from the image transfer device. This new page holds a zero value, meaning no post-production operation is to be performed to it. At the same time, the post-production device has relatively synchronously transferred out a completed page. This page is shown in the previous time frame register having a one value 108 at the register end position. The determination system has read the last end value and commanded the post-production device to operate upon the page. The new end value 110 of the register 96 of the second time frame contains a zero value and, thus, shall have no post production operation performed to it. All other zeros and ones in the register have been shifted one space. This process continues indefinitely, until all web images have been processed.
In the final time frame 98 of FIG. 3, another new page 104 has been added to the front of the register having a zero, non post production, value. However, the post-production device has not yet received and processed the last page designated by a zero in the end register 110. Thus, a slack has developed in the loop. The counter means depicted in FIG. 2 will, therefore, be incremented without a nearly simultaneous decrement due to a page leaving the post-production device. The shift register then gains a value holding the new page instruction at the front of the register 106. When the post production device again passes through a sheet, decrementing the counter, the shift register will disable the front location as the simultaneous shifting of all values in the register occurs.
A general flow chart depicting this block adding operation of the shift register of FIG. 3 is shown in FIG. 4. The current number of pages in the loop 142 is input to a decision block 144 in response to the output of an image page by the image transfer unit 140. If the number of pages has increased 146, then a block is added to the shift register for storage of the new page data 150 and no shift occurs. Similarly, if the number of pages has not changed 148, then all blocks will be shifted down, and the new image page data, when ready, is added to the first block 152.
The above embodiment generally involves the storage of a piece of data corresponding to each page in the intermediate loop 74 between the image transfer device 40 and the post-production device 48. As each page is shifted down the loop, the data of the shift register means is also shifted with new page data added at the front and old page data read for commands and dropped off at the rear of the register, just a the pages in the loop themselves enter and leave. An alternative means for storage of data corresponding to pages in the loop is depicted in FIG. 5. This means stores the number of pages disposed between the post-production pages rather than a single data value for each page. The last storage block 162 in the register 160 at the exemplified starting state depicts nine pages until the next post-production page will appear at the post-production means. Once nine pages have moved through the post-production unit, the operation will then be performed to that ninth page. All the storage blocks will then be shifted, as shown by the second register 170, such that the second to last block 164 in the starting register 160 is now the new last end block upon which the determining system 44 bases its count of identified pages 56 from the post-production unit for the next post production operation 168. In this exemplified register 170, the number of pages until the next post production operation is seven.
At a point in time when a new post production page enters the loop, based upon signals 52 and 53 shown in FIG. 1, the next incremental page distance value 174 is placed at the front of the storage register. Generally, this system requires fewer storage blocks than the shift register system of the embodiment of FIG. 3. However, it is possible that, if a post-production operation must be performed at each page within the loop, as many storage locations are required as for the shift register system of FIG. 3. The creation of additional storage blocks may be accomplished in this type of system with a counter that detects pages in the loop.
An advantage of the second storage embodiment is more clearly prevalent in FIG. 6. Here, absolute distance consisting of the number of pulses between post-production operations is stored rather than numbers of pages. This system depicts a storage register 210 at a starting time and then at a time 212 after 30 pulses have been counted off by the post-production device wherein a shift 214 has occurred and a new distance of 14 pulses to 16 has been added to the front of the register 216. An advantage of using pulses directly from the distance measuring devices 180 of FIG. 7 and 220 of FIG. 8 is that post-production operations can be more accurately pinpointed to specific variable locations upon each page as designated by a specified number of pulses, rather than simply at the page. Furthermore, since post-production operations are located relative to an absolute distance measurement rather than an arbitrary preprogrammed page measurement, pages of varying length may be easily included in the same web.
In any of the above embodiments, several post-production devices may be included and a multiplicity of types signals may be shifted by the storage means in order to perform one or more selectable types of post-production operations. These different operations may each be performed upon the same or upon differing pages within the web.
It should be understood that the preceding is merely a detailed description of a preferred embodiment. It will be obvious to those skilled in the art that various modifications can be made without departing from the spirit or scope of the invention. The preceding description is meant to describe only a preferred embodiment and not to limit the scope of the invention. | A system for incorporating, in the production of a continuous stream of images, by an image transfer device upon a moving web, post-production operations upon the web at various locations. Locations of a web, having a plurality of images placed thereon, output from an image transfer device are tracked. Specific operations at various locations upon the web are performed by a post-production device as the web passes through it. The web is directed from the image transfer device to the post-production device. In response to the tracking of locations upon the web, the point when a location has entered the post-production device is determined. In response to this determination, the post-production device is commanded to perform its specific operation at a connect location. | 1 |
This application is a CIP of PCT/EP95/00083 filed Jan. 11, 1995.
FIELD OF THE INVENTION
The present invention relates to the field of heat treatment of metallic workpieces. Still more specifically, the invention relates to a method and an apparatus for quenching such workpieces.
BACKGROUND OF THE INVENTION
In conventional systems for quenching workpieces, as described for example in German Patent Specification 42 18 126, the workpieces are conveyed through a quenching apparatus on a horizontally extending roller conveyor. On their path through the apparatus the workpieces have applied to them from the underside, in an arrangement designed like a steeping pot, a quenchant that flows as a liquid against the workpieces from below, flows through the gaps between the workpieces, and is then carried off upward and to the side. A corresponding pump device that allows a flow of the liquid quenchant from below is provided for these purposes.
An apparatus for achieving uniform cooling in a hardening bath is known disclosed in German Published Patent Application 21 43 536. The known apparatus comprises a vessel with coolant liquid. A conveyor belt equipped with holes is arranged in the hardening bath. The workpieces pass via a conveyor trough, under their own weight, onto the conveyor belt, are conveyed thereon initially in a horizontal direction, and are then transported obliquely upward via a rising section, out of the bath, to a delivery end.
Propellers with pivotable blades are arranged in the hardening bath. The propellers are controlled by means of a timing relay in such a way that the direction of incidence of the propeller blades changes, for example, every 5 seconds. As a result, the flow direction of the coolant liquid flow passing vertically through the conveyor belt is reversed each time, so that the coolant liquid flows alternately from top to bottom, and from bottom to top, through the conveyor belt.
The known apparatus has the disadvantage that the merely perforated conveyor belt, with its uniform motion in only one direction, results in perceptible shadowing. Consequently the workpieces to be cooled experience an inhomogeneous incident flow despite the cooling flow which reverses in the vertical direction, since portions of the workpieces are shadowed by the remaining webs in the conveyor belt. This leads to distortion phenomena on the workpieces, which are intolerable for many workpieces.
It is therefore the object of the invention to develop a method and an apparatus of the aforesaid kind in such a way that the quenching effect is further improved, and that the workpieces can be quenched without distortion.
SUMMARY OF THE INVENTION
For solving the above-mentioned objects, the invention encompasses a method for quenching workpieces comprising the steps of:
generating a flow of a quenchant fluid, the flow having a direction along a first axis;
cyclically inverting the direction of the flow along the first axis;
exposing the workpieces to the flow with the workpieces being moved through the flow in a direction along a second axis arranged essentially transversely to the first axis; and
cyclically inverting the direction of the workpiece movement along the second axis.
The invention, further, encompasses an apparatus for quenching workpieces comprising:
means for generating a flow of a quenchant fluid, the flow having a direction along a first axis;
means for cyclically inverting the direction of the flow along the first axis;
means for exposing the workpieces to the flow with the workpieces being moved through the flow in a direction along a second axis arranged essentially transversely to the first axis; and
means for cyclically inverting the direction of the workpiece movement along the second axis.
Specifically, in contrast to the apparatus according to German Published Patent Application 21 43 536, shadowing on the workpieces is entirely eliminated by the fact that a horizontally reversing motion of the workpieces is superimposed on the vertically reversing motion of the coolant. In addition, the workpieces are located on a roller train with which they have only line or point contact. Flow therefore occurs around the workpieces in a double back-and-forth motion; because a minimal surface of the workpieces rests on the roller train, no shadowing at all can occur on the workpieces. In this manner a articular intimate contact is achieved between workpieces and quenchant, so that all regions of the workpieces come into contact with the quenchant in the briefest possible time.
Practical experiments have shown that the quenching effect and freedom from distortion of the workpieces can be substantially increased in this manner.
A further increase in quenching effect and freedom from distortion can, according to an exemplified embodiment of the invention, be achieved by the fact that the rollers are equipped with constrictions in such a way that the workpieces rest only on circumferential knife-edges of the rollers. The workpieces are thus supported only with point contact.
An improved quenching effect in the support region of the workpieces, as compared with conventional devices, is achieved in this manner. The freedom from distortion of the workpieces is thus further increased.
In preferred embodiments of the method according to the invention, the quenchant is a liquid or a mixture of a liquid and a gas. The gas can be air or an inert gas. In the latter case any change in the surface finish of the workpieces is avoided.
The liquid is preferably water, but can also be another common quenching liquid. The use of a corrosion protection agent is particularly preferred, since this prevents the surface of the workpieces from immediately oxidizing while they are still hot.
When a mixture of liquid and water is used, it is preferred if the mixture is formulated with a liquid content of between 1 and 250 liters per square meter of workpiece surface per minute, at a velocity of from 10 to 30 m per second.
In practical experiments conducted with the method and apparatus according to the invention, it was found that the quenching effect could be substantially improved. It was moreover noteworthy that workpieces could be hardened with minimal distortion. This is particularly important for certain workpieces, for example rolling bearings, in which optimum distortion results have a direct and considerable economic effect. The invention is therefore applicable with particular advantage to this type of workpiece.
Further examples are evident from the drawings and the attached description.
It is understood that the features mentioned above and those yet to be explained below can be used not only in the respective combinations indicated, but also in other combinations or in isolation, without leaving the context of the present invention.
BRIEF DESCRIPTION OF THE DRAWING
Embodiments of the invention are depicted in the drawings and will be explained in more detail in the description below. In the drawings:
FIG. 1 shows a first exemplified embodiment of an apparatus according to the invention, in side view and highly schematized;
FIG. 2 shows the arrangement according to FIG. 2 in a front view;
FIG. 3 shows a second exemplified embodiment of an apparatus according to the invention;
FIG. 4 shows in detail a roller for use in one of the apparatuses according to FIGS. 1 to 3.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a first exemplified embodiment of an apparatus according to the invention for quenching workpieces is designated overall as 10. Quenching apparatus 10 is connected to a upstream annealing furnace via a relative narrow opening 22.
Quenching apparatus 10 has a closed quenching chamber 11 whose lower part is designed as a tank 14. Located in tank 14 is a quenching bath with a quenchant 12 in the form of an oil bath, water bath, or salt bath.
A transport device 15, which is designed in the form of a roller conveyor with rollers 16, runs transversely through quenching chamber 11. Roller conveyor 16 passes horizontally from furnace 20 through furnace outlet 22 transversely through quenching chamber 11, and continues in an outlet region 19 outside quenching chamber 11. Rollers 16 of transport device 15 serve as the support for metal workpieces 18.
Arranged in the center of quenching chamber 19, beneath transport device 15, is a duct designated overall as 25, which has an open-top duct section 24. Duct section 24 widens in its upper region and opens directly beneath rollers 16. In the quenching position shown according to FIG. 1, workpieces 18 are located above the space enclosed by open-top duct section 24. Open-top duct section 24 continues above rollers 16 in the form of a correspondingly shaped frame 34 with laterally closed valves. Frame 34 is open at the top. Frame 34 is connected, via vertical holders 35, to a hood 32 which encloses frame 34 from the outside and with its lower end extends to rollers 16 of transport device 15. Frame 34 can be moved vertically, together with hood 32, by means of a lifting apparatus 46.
In the position shown in FIG. 1, workpieces 18 have already been moved on the roller conveyor into a stipulated quenching position, and are there enclosed by frame 34, which is lowered from above while the roller conveyor is stationary. The quenching process can now begin.
For this purpose, quenching liquid is first pumped in the direction of an arrow 26 upward from below through open-top duct section 24, so that quenchant 12 floods onto workpieces 18 from below. Quenchant 12 rises inside frame 34, then emerges laterally outward over the walls of frame 34, and runs back down, inside the region surrounded by hood 32, into quenching bath 12. In FIG. 1 the quenching process has not yet begun. Liquid level 48 of quenchant 12 is in this case still below the roller conveyor, and is at the same height both inside and outside duct 25.
FIG. 2 shows that quenchant 12 has already risen, inside open-top duct section 24, above rollers 16 on which workpieces 18 rest.
It is further evident from FIG. 2 that open-top duct section 24 tapers downward in its lower region and opens into a horizontal pressure tube 36 that in turn is connected to a vertical, open-top intake tube 42. A pump device 44, which projects with an impeller 43 into intake tube 42, is provided above intake tube 42.
To this extent apparatus 10 as so far described corresponds to the prior art according to the aforesaid German patent 42 18 126.
Pump device 44 is such that impeller 43 can be moved in opposite directions, as indicated by an arrow 45. Because of this, it is possible with the apparatus according to the invention to configure the flow (double arrow 26) of quenchant 12 reversingly, resulting in a liquid column in open-top duct section 24 that moves oscillatingly upward and downward.
In FIG. 2 this is indicated by the fact that above workpieces 18, a lower liquid level is drawn in in the left half with 48', and an upper liquid level in the right half with 48". The liquid column in duct section 24 oscillates between these extreme values 48' and 48", as indicated by a further arrow 29.
In this manner, flow occurs completely around workpieces 18.
A further particularity of apparatus 10 is indicated in FIG. 1. The number 55 therein designates a double arrow which is intended to illustrate that workpieces 18 can be moved on rollers 16 not only in the inherently stipulated feed direction 27, but also reversingly. For this purpose the roller train is controlled so that in the position of FIG. 1, workpieces 18 can be moved forward and backward in rapid alternation. In FIG. 1 this is further indicated with dotted lines at 18'.
Alternatively it is possible (although not depicted) also to move roller train 16 reversingly in the vertical direction or in a direction perpendicular to the drawing plane of FIG. 1, in order to produce a relative motion with respect to flow 26 of quenchant 12.
The two aforementioned possibilities for a reversing configuration of, on the one hand flow 26 of quenchant 12, and on the other hand motion 55 of workpieces 18, can be used both alternatively and together.
A further exemplified embodiment of the invention is depicted in FIG. 3.
A quenching apparatus 100 comprises a quenching chamber 111 through which a roller train with rollers 116 passes. Workpieces 118 are located on rollers 116.
To this extent the view in FIG. 3 corresponds analogously to that of FIG. 2 for the first exemplified embodiment described above. Workpieces 118 thus move, in the depiction of FIG. 3, perpendicular to the drawing plane.
Located respectively above and below rollers 116 are hoods 160 and 161, the open cross-sectional areas of which are delimited, in the region bordering rollers 116, in such a way that once again a predefined charge of workpieces 118 can be laterally surrounded by them.
Hoods 160, 161 are connected to pipes 165 and 166, respectively, in which fans 167 and 168, respectively, are located. Air can be taken in laterally by means of fans 167, 168, as indicated by arrows 169, 170.
Liquid lines 175, 176 open from above into hoods 160, 161 in the transition of pipes 165, 166 into hoods 160, 161. This takes place in the form of spray heads 177, 178 arranged there.
Liquid can be fed in via liquid lines 175, 176, as indicated by arrows 179, 180.
When liquid is fed in (179, 180) and air is taken in (169, 170), an air flow forms in pipes 165, 166 as indicated by arrows 185, 186. The air flow mixes, in the region of spray heads 177, 178, with the fed-in liquid, so that a mixture 190, 191 of air and liquid is sprayed and splashed from above and below onto work pieces 118.
By configuring fans 167, 168 or spray heads 177, 178 alternatingly, workpieces 118 can have mixture 190 and 191 applied onto them alternatingly from above and below.
Of course it is also possible in this instance to impart to workpieces 118, by suitable reversing of rollers 116, a motion as already described above with reference to the first exemplified embodiment.
In the exemplified embodiment according to FIG. 3, water is preferably used as the liquid; the water can also have a corrosion protection agent added to it, or can be entirely replaced by corrosion protection agent.
Instead of using air as the gas, as described, an inert gas can also be fed in via fans 167, 168.
It is preferred if mixture 190, 191 is formulated with a liquid concentration between 1 and 250 liters per square meter of workpiece surface per minute, at a gas velocity of 10 to 30 meters per second.
Lastly, FIG. 4 shows another structural detail of rollers 16 or 116 that are used.
Specifically, rollers 16, 116 are equipped with circumferential constrictions 80 between which circumferential knife-edges 81 are arranged. When workpieces 18, 118 then rest on rollers 16, 116, the contact occurs at points only, since knife-edges 81 offer only a circumferential line as support.
Quenching apparatuses 10, 100 can otherwise be operated in the usual manner. For this purpose, the furnace charge, heated to hardening temperature, is moved in a rapid traverse through quenching apparatus 10, 100. In accordance with the exemplified embodiments of the invention as described, quenchant 12 is then guided in oscillating fashion past workpieces 18, 118 to be cooled down. Alternatively or simultaneously, a reversing motion of workpieces 18, 118 is performed via the roller train. Optimum distortion results for workpieces 18, 118 are achieved by the oscillating motion of quenchant 12 and/or workpieces 18, 118.
In the exemplified embodiment according to FIG. 3, the oscillating effect described is achieved via air-water mixture 190, 191, which is fed in alternatingly from the top and bottom. A reversing motion of workpieces 118 can additionally be provided here as well.
Instead of water, a quenching emulsion can also be injected into the air flow. In addition, a corrosion protection agent can be mixed into the water in order to prevent corrosion of the workpieces in the subsequent tempering process.
When a quenching emulsion is used, it is possible to displace the collapse of the vapor film (Leidenfrost temperature) toward higher temperatures. When the emulsion subsequently evaporates without residue, it is also possible to omit the washing procedure that is otherwise usual.
Depending on the application, one of the common shielding gases can also be used instead of air in order to prevent any surface oxidation. The cooling process can in any case be controlled in its intensity, as a function of material and dimensions, so that for example the inevitable wide temperature differences in the interior of the workpiece in the lower temperature range can be intercepted and compensated for.
In summary, all the prerequisites for largely distortion-free hardening are provided in this manner. | A method and an apparatus are disclosed for quenching workpieces. The workpieces are exposed to a flow of a quenchant fluid. The flow is reversed in its direction. The workpieces are moved through the flow along an axis being essentially transversely to the axis of fluid flow. The workpieces are also reversingly moved. | 2 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] N/A
FIELD OF THE INVENTION
[0002] The invention is related to a multi-purpose catheter that is used to deliver dose, measure the dose and remove human waste while providing an easy connection module.
BACKGROUND
[0003] In medicine, a catheter is a tube that can be inserted into a body cavity, duct, or vessel. Catheters thereby allow drainage, injection of fluids, or access by surgical instruments. The process of inserting a catheter is catheterization. In most uses, a catheter is a thin, flexible tube (“soft” catheter), though in some uses, it is a larger, solid (“hard”) catheter. A catheter left inside the body, either temporarily or permanently, may be referred to as an indwelling catheter. A permanently inserted catheter may be referred to as a permcath.
[0004] The ancient Syrians created catheters from reeds. “Katheter—καθετ{acute over (η)}ρ” originally referred to an instrument that was inserted such as a plug. The word “katheter” in turn came from “kathiemai—ηαθ{acute over (ι)} εμαι” meaning “to sit”. The ancient Greeks inserted a hollow metal tube through the urethra into the bladder to empty it and the tube came to be known as a “katheter”.
[0005] Prior catheters were used only for single functions, such as removing human remains and enlarging an area inside the human body. The single functioning catheters requires that a medical personnel remove one catheter and insert another catheter into the patient when multiple functions are required to be performed on the patient. This removal and insertion process creates much discomfort to the patient, because the removal of the tube and insertion of the catheter creates a pain. Also, when multiple catheters need to be inserted into a patient, each catheter is inserted into the patient; however, the catheter's excessive length can cause confusion to the medical personnel, and the medical personnel may perform a function on the wrong catheter resulting in mal-practice.
[0006] Thus, the need exists to have a catheter that can provide multiple functions and which is less traumatic than current procedures involving insertion and removal. The present invention meets that need without the risk of causing damage or producing pain.
SUMMARY OF THE INVENTION
[0007] According to one general aspect, there is A medical device comprising a locking mechanism that is used to connect a plurality of catheters, a multi-balloon inflator that inflates multiple balloons on a single catheter, a extraction point used to remove human fluids from the human body, and a connecting point that allows a syringe or a machine to insert liquid saline solution or radioactive isotopes into said multi-balloon inflator.
[0008] The medical device that contains the locking mechanism can be affixed to any male or female connection attached to any type of catheter.
[0009] The medical device that contains the said multi-balloon inflator that is connected to each individual said connecting point to allow the volume of inflation.
[0010] The medical device that contains the said locking mechanism when affixed to another catheter creates a vacuum seal that does not allow the fluids or any air to pass through any said connecting point.
[0011] The medical device that contains the extraction point contains an inner seal within the opening that only allows for a single direction flow for only removal of fluids which does not allow for fluids to be inserted into the human body.
[0012] The medical device that contains the extraction point is large enough to contain a measuring device used to measure the amount of dose radiated to human tissue while said extraction point is removing fluids from the human body.
[0013] The medical device that contains a medical device that contains a plurality of said multi-balloon inflator wherein at least one said multi-balloon inflator contains radioactive isotopes while the remaining said multi-balloon inflators contains air or any other liquid for inflation of the balloon.
[0014] The medical device that contains a plurality of said medical devices can be inserted into both the rectum and urethra with a plurality of said measuring devices take dose measurements while applying dose therapy through said multi-balloon inflator.
[0015] According to another general aspect, there is a method of operating a multi-functional catheter, wherein said method comprises connecting a plurality of catheters, inflating multiple balloons on a single catheter, removing human fluids from the human body, and pumping liquid saline solution or radioactive isotopes into said multi-balloon inflator.
[0016] The connecting may be affixed to any male or female connection attached to any type of catheter.
[0017] The inflating is connected to each individual said connecting point to allow the volume of inflation.
[0018] The affixing to another catheter creates a vacuum seal that does not allow the fluids or any air to pass through any said connecting point.
[0019] The removing fluids by an inner seal within the opening that only allows for a single direction flow for only removal of fluids which does not allow for fluids to be inserted into the human body.
[0020] The removing a measuring device used to measure the amount of dose radiated to human tissue while said extraction point is removing fluids from the human body.
[0021] The radiating by a multi-balloon inflator with radioactive isotopes while the other plurality said multi-balloon inflators contains air or any other liquid for inflation of the balloon on a medical device that contains a plurality of said multi-balloon inflator.
[0022] A plurality of said medical devices can be inserted into both the rectum and urethra with a plurality of said measuring devices take dose measurements while applying dose therapy through said multi-balloon inflator.
DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an illustration of a first position rectum balloon attached to first position urethra catheter balloon.
[0024] FIG. 2 is an illustration of a first position rectum balloon with a MOSFET™ attached to first position urethra catheter balloon.
[0025] FIG. 3 is an illustration of a first position rectum balloon and second position rectum balloon attached to first position urethra catheter balloon.
[0026] FIG. 4 is an illustration of a first position rectum balloon and second position rectum balloon with a MOSFET™ attached to first position urethra catheter balloon.
[0027] FIG. 5 is an illustration of a first position rectum balloon, a second position radiation balloon, a third position rectum balloon attached to first position urethra catheter balloon.
[0028] FIG. 6 is an illustration of a first position rectum balloon, a second position radiation balloon, a third position rectum balloon with MOSFET TM attached to a first position urethra catheter balloon.
[0029] FIG. 7 is an illustration of a first position rectum balloon and a second position rectum balloon in the human body and a first position urethra catheter balloon in the human body.
[0030] FIG. 8 is an illustration of a first position rectum balloon and a second position rectum balloon attached to first position urethra catheter balloon.
[0031] Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals will be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience.
DETAILED DESCRIPTION
[0032] The following detailed description is provided to assist the reader in gaining a comprehensive understanding of the methods, apparatuses and/or systems described herein. Accordingly, various changes, modifications, and equivalents of the systems, apparatuses, and/or methods described herein will likely suggest themselves to those of ordinary skill in the art. Also, descriptions of well-known functions and constructions are omitted to increase clarity and conciseness.
[0033] FIG. 1 shows an exemplary sample of a first position rectum balloon 1 - 11 attached to an urethra catheter 1 - 10 . The rectum balloon has multiple uses and features. The rectum balloon can be used to deliver radiation and simultaneously measure the radiation that is being delivered to the abnormal growth and remove human waste. The rectum balloon has a female or male connection 1 - 8 , that is used to insert any form of a sensor and simultaneously remove human waste by the opening 1 - 12 . The removing of human waste travels through the tube 1 - 3 that is connected to male or female connection 1 - 8 . Furthermore, the rectum balloon has luer lock connection 1 - 7 that is used to inflate the balloon to a predetermined size. The balloon inflation may be used as a locking mechanism for the rectum catheter in the patient or can be used to push internal organs in a certain direction. The rectum balloon 1 - 11 may be attached by a locking mechanism 1 - 9 to the urethra catheter 1 - 10 . The locking mechanism 1 - 9 may be attached by either male or female connection. The locking mechanism 1 - 9 allows for medical personnel to have an easier controlled section to all openings to provide delivery guidance and extraction within a single area. The urethra catheter 1 - 10 has urine extraction whole 1 - 4 that is used to remove fluids in the bladder and is taken out by extraction opening 1 - 5 . Furthermore, a measuring device may be inserted into the opening 1 - 5 while removing the urine. The advantage allows for simultaneously measuring and removing. The urethra catheter balloon 1 - 1 is an inflatable balloon. The balloon inflation can be done by male or female luer lock 1 - 6 . Further drawings will show modification to the both the urethra catheter 1 - 11 and rectum catheter 1 - 10 .
[0034] FIG. 2 shows an exemplary sample of a first position rectum balloon 1 - 11 attached to a first position urethra catheter balloon 1 - 10 . Upon further review, the rectum balloon allows for a measuring device 2 - 1 such as MOSFET to be inserted into the center valve. The advantage for inserting the measuring device 2 - 1 will allow medical personnel to measure the dose simultaneously while delivering the radiation to the tumor region. Furthermore, a second measuring device 2 - 2 may be inserted into urethra catheter 1 - 10 . Inflating the balloon 1 - 2 allows for determining the organ region and for a fixing or locking mechanism. The inflating balloon 1 - 2 on the rectum catheter can also be filled with radioactive isotopes that delivers dose while being measured by the measuring device 2 - 1 . This is a big advantage since the dose can be measured and the volume of radio-isotopes can be reduced depending on the inflating size. Next, the second measuring device 2 - 2 can also be inserted to urethra catheter along with a measuring device 2 - 1 in the rectum catheter to allow medical personnel to measure the dose from two different locations at the same time.
[0035] FIG. 3 shows an exemplary sample of a first position rectum balloon 1 - 2 and second position rectum balloon 4 - 1 attached to first position urethra catheter balloon 1 - 1 . The rectum catheter 1 - 11 contains two balloons, which allows for the first position rectum balloon 1 - 2 to be used for fixing or locking The second position rectum balloon 4 - 1 can be filled with radioactive isotopes. The second position rectum balloon 4 - 1 can deliver the radiation after the first position balloon has been inflated. Another advantage for a double inflatable balloon can be the first position balloon can be used to move sensitive organs out of the region, which the second position rectum balloon 4 - 1 can deliver the dose. Each balloon has the ability to be filled up with is unique male or female connection. Specifically, the second position balloon 4 - 1 is enlarged by the male/female connection 4 - 2 ; and, the first position rectum balloon 1 - 2 is enlarged by male/female connection 1 - 7 . By allowing each balloon to have its unique connection, the advantage will allow medical personnel to control the size of each balloon independently.
[0036] FIG. 4 shows an exemplary sample of a first position rectum balloon 1 - 2 and second position rectum balloon 4 - 1 attached to first position urethra catheter balloon 1 - 1 . The rectum catheter 1 - 11 contains two balloons. The second position rectum balloon 4 - 1 contains radioactive isotopes whiles the first position rectum balloon can contain air or liquid to fill the balloon. The rectum catheter 1 - 11 contains a measuring device 5 - 1 that allows for measuring the dose that is applied to the patient. Next, a measuring device 5 - 2 can also be inserted to urethra catheter along with a measuring device 5 - 1 in the rectum catheter to allow medical personnel to measure the dose from two different locations at the same time.
[0037] FIG. 5 shows an exemplary sample of a first position rectum balloon 1 - 2 , a second position radiation balloon 4 - 1 , a third position rectum balloon 7 - 1 attached to first position urethra catheter 1 - 10 . The rectum catheter 1 - 11 has three balloons; however, there can be any number of balloons depending upon the length of the catheter. The rectum catheter 1 - 11 has a second position radiation balloon 4 - 1 that contains radioactive isotopes, while the first position rectum balloon 1 - 2 and the third position rectum balloon 7 - 1 may contain no dose delivery mechanism. The third position rectum balloon 7 - 1 can be inflated by any male/female connector 7 - 3 . When there are many balloons on a single catheter; A-A view 7 - 2 of the catheter is shown below. The A-A view 7 - 2 shows cross-sectional view of the rectum catheter and the unique tubes for inflating or deflating the balloons. By having multiple balloons on a single catheter, you are able to change the shape of each balloon relative to the location in the human body to allow for a proper fixture.
[0038] FIG. 6 shows an exemplary sample of a collapsed first position rectum balloon 1 - 2 , a second position radiation balloon 4 - 1 , a third position rectum balloon 7 - 1 attached to the urethra catheter 1 - 10 . The collapsed balloon 8 - 1 allows for minimum expansion of the balloon to keep the human tissue from being moved into any direction. Furthermore, a measuring device 8 - 2 can be inserted into the open section 1 - 3 . The benefit for having multiple balloons allows the control of how much dose can be given. The less inflated the balloon; the closer the radiation source is to the human tissue, but the more inflated the balloon the less the human tissue gets exposed to the radiation source. Next, a measuring device 8 - 3 can also be inserted to urethra catheter along with a measuring device 8 - 2 in the rectum catheter to allow medical personnel to measure the dose from two different locations at the same time. The advantage for having multiple balloons allows medical personnel to have more control.
[0039] FIG. 7 is an illustration of how both the urethra catheter and rectum catheter are inserted into the human body. The urethra catheter 10 - 1 is inserted into the penis via urethra. Thereafter, the medical personnel inflates the balloon on the catheter 10 - 2 . This will allow the surround tissue to expand and move out of the way to create space near the prostate 10 - 5 . Furthermore, the rectum catheter 10 - 6 can insert into the rectum of the patient. The rectum catheter has a first position rectum balloon 10 - 3 and a second rectum balloon 10 - 4 . Looking specifically at this illustration, but not limiting it to just second balloon, the second position rectum balloon 10 - 4 contains radioactive isotopes. This can be used to dose the prostate 10 - 5 , and the first position balloon 10 - 3 can be used as a locking or fixing mechanism to the hold the catheter in place. Furthermore, a measuring device can be inserted into both urethra catheter 10 - 1 and a rectum catheter 10 - 6 .
[0040] FIG. 8 is an illustration of how both the uretra catheter and rectum catheter are inserted into the human body. The urethra catheter 10 - 1 is inserted all way into the male bladder and inflated with a balloon 11 - 1 . The inflation of the follow will not allow for the urethra catheter to slip out of the bladder. Furthermore, the rectum catheter 10 - 6 has a first position rectum balloon 10 - 3 and a second rectum balloon 10 - 4 . Looking specifically at this illustration, but not limiting it to just second balloon, the second position rectum balloon 10 - 4 contains radioactive isotopes. This can be used to dose the prostate 10 - 5 , and the first position balloon 10 - 3 can be used as a locking or fixing mechanism to the hold the catheter in place. Furthermore, a measuring device can be inserted into both urethra catheter 10 - 1 and a rectum catheter 10 - 6 .
[0041] The above disclosure is intended to be illustrative and not exhaustive. This description will suggest many variations and alternatives to one of ordinary skill in this art. All these alternatives and variations are intended to be included within the scope fo the claims where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims.
[0042] Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of claim publication, any dependant claim which follows should be taken as alternatively written in a multiple depend form from all prior claims which possess all antecedents referenced in such dependent claim if such multiple dependent format is an accepted format within the jurisdiction (e.g. each claim depending directly form claim 1 should be alternatively taken as depending from all previous claims). In jurisdictions where multiple dependent claim formats are restricted, the following dependent claims should each be also taken as alternatively written in each singly dependent claim format which creates a dependency from a prior antecedent-possessing claim other than the specific clim listed in such dependent claim below.
[0043] With this description, those skilled in the art may recognize other equivalents to the specific embodiments described herein. Such equivalents are intended to be encompassed by the claims attached hereto. | According to one general aspect, there is A medical device comprising a locking mechanism that is used to connect a plurality of catheters, a multi-balloon inflator that inflates multiple balloons on a single catheter, a extraction point used to remove human fluids from the human body, and a connecting point that allows a syringe or a machine to insert liquid saline solution or radioactive isotopes into said multi-balloon inflator. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a drilling fluid telemetry system and, more particularly, to a valve for modulating the pressure of a drilling fluid circulating in a drill string in a well bore.
2. Description of the Background
Drilling fluid telemetry systems, referred to as mud pulse systems, are particularly adapted for telemetry of information from the bottom of a borehole to the surface of the earth during oil well drilling operations. The information telemetered often includes, but is not limited to, parameters of pressure, temperature, salinity, direction and deviation of the well bore, bit conditions and logging data, including resistivity of the various layers, sonic density, porosity, induction self potential and pressure gradients.
In previous borehole telemetry systems, it was first necessary to pull up the drilling pipe section by section including the drilling bit to completely vacate the drilled hole prior to making measurements of important parameters at the bottom of the borehole. Sensors were then lowered down to the bottom of the well on a wireline cable, the measurements were taken, the sensors and wireline were removed and finally the bit and drilling pipe was reassembled and put back into the hole. Obviously, these procedures were extremely expensive and time consuming as a result of the cessation of drilling operations during measurement times.
These problems have led to research in borehole telemetry systems in which the drilling pipe and bit do not have to be removed from the well before measurements are made. Attempts have been made to telemeter data by means of sonic waves traveling through either the drilling pipe or through the drilling mud present both inside and surrounding the drilling pipe. Unfortunately, the drilling mud is a strong sonic dampening medium and substantially attenuates the sonic waves before they can travel a usable distance. Acoustic systems using the drill pipe as the conductor require the use of repeater subs in the pipe string and are electrically complicated. No commercial acoustic system has yet been developed. Total useful telemetry depth with these systems is less than minimally needed in a practical operation.
Other proposed systems have employed an electrical conductor installed either inside or outside the drill pipe or the casing pipe. Unfortunately, the physical forces encountered in a borehole drilling operation inside the well bore and the cuttings and other debris brought up from the bottom of the well bore often produce malfunctions in the conductors and associated electrical connectors.
Another proposed system utilizes a conductor inside of each section of drill pipe with transformer coupling between sections of pipe. Besides requiring expensive modifications to the drill pipe, these systems are unreliable because the magnetic coupling between sections if frequently hindered by mechanical misalignment between drill pipe sections and because the alignment of coupling coils with one another is difficult to achieve.
Still other proposed systems employ either the drilling pipe or casing pipe as one of the conductors in an electrical transmission system. The earth itself may form the other conductor. Unfortunately, the conductivity of the earth is unpredictable and is frequently too low to make this system practical at typical borehole depths. Still further, these systems often include a single wire along the casing pipe or drilling pipe. These systems suffer from the problems discussed above with the hard wire systems. Both of these systems suffer the additional common problem that the conductivity between pipe sections is greatly affected by the presence of contaminants on the pipe joints. Frequently the resistance of the pipe joints is too high to permit telemetry using any practical power levels.
Still other proposed systems involve various electromagnetic transmission schemes for directing electromagnetic signals up the pipe string to the surface, either through the pipe or mud. These systems, similar to the sonic systems discussed above, are complicated by attempts to overcome the attenuating affects of these transmitting mediums.
At present the only drill string telemetry systems which have achieved commercial success are those related to mud pulse telemetry. One example of such a prior mud pulse system is illustrated in U.S. Pat. No. 3,964,556 which requires that circulation of drilling fluids be ceased in order to operate the system. Other systems have used a controlled restriction placed in the circulating mud stream and are commonly referred to as positive pulse systems. With mud volume sometimes surpassing 600 gpm and pump pressures exceeding 3000 psi, the restriction of this large, high pressure flow requires very powerful downhole apparatus and energy sources. Further, these systems must deal with the movement of valve parts under such high pressure conditions, resulting in a source of problems dealing with the durability of valve parts subjected to high pressure, abrasive, fluid flow conditions.
A presently employed mud pulse system involving negative pressure pulse techniques includes a downhole valve for venting a portion of the circulating drilling fluids from the interior of the drill string to the annular space between the pipe string and the borehole wall. As drilling fluids are circulated down the inside of the drill string, out through the drill bit and up the annular space to the surface, a pressure of about 1000 to about 3000 psi is developed across the drill bit. Thus, a substantial pressure differential exists across the wall of the drill string above the drill bit. By momentarily venting a portion of the fluid flow out a lateral port above the bit in the drill string, a momentary pressure drop is produced and is detectable at the surface to provide an indication of the downhole venting. A downhole instrument or detector is arranged to produce a signal or mechanical action upon the occurrence of a downhole detected event to produce the above-described venting. As may be readily appreciated by those skilled in the art, the sophistication to which this signalling may be developed is practically unlimited.
A major problem associated with negative pressure pulse systems is the wear and replacement of valve parts, particularly as the data rate is expanded. It is highly desirable to operate such a system as long as possible since replacement of system components typically requires the time consuming and expensive removal of the valve system from its downhole location and from the drill string at the surface.
One negative pulse system uses a poppet valve having a circuitous flow path through the valve. The seat of the poppet is worn rapidly by high rates of abrasive fluid flow when the valve is in the open position. In addition, it is desirable to have a fast acting opening and closing movement of the valve parts in order to create a sharp pressure pulse for adequate detection at the surface. Rapid closing of the poppet valve generates a high valve head impact force on the seat. This force rapidly wears the valve parts, particularly when abrasive particles are present in the fluid flow through the valve. Such particles become impacted in the valve parts and deteriorate the sealing surfaces of the valve. The repeated impact forces may also break portions of the valve parts because erosion resistant materials are generally not impact resistant.
Another negative pulse system employs a rotary acting valve which as a result of the mass of rotary valve parts and the motor system used to operate the valve is a slow acting system.
These examples illustrate some of the crucial considerations that exist in the application of a rapidly acting valve to a fluid flow to generate a sharp pressure pulse. Other considerations in the use of these systems in borehole operations involve the extreme impact forces and vibrational forces existing in a drill string application and resulting in excessive wear and fatigue to operating parts of the system. The particular difficulties encountered in a drill string environment, including the requirement for a long-lasting system to prevent premature malfunction and replacement of parts require a simple and rugged valve system.
The present invention overcomes the foregoing disadvantages and provides a new and improved mud pulse telemetry system having an improved shear type valve gate which is simple, durable, efficient and conveniently serviceable.
SUMMARY OF THE INVENTION
The present invention contemplates a drilling fluid telemetry system utilizing a shear type valve arranged having a straight through fluid flow path to minimize pressure losses in the valve and maximize pressure modulation by the action of the valve. The improved shear type valve includes a through conduit gate which covers a raised rim about the opening of the valveseat face when the valve is in an open, flow condition.
One feature of the invention includes the operation of the valve by a means such as a solenoid having an actuating stem operably connected to the valve gate by a floating connection which isolates the solenoid armature from lateral forces applied to the valve gate. The valve gate is constantly urged into contact with the valve seat by a biasing force.
Another feature of the invention is the designing of gate and seat opening geometries and valve actuating means to minimize the opening and closing times in order to minimize the time that the seat is subjected to erosive wear by the drilling fluid. In a preferred embodiment the valve opening in the through conduit gate and in the seat are arranged in an oblong configuration which maximizes flow rate through the valve for a minimum amount of travel of the solenoid stem and gate to conserve energy utilized to operate the system.
The invention further features an access opening in the side of the tool housing which in turn is on the outside of the drill string to permit removal of the valve wear components without removing the valve assembly from the pipe string.
These and other meritorious features and advantages of the present invention will be more fully appreciated from the following detailed description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Other features and intended advantages of the invention will be more readily apparent by the references to the following detailed description in connection with the accompanying drawings wherein:
FIG. 1 is a schematic drawing of a drill string utilizing the pressure pulse valve of the present invention and illustrating surface equipment for receiving telemetered data from downhole;
FIG. 2 is a cross-sectional elevation view of the modulating valve of the present invention; and
FIG. 3 is a section taken along lines 3--3 of FIG. 2 showing the face of the valve seat and the oblong through conduit opening in the valve.
While the invention will be described in connection with the preferred embodiment, it will be understood that it is not intended to limit the invention to that embodiment. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit of the invention as defined in the appended claims.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1 of the drawings, a drill string 11 is schematically illustrated as including sections of drill pipe 10 suspended from a drilling platform at the surface and having drill collars 15 together with various downhole subassemblies at the bottom of the drill string. The downhole assembly includes bit 12 at its lower end, above which is located bit sub 13. Bit sub 13 may house borehole parameter detecting instruments. Next in the string is illustrated power supply sub 14 and above that valve subassembly 16 which is the subject of the present invention. Instrument sub 17 houses associated electronics for encoding information indicative of detected data into a format which in turn drives valve subassembly 16 to impart data to the drilling fluid for telemetry to the surface. The drilling fluid or mud is circulated from storage pit 18 or the like at the surface by means of pump 19 which moves the mud through stand pipe 21 into the drill string. The mud is carried through the string of hollow pipe comprising the drill string to the bottom of the borehole where it exits through drill bit 12 carried on the bottom of the drill string. As the mud passes through bit 12, it experiences a substantial drop in pressure as it moves into the enlarged space of borehole annulus 22 surrounding the drill string. The mud then carries cuttings from the bottom of the borehole to the surface where they are removed and the mud is returned to pit 18 by conduit 20.
Valve assembly 16 includes a bypass passageway which serves to connect the interior of the drill pipe fluid flow path with borehole annulus 22. A sufficient volume of mud can be vented through valve 16 to cause a modulation of the mud pressure detectable at the surface. Transducer 23 is located in stand pipe 21 at the surface for detecting such modulations of pump pressure in order to receive data transmitted from downhole. The output of transducer 23 is decoded by surface electronics package 24 and the processed signals are then passed to readout equipment 26. A schematic format of an analog readout is illustrated in FIG. 1 adjacent electronics package 24. The top line (a) illustrates the pressure fluctuations that typify the normal oscillating pressure drop seen across the drill bit. Line (b) illustrates the effect on surface pressure caused by venting fluid through valve assembly 16 downhole. Simplistically, this describes a mud pulse telemetry system for utilizing the valve of the present invention in a drilling operation as will be described hereinafter in greater detail.
Referring now to FIG. 2 of the drawings, the valve assembly which forms the subject of this invention is located in housing 27 which is sized for positioning within the bore of a drill collar or valve sub 16 having the dimensions of a drill collar. This assembly is then connected into drill string 11 as illustrated in FIG. 1.
Valve assembly 16 includes side port sleeve 29 which is threadedly received within shouldered portion 31 on the wall of housing 27 and is illustrated extending through aligned opening 32 in wall 28 of valve sub 16. Sleeve 29 has a hex shaped portion formed in the bore thereof to facilitate its convenient removal from wall 28 of sub 16. O-ring seal 33 is positioned between sleeve 29 and opening 32 to seal interior bore 34 of the drill string from annulus 22 between the drill string and the borehole wall. A shear valve gate 38 is mounted for reciprocating movement within a valve chamber 50. Valve gate 38 is slidably positioned adjacent seat On the other side of gate 38 opposite seat 36 is preload collar 39 which is biased by means of spring 41 into contact with the side wall of gate 38. Spring retainer sleeve 42 which is threadedly attached to housing 27, holds spring 41 against collar 39. The interior bore of preload collar 39 and spring retainer sleeve 42 form fluid inlet opening or passageway 43 into the valve. On the other side of the valve gate and seat, a passageway or fluid outlet opening 44 is formed in the bore of sleeve 29 with the valve seat 36 rigidly mounted between the bore 44 and the valve chamber 50. The inlet and outlet openings 43, 44 respectively form a straight through passage through the valve when valve openings 46 and 47 respectively in valve seat 36 and gate 38 are aligned. Fluid screen 48 is shown positioned over inlet passageway 43 by means of bolts 49 or the like.
It is desirable to have the seating face of the valve seat 36 smaller than the opposing seating face. In a preferred embodiment, valve seat 36 has upset portion 51 which provides a raised seat face for contacting gate 38. By raising face 51 of seat 36 in a narrow upset portion (see also the dotted lines showing seat face 51 in FIG. 3), the contact area between the gate and seat is minimized and thus the force required to open the valve is held to a minimum.
In this downhole application, where the number of valve actuations for a given power supply may be of a critical nature, the minimization of power usage becomes very important. In this respect, the narrow width of the upset face portion 51 together with the oblong shape of openings 46 and 47 provides a minimum length of travel that the gate and seat must move relative to one another to open and close the valve. The power used to open the valve is proportional to the surface area of the seat face contacting the gate and the distance of relative movement of the ports. Thus, the shape of seat face 51 and openings 46 and 47 is significant in reducing the usage of power to operate the valve.
Gate 38 has a T-slotted end portion which is shaped to receive a mating T-shape formed on end 52 of solenoid stem 53. Stem 53 is vertically arranged in the body of housing 27 and has an "O" ring seal 54 positioned between stem 53 and housing body 27. Stem 53 in turn is connected to armature 56 of valve opening solenoid 57. Solenoid 57 is shown in FIG. 2 in the unactuated position with armature 56 spaced as at 58 from the closed position. This is the configuration of armature 56 when the valve assembly is closed as shown in FIG. 2, i.e. the valve openings 46 and 47 are not aligned.
Armature 56 of solenoid 57 is operatively connected to armature 59 of valve closing solenoid 61 so that the armatures move together as one unit.
Housing 27 extends upwardly from the solenoid housing portion described above to form fluid chamber 73 in which is housed movable piston 74. The walls of housing 27 form a cylinder in which piston 74 moves. O-ring seal 76 on piston seals it within the chamber 73. A port 77 in housing 27 provides a drilling fluid inlet to the top side of piston 74. Oil which fills chamber 73 is thus subjected to the pressure of drilling fluids in the bore of the drill string. This pressure is then passed by the oil which fills the interior of the valve assembly. This communication of drilling fluid pressure to the valve parts provides a pressure balance across the moving parts of the valve to thereby minimize force requirements to operate the valve.
Referring now to FIG. 3 of the drawings, gate 38 is illustrated in its closed position relative to seat 36 with the portion of conduit 47 shown with dotted lines. FIG. 3 illustrates that the thickness of the peripheral wall of upset portion 51 has been minimized to diminish the forces required for moving the valve parts relative to one another. Additionally, FIG. 3 illustrates the respective openings 47 and 46 of the gate and seat as oblong shaped with a width to height ratio as great as possible but preferably 3.5 or more. This minimizes the distance "h" which the gate must move between open and closed positions, which in turn minimizes the power required to operate the system. With respect to power expended to operate the system, it is appreciated that in a downhole configuration the power supply must be sustained as long as possible. Thus, in order to increase the data rate of the system, expediences to facilitate power supply life may become quite important. The oblong shape of the valve ports gives a sufficient volume of flow through the valve to produce a detectable pulse in mud pressure at the surface while minimizing the length of solenoid armature movement, thus conserving power.
FIG. 3 also clearly shows another aspect of the invention involving the through conduit configuration of the valve gate. With this feature, when the valve gate is in the fully open or closed position, the gate covers all or the major portion of sealing face 51 of the valve seat. Abrasive fluid flow through the valve is not wearing the seat in the valve open position. The portion of seat face 51 near opening 46 is only exposed to flow during the very short duration involved in opening and closing the valve. This feature greatly extends the life of the valve parts and likewise increases the possibility of improved data rates without premature failure of the valve. The shear action of the valve arrangement shown herein is also conducive to wiping the seat of the valve upon each movement of the gate between open and closed positions. This wiping action constantly cleans and laps the valve seat.
Because of the floating connection between valve gate 38 and solenoid stem afforded by T-slot connection 52, lateral forces acting on gate 38 are not transmitted to solenoid stem 53. In addition, the gate is free to move in contact with face 51 of seat 36 under the constant biasing action of spring 41. This in turn provides a wear compensating feature in that the gate is always pushing against the seat even as the seat wears.
FIG. 2 of the drawings further illustrates sleeve 29 which is threadedly received in the side of housing 27 and sized to provide an opening when removed that is sufficient to permit removal of both seat 36 from outlet passage 44 as well as gate 38 upon its slippage off of T-slot connection 52 between the gate and stem 53. This side removal feature permits the critical wear parts, i.e. the seat and gate of the valve to be removed at the surface on the floor of the drilling platform without removing the valve assembly from sub 16 and thus without breaking sub 16 out of the pipe string. Such ease of change out of valve parts is a significant time saving feature in the operation of this system.
In the typical operation of the system described above, the tool string illustrated in FIG. 1 is provided with one or more instruments or tools for detecting downhole parameters or the occurrence of downhole events. With any one of a number of detected events, the circuit components of the system provide a signal which, because of its encoded position in a format of signals, is indicative of the occurrence of or value of a specific event. Thus, this signal is sent in the form of an electrical pulse of sufficient time duration to operate solenoid 57 to a solenoid closed position. This in turn will move stem 53 downwardly as viewed in FIG. 2 to align opening 47 in gate 38 with opening 46 in valve seat 36. The movement of the gate is rapid so that a rapid release of drilling fluid occurs through the aligned inlet and outlet openings 43 and 44, respectively. This sudden flow through the valve openings permits drilling fluids under pump pressure in the drill string 34 to be momentarily discharged into borehole annulus 22. This discharge of high pressure drilling fluids from the drill pipe into the low pressure annulus causes a rapid pressure drop in the column of mud in the drill pipe which is observable by transducer 23 in the mud standpipe as a negative pulse. Recordings of the pressure fluctuations observed at transducer 23, when format decoded by electronics 24, can provide a readout at 26 directly indicative of the downhole detected event or valve. (line (b) in FIG. 1)
After the valve gate has been opened by momentary activation of solenoid 57, power to solenoid 57 is ceased whereupon the residual magnetism in the coil of solenoid 57 holds the solenoid sufficiently long to provide a surface detectable pressure pulse. When the valve has opened for a sufficient duration to provide a pulse, the close valve solenoid 61 is operated to move the unitary solenoid armatures toward the valve closed position as illustrated in FIG. 2.
The foregoing description of the invention has been directed in primary part to a particular preferred embodiment in accordance with the requirements of the patent statutes and for purposes of explanation and illustration. It will be apparent, however, to those skilled in the art that many modifications and changes in this specific apparatus may be made without departing from the scope and spirit of the invention. For example, the size, shape and materials as well as the details of the illustrated embodiment may vary. Therefore, the invention is not restricted to the particular form of construction illustrated and described, but covers all modifications which may fall within the scope of the following claims.
It is applicants' intention in the following claims to cover such modifications and variations as fall within the true spirit and scope of the invention. | A mud pulse telemetry system for imparting data pulses to drilling fluids circulating in a drill string including an improved valve arrangement for modulating the pressure of the circulating drilling fluid is disclosed. A shear-type valve is arranged in a through conduit configuration so that the seat face of the valve is covered when the valve is in an open position, thus preventing impingement of abrasive fluid particles on the valve seat face during the open flow position of the valve. The activation means is connected to the valve gate through a floating connection which prevents lateral stress forces operating on the valve from being imparted to the solenoid. The floating connection also permits convenient removal of the valve seat and gate from an access opening on the exterior of the drill string housing to facilitate the replacement of critical valve parts without removing the valve subassembly from the drill string. The valve gate and seat have an oblong valve flow opening therein which provides for sufficient fluid flow to adequately modulate the fluid pressure and at the same time provide a minimum length of stroke for the solenoid to operate the valve. An upset rim on the valve seat provides a seating face smaller than the opposing seating face of the gate. | 4 |
BACKGROUND OF THE INVENTION
This invention relates to a needle selection device in a circular knitting machine, in particular a hose knitting machine. More specifically, the invention relates to a selection device of the type which comprises a plurality of superimposed selecting levers, which are individually pivoted to a common structure and selectively movable between a position whereat one end thereof is located level with pattern jack butts to interfere therewith and urge the respective pattern jacks into an inoperative or rest position, and a position whereat said end is located at an intermediate level between the jack butts such as not to interfere therewith, the selective movement of the levers being accomplished through program controlled actuator means.
A device of this type is known from French Pat. No. 2,219,264. In this device, the actuator means for the selective movement of the selecting levers comprise electromagnets, each associated with a respective selecting lever at the end of the latter remote from the end intended for interfering with the jack butts, the various electromagnets being selectively energized in accordance with the machine knitting program.
This known device, however, has the disadvantage of being unsuitable for use on small size machines, such as hose knitting machines, because the arrangement of the various electromagnets above the respective levers requires much space. If the dimensions of the electromagnets are reduced for space reasons, the power available would be insufficient to attract the levers, which attraction is to occur, among others, against the bias of return members to permit the levers to return to the rest position upon de-energization of the respective electromagnets.
To obviate this shortcoming, attempts have been made to reduce the attraction distance between each electromagnet and the respective selecting lever. That is, it has been proposed to mechanically displace the individual levers into a position very close to the pole pieces of the respective electromagnets, or even to contact them, and to energize the electromagnets after the levers have reached that position. In practice, the electromagnets have rather been assigned the task of holding levers which have been previously displaced mechanically.
However, that procedure involves the preliminary displacement of all the levers, even those which, in accordance with the knitting program, should not be moved out of their rest positions. These are thus returned to their rest positions because the respective electromagnets are no longer energized to hold them.
The preliminary mechanical displacement is achieved, for example, through pattern jack butts acting on a profile portion of the selecting levers, as disclosed in British Pat. No. 1,481,146 (corresponding to U.S. Pat. No. 3,998,073) and in British Pat. No. 1,445,038, in which latter the selecting levers actually comprise flexible foils secured at one end thereof. The profile portion is followed by a recessed portion, which allows the respective levers to be returned to the rest postion lacking attraction by the associated electromagnets. It will be appreciated, however, that in addition to the need for mechanically urging indifferently all of the butts prior to the selection proper and for providing other complementary means of preliminary displacement, it becomes necessary to widen the individual levers apart such as to produce a sufficient circumferential extension of the profile and recessed portions to allow for the required displacements of the levers during the short time period of passage of the butts. In other words, it is necessary to increase the mass of the levers, which again imposes higher power requirements on the electromagnets, even though they are only energized to hold the levers. Above all, however, a device of that type is not useful for high speed machines, where the time allowed for the various displacements would be not enough unless the circumferential bulk of the levers themselves were further increased.
In the cited British Pat. No. 1,445,038, a solution is also described wherein the individual levers or foils are preliminarily shifted by means of disk cams arranged respectively under the foils and set to rotate synchronously with the needle cylinder. However, the latter solution exhibits serious space problems, especially in height, resulting from the need for superimposing a disk cam and electromagnet for each selecting lever. Moreover, that solution is also unsatisfactory from the standpoint of the knitting operation rate, owing to the sudden release of those foils which are not intended to be held attracted, which release action involves vibrations of the foils themselves before they are brought to their rest positions, a behavior which is further aggravated by the foils being of a flexible nature. Thus, in the instance of high rate knitting, the time available would be insufficient to ensure damping of such vibratory movements.
SUMMARY OF THE INVENTION
A primary object of this invention is to eliminate the aforementioned known device deficiencies by providing a section device of the type mentioned in the preamble, which only entails a limited constructional effort, lends itself for high speed or rate knitting, allows the use of electromagnets of minimal size, and requires no special profile configuration of the selecting levers, nor any prior mechanical displacement action by pattern jack butts.
This object is achieved by a needle selection device in a circular knitting machine, in particular a hose knitting machine, of the general type mentioned in the preamble, by the fact that between said actuator means, in particular of the type comprising one electromagnet for each selecting lever, and the respective selecting levers, there are provided intermediate drive elements selectively actuated by said actuator means and mechanically cooperating with the respective selecting levers to displace the same between said two positions.
Thus, in a device as indicated, it is no longer the electromagnet which attracts, or holds attracted, any respective selecting lever against the bias of its respective return member, but rather the electromagnet moves an intermediate element, the displacement whereof results in the pivotal movement of the respective selecting lever from one position into the other, specifically from the rest position into the operative one. Advantageously, it is possible to accomplish a multiplication of the displacement movements such that the intermediate element only performs a small distance displacement to provide the desired amount of displacement of the related selecting lever. More specifically, a cooperation becomes feasible between geometrical surfaces respectively formed on the intermediate element and associated selecting lever, so that the displacement of the intermediate element occurs in a different direction from the displacement of the related selecting lever. Thus, the biasing action exerted on the selecting lever by the return member only partly affects the electromagnet, it being mostly absorbed by suitable linking means, such as a guide wherealong the intermediate element is caused to move. It will be appreciated that, by virtue of the above provisions, not only may the electromagnets be of minimal power and, accordingly, of minimal size, but it is also possible to locate the bank of electromagnets in the most favorable position, given that the electromagnets are no longer to act directly on the selecting levers.
BRIEF DESCRIPTION OF THE DRAWINGS
Further features and advantages of the invention will be more clearly understood from the following detailed description of a preferred, but not limitative, embodiment thereof, given herein by way of example only and illustrated in the accompanying drawings, where:
FIG. 1 is a fragmentary sectional view, taken along the line I--I of FIG. 3, of a selecting device according to the invention, showing two selecting levers in their rest positions and with the remaining levers omitted from view for simplicity of illustration;
FIG. 2 is a fragmentary sectional view, taken similarly to FIG. 1, but showing the lower selecting lever in its operative position;
FIG. 3 is a partly sectional top plan view of the device shown in the preceding figures;
FIG. 4 is a fragmentary schematic representation of the butt arrangement on the adjacent pattern jacks, in a side view and front view with respect to the needle cylinder, respectively;
FIG. 5 is a detail view of the device as seen from the cylinder outside, the individual electromagnets being only shown schematically; and
FIGS. 6 and 7 are enlarged views of the engagement area between one intermediate control or drive element and the respective selecting lever in the two different positions of the latter.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As may be noted in the drawings, on a stationary support surface or deck 1, which encompasses the needle cylinder 2 of a circular knitting machine all around, is arranged a housing structure 3 for accommodating a plurality of superimposed selecting levers 4 which extend in a substantially radial direction of the machine (FIG. 3). The levers 4 are pivoted individually, by means of related pivot pins 5, in holes 6 of two uprights 7 of the structure 3. The holes 6 are located spaced apart by a distance equal to that between the various levels of the pattern butts 8 provided on rockable pattern jacks 9 of conventional design. The levers 4, which have a flattened shape, have a smaller thickness than the clearance between the butts 8 of two adjacent levels.
The levers 4 are selectively movable between an operative position, whereat their active ends 4a are located level with the butts 8, and an inoperative or rest position, whereat those same ends are located at an intermediate level between the butts 8. At the former position, each end 4a, which has a corner edge converging toward the cylinder 2 in the direction of rotation thereof (or in both directions, as shown in FIG. 3), urges those butts 8 which are on the same level toward the cylinder 2 (FIG. 2, bottom, and FIG. 3), so that the respective jacks 9 will not bring the corresponding needles to knit. At the latter position, the end 4a interferes with no butts 8, thereby the respective jacks 9 still protrude out of the cylinder 2 (FIG. 1) and bring the respective needles to knit in a known manner.
The two positions of the levers 4 are defined by small crossbars 10, which are attached to the uprights 7 at spacings which correspond to those of the holes 6 and which define stops means for the lever 4, so that any two adjacent crossbars 10 are alternately engaged by a part of the end 4b of one lever 4, which end has a smaller thickness dimension than the clearance between each crossbar 10. Torsion springs 11, being coiled each around one of the pins 5, serve to hold the respective levers 4 in their rest positions, whereat the end parts 4b engage the lower faces of the crossbars 10, at a point directly above the respective levers. Each spring 11 bears onto the ends of one of the crossbars 10, on one side, and on the respective lever 4, on the other side, or alternatively, is configured with its two ends in contact with one crossbar 10 and the middle part of it in contact with the respective lever 4 (FIG. 3).
Alongside the supporting structure 3, there is secured a guiding and supporting body 12 having a substantially U-like cross-sectional configuration, with two wings or extensions 13 and 14 and a base 15. As viewed from above (FIG. 3), the two wings or extensions 13 and 14 are arcuately shaped, and the base 15 is in the form of a sector of an annulus. To the outermost wing 13, there are attached plural electromagnets 16, the number whereof is the same as the number of levers 4, there being associated with each electromagnet a drive or control element 17, preferably of rod-like configuration, which extends substantially in the same plane as a respective one of the levers 4 and in a direction generally corresponding to the radial direction of the respective lever 4 to converge toward it by penetrating a related hole 18 through the wing 13 (which hole is also utilized to provide support for the corresponding electromagnet 16) and related hole 19 through the innermost or inboard wing 14.
The substantially radial arrangement of the drive elements 17 and respective electromagnets 16, whereby they converge toward the selecting levers 4, is preferred for space reasons. It allows the electromagnets 16 to be arranged staggered at various levels and different columns, as shown in FIG. 5, so as to maintain a minimal spacing between the levels or tiers of levers 4 and butts 8.
According to the invention, the drive elements 17, which are configured as intermediate elements between the program operated actuator means, as defined by the electromagnets 16, and respective selecting levers 4, are directly actuated by the electromagnets 16 and cooperate mechanically with the respective selecting levers 4 in displacing them between the two positions described hereinabove.
According to a particularly advantageous embodiment of the invention, the end of each intermediate drive element 17 located on the same side as the respective lever 4 and the adjacent control end 4b of each lever 4 i.e. the end opposite to the active end 4a are given a geometrical profile defining a geometrical coupling such that the axial displacement of each drive element 17 entails a pivotal movement of the respective lever 4 between the rest position and the operative position thereof. More specifically, the two associated ends have sloping profiles, the end of the element 17 having a substantially conical shape and the end of the lever 4 having a flat inclined portion 4c, followed by a notch 4d. The inclination angles are substantially the same. Advantageously, the inclination angle over the horizontal is less than 45 degrees. The thickness of each selecting lever 4 at the notch 4d and the thickness of the associated end of the element 17 are such that, in combination, these dimensions equal the spacing between any two adjacent crossbars 10.
It will be apparent how the axial displacement of each drive element 17 from the rest position shown in FIG. 1 and FIG. 6, whereat the active end of the element is disengaged from the associated control end 4b of the respective selecting lever 4, into the operative position shown in the bottom portion of FIG. 2 and in FIG. 7, whereat the active end of the element 17 engages the associated end of the respective selecting lever 4, entails a very fast pivotal movement of the lever itself from the rest position into the operative position thereof. Moreover, the insertion of the active end of the element 17 between the notched end of the associated lever 4 and adjacent crossbar 10 stabilizes at once and definitely the operative position of the selecting lever involved. It would be noted that said inclination of the ends, or appropriate choice of the cooperating inclined surfaces, affords the possibility of reducing the effort on the element 17 and accordingly on the electromagnet 16, relatively to that, however minimal, required to displace the lever 4 and corresponding, neglecting frictional resistances, to the action of the torsion spring 11. It will be obvious that proper surface machining or an adequate lubrication of the same can make frictional resistances virtually insignificant. Minimal size electromagnets will, therefore, be quite adequate. Of course, this is also favored by that the efforts exerted on the levers 4 by the butts 8 in a radial (i.e. horizontal) direction are in all cases taken in by the pivot pins 5 and uprights 7. The selective energization of the electromagnets 16 thus enables a selective movement of the selecting levers 4 into the operative position in accordance with the machine program, whereas the de-energization of the electromagnets 16 results in the respective rod elements 17 being returned to the rest position because of the ceasing of the electromagnetic force thereon, and the respective levers 4 returning to their rest position under the action of the respective springs 11.
It will be appreciated that with the device described hereinabove there occur no vibrations of the various levers, the latter being readily locked into their operative position, whereas during the return travel thereof into the rest position, the torsion springs 11 act progressively on the lever 4, the disengagement of the active ends 17 from the associated ends of the respective levers 4 occurring progressively by virtue of the inclined surfaces provided.
Thanks to the minimal displacement undergone by the drive elements 17 and to the instantaneous action on the respective selecting levers 4, the device of this invention also lends itself to use on high speed knitting machines, and the more so because the available actuation time is not conditioned by the provision of special lever profiles but only depends on the distance, made besides quite large, between consecutive butts 8 in one tier or on the same level (FIG. 4).
From an examination of the drawings, the simple construction of the device as a whole is also apparent, it only requiring, additionally to the articulated arrangement of the levers 4, the arrangement of linearly movable elements 17 and related electromagnets 16. The overall dimensions are also quite limited, and in all cases the device will mainly extend in a radial direction, namely the least critical machine direction.
The device as described in the foregoing is susceptible to many modifications and variations, without departing from the scope of the instant inventive concept. Thus, as an example, the intermediate drive elements 17 may be pneumatically operated instead of by means of electromagnets, or may be operated through traditional pattern drums, where circumstances are such that no special fast response requirements are imposed. Furthermore, return springs may be provided to return the drive elements 17 into their rest positions. Of course, the de-energization state of the electromagnets 16 may be made to correspond to the position of the levers 4 level with the butts 8, with the energization state of the electromagnets 16 arranged to correspond to the intermediate level between the butts 8. This device is obviously useful for application on single cylinder knitting machines, as well as double cylinder or cylinder and dial machines. | For needle selection in a circular knitting machine, a device is disclosed which comprises a plurality of superimposed selecting levers, individually pivoted to a common structure and selectively movable between a position where they do not interfere with the pattern jack butts and a position where they interfere therewith, to urge them toward the needle cylinder. The selective movement is accomplished by means of electromagnets, one for each selecting lever, which are energized in accordance with the machine knitting program and move intermediate, preferably rod-like, drive elements the axial displacement whereof results in a pivotal movement of the respective selecting levers between the cited positions. The engagement of the intermediate elements with the selecting levers is accomplished through geometrical coupling. A minimal force is sufficient for the actuation, so that the size of the electromagnets can be minimized, while a prompt response is ensured. | 3 |
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to U.S. Provisional Application Ser. No. 61/505,076 filed on Jul. 6, 2011, entitled “Systems and Methods for Semi-Autonomous Vehicular Convoying”, which is incorporated by reference herein for all purposes.
Additionally, this application is related to co-pending application Ser. No. 13/542,622, filed Jul. 5, 2012, entitled “Systems and Methods for Semi-Autonomous Vehicular Convoys”, which is incorporated by reference herein for all purposes.
BACKGROUND
The present invention relates to systems and methods for enabling vehicles to closely follow one another through partial automation. Following closely behind another vehicle has significant fuel savings benefits, but is generally unsafe when done manually by the driver. On the opposite end of the spectrum, fully autonomous solutions require inordinate amounts of technology, and a level of robustness that is currently not cost effective.
Currently the longitudinal motion of vehicles is controlled during normal driving either manually or by convenience systems, and during rare emergencies it may be controlled by active safety systems.
Convenience systems, such as adaptive cruise control, control the speed of the vehicle to make it more pleasurable or relaxing for the driver, by partially automating the driving task. These systems use range sensors and vehicle sensors to then control the speed to maintain a constant headway to the leading vehicle. In general these systems provide zero added safety, and do not have full control authority over the vehicle (in terms of being able to fully brake or accelerate) but they do make the driving task easier, which is welcomed by the driver.
Some safety systems try to actively prevent accidents, by braking the vehicle automatically (without driver input), or assisting the driver in braking the vehicle, to avoid a collision. These systems generally add zero convenience, and are only used in emergency situations, but they are able to fully control the longitudinal motion of the vehicle.
Manual control by a driver is lacking in capability compared to even the current systems, in several ways. First, a manual driver cannot safely maintain a close following distance. In fact, the types of distance to get any measurable gain results in an unsafe condition, risking a costly and destructive accident. Second, the manual driver is not as reliable at maintaining a constant headway as an automated system. Third, a manual driver when trying to maintain a constant headway has rapid and large changes in command (accelerator pedal position for example) which result in a loss of efficiency.
The system described here combines the components to attain the best attributes of the state of the art convenience and safety systems and manual control. By using the components and communication for the very best safety systems, together with an enhanced version of the functionality for convenience systems, together with the features and functionality of a manually controlled vehicle, the current solution provides a safe, efficient convoying solution.
It is therefore apparent that an urgent need exists for reliable and economical Semi-Autonomous Vehicular Convoying. These improved Semi-Autonomous Vehicular Convoying Systems enable vehicles to follow closely together in a safe, efficient, convenient manner.
SUMMARY
To achieve the foregoing and in accordance with the present invention, systems and methods for a Semi-Autonomous Vehicular Convoying are provided. In particular the systems and methods for 1) A close following distance to save significant fuel, 2) Safety in the event of emergency maneuvers by the leading vehicle, 3) Safety in the event of component failures in the system, 4) An efficient mechanism for vehicles to find a partner vehicle to follow or be followed by 5) An intelligent ordering of the vehicles based on several criteria, 6) Other fuel economy optimizations made possible by the close following, 7) Control algorithms to ensure smooth, comfortable, precise maintenance of the following distance, 8) Robust failsafe mechanical hardware, 9)Robust failsafe electronics and communication, 10) Other communication between the vehicles for the benefit of the driver, 11) Prevention of other types of accidents unrelated to the close following mode, 12) A simpler system to enable a vehicle to serve as a leading vehicle without the full system
Note that the various features of the present invention described above may be practiced alone or in combination. These and other features of the present invention will be described in more detail below in the detailed description of the invention and in conjunction with the following figures.
BRIEF DESCRIPTION OF THE DRAWINGS
In order that the present invention may be more clearly ascertained, some embodiments will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 shows the airflow around a heavy truck, in accordance with some embodiments;
FIG. 2 shows US transportation fuel use;
FIG. 3A shows typical fleet expenses for a heavy truck fleet;
FIG. 3B shows typical heavy truck fuel use from aerodynamic drag;
FIG. 4 shows typical fuel savings for a set of linked trucks;
FIG. 5 shows fuel savings versus following distance gap for a set of heavy trucks;
FIG. 6 shows an example of long range coordination between two trucks in accordance with one embodiment of the present invention;
FIG. 7 shows an example of short range linking between two trucks;
FIG. 8 illustrates exemplary long range communications between trucks;
FIG. 9 illustrates exemplary short range communications between trucks;
FIG. 10 illustrates an exemplary purpose behind the short range communications between trucks;
FIG. 11 show an exemplary installation of system components for one embodiment of the invention;
FIGS. 12 and 13 are block diagrams illustrating one embodiment of the vehicular convoying control system in accordance with the present invention;
FIG. 14 shows exemplary components for a simplified version of the embodiment of FIG. 12 suitable for a lead vehicle;
FIG. 15 shows an exemplary flowchart for coordination and linking functionality;
FIG. 16 shows some additional safety features for some embodiments; and
FIG. 17 shows one exemplary embodiment of aerodynamic optimization for use with convoying vehicles.
DETAILED DESCRIPTION
The present invention will now be described in detail with reference to several embodiments thereof as illustrated in the accompanying drawings. In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent, however, to one skilled in the art, that embodiments may be practiced without some or all of these specific details. In other instances, well known process steps and/or structures have not been described in detail in order to not unnecessarily obscure the present invention. The features and advantages of embodiments may be better understood with reference to the drawings and discussions that follow.
The present invention relates to systems and methods for a Semi-Autonomous Vehicular Convoying. Such a system enables vehicles to follow closely behind each other, in a convenient, safe manner.
To facilitate discussion, FIG. 1 shows the airflow around a typical truck 100 . This system is aimed at reducing the drag caused by this type of airflow. This drag causes the majority of fuel used in transportation, especially in the Heavy Truck sector (see FIG. 2 ). The expense of this fuel is significant for all private and industrial vehicle users, but especially so for heavy truck fleets, where the fuel is about 40% of operating expenses (see FIG. 3A ). As shown in FIG. 3B , the wind resistance for a typical truck 100 is approximately 63% of engine power at highway speeds. This wind resistance power is approximately proportional to vehicle speed, as Drag_Power=Cd*(Area*0.5* density*Velocity^3), where Cd is the coefficient of drag and is a function of the object's shape.
Embodiments of the present invention enable vehicles to follow closely together. FIG. 5 (from “Development and Evaluation of Selected Mobility Applications for VII (a.k.a. IntelliDrive)”, Shladover 2009) shows the fuel savings possible for heavy trucks at various gaps, while FIG. 4 shows one specific example of heavy trucks following closely.
In accordance with the present invention, a key part of the functionality of one such embodiment is long range coordination between the vehicles. Shown in FIG. 6 this serves to allow vehicles 410 and 420 to find linking partners. The system has some knowledge of the location and/or destination of the self-vehicle and of other equipped vehicles on the road. The system can thus suggest nearby vehicles with which to link.
FIG. 8 shows the technology to enable such a system: a long range communication system 880 and a central server 890 . The server 890 and/or the system onboard each vehicle makes decisions and suggestions based on knowledge of one or more of vehicle location, destination, load, weather, traffic conditions, vehicle type, trailer type, recent history of linking, fuel price, driver history, or others. When a linking opportunity presents itself, the driver is notified, and can manually adjust his speed to reduce the distance between the vehicles, or the system can automatically adjust the speed.
These linking opportunities can also be determined while the vehicle is stationary, such as at a truck stop, rest stop, weigh station, warehouse, depot, etc. They can also be calculated ahead of time by the fleet manager. They may be scheduled at time of departure, or hours or days ahead of time, or may be found ad-hoc while on the road, with or without the assistance of the coordination functionality of the system.
The determination of which vehicle to suggest may take into account several factors, and choose an optimum such as the vehicle which minimizes a cost function. For example, it may minimize a weighted cost function of the distance between the vehicles and the distance between their destinations: Optimum=min(W p (POS a −POS b ) 2 +W d (Des a −Des b ) 2 ), where W p and W d are the weights on the two cost terms respectively. This cost function could have any of the factors listed above.
Once the two vehicles have decided to coordinate, they may manually adjust their speed, or it may be automatic. If manual, the system may suggest to the leader to slow down, and to the follower to speed up. Or if the leader is stationary (at a truck stop, rest stop, etc.), it may suggest that he delay his departure the appropriate amount of time. These suggestions may be based on vehicle speed, destination, driver history, or other factors. If the system automatically controls the speed, it may operate the truck in a Cruise Control or Adaptive Cruise Control type mode, with the speed chosen to bring the two vehicles closer together. The system may also operate in a semi-automatic mode, where it limits the speed of the leading vehicle, to bring them closer together.
Once the vehicles are close together, the system takes control of the rear vehicle 420 and controls it to a close following distance behind the front vehicle 410 ( FIG. 7 ). The driver may use an input of the system (such as the GUI) to activate this transition, or it can be automatic based upon distance between the two vehicles. The key technology to allow this link is shown in FIG. 9 , consisting primarily of a distance/relative speed sensor, and a communication link. The type of functionality of this link is shown in FIG. 10 , where information about a braking event is sent from the front vehicle 410 to the rear vehicle 420 . Other information may include accelerometer data (filtered or unfiltered), tire pressure, information about obstacles or other vehicles in front of the lead truck. Also, any of the above data may be passed from the front truck 410 to the rear truck 420 that relates to trucks in front of the pair (for example, to allow safe platoons of 3 or more trucks) During the close-following mode, the system controls the engine torque and braking, with no driver intervention required. The driver is still steering the vehicle.
The linking event may consist of a smooth transition to the close distance following. This may take the form of a smooth target trajectory, with a controller that tries to follow this trajectory. Using Dm as the safe relative distance in manual mode, and Da as the desired distance in semi-autonomous following mode, and a time Tt for the transition to occur, the target distance may be D g =D m +(D a −D m )*(1−cos(pi*t/T d ))/2 for t less than or equal to T d . Thus in this way the change in gap per time is smallest at the beginning and the end of the transition, and largest in the middle, providing a smooth response. Other possible forms of this equation include exponentials, quadratics or higher powers, hyperbolic trigonometric functions, or a linear change. This shape may also be calculated dynamically, changing while the maneuver is performed based on changing conditions or other inputs.
The driver may deactivate the system in several ways. Application of the brake pedal may resume normal control, or may trigger a mode where the driver's braking is simply added to the system's braking Applying the accelerator pedal may deactivate the system, returning to a manual mode. Other driver inputs that may trigger a system deactivation include: Turn signal application, steering inputs larger or faster than a threshold, clutch pedal application, a gear change, Jake (compression) brake application, trailer brake application, ignition key-off, and others. The driver can also deactivate the system by selecting an option on the GUI screen or other input device.
In the event of any system malfunction, including but not limited to component failures, software failures, mechanical damage, etc., the system may react in one of several safe ways. In general the trailing truck will start braking to ensure a safe gap is maintained. This braking may continue until the trailing truck has come to a complete stop, or it may continue only until a nominally safe distance is achieved (safe without automated control), or it may continue only until the malfunction has been identified. Additionally, one of several alerts may be used to notify the driver of the malfunction and subsequent action of the control system: A braking jerk, consisting of a small braking command, an audible tone, a seat vibration, a display on the GUI or other display, flashing the instrument cluster or other interior lights, increasing or decreasing engine torque momentarily, activation of the “Jake” (compression) brake, or other useful alerts.
To enable some or all of the described functionality, the system may have some or all of the following components shown in FIG. 11 : An accelerator pedal interceptor 1140 , either on the vehicle bus or as a set of analog voltages, to be used to command torque from the engine. A modified brake valve 1150 , which allows the system to command braking even in the absence of driver command. A forward-looking RADAR or LIDAR unit 1130 , which senses distance and relative speed of the vehicle in front 410 . A dash mounted user interface 1120 , which may also house a forward looking camera, which is used for the driver to interact with and control the system. An antenna array 1110 , used for the short and long range communication systems, and for a GPS receiver.
FIG. 12 shows the system architecture for one embodiment 1200 . The user 1210 interacts with the system through a Graphical User Interface box 1220 (which may alternatively be integrated with the control box 1230 ). The user 1210 receives information (a) from visual and or auditory alerts, and can make system requests (e.g., for linking or coordination). The GUI box 1220 communicates with a long range data link 1240 (b). The GUI box 1220 is responsible for managing this data link, sending data via the link, and receiving data via the link. A control box 1230 (which may be alternatively integrated with the GUI box) receives sensor information 1250 (c), short range data link 1260 information (e), and controls the actuators 1270 (f). It receives information from the GUI 1220 via a wired or wireless link (d), and sends information to the GUI 1220 to be relayed to the driver and/or long range communication link 1240 . Alternately, the long range communication link 1240 may connect to the control box 1230 . In this case, the GUI box 1220 may be an extremely simple (low cost) device, or may even be eliminated from the system entirely.
FIG. 13 shows one embodiment of the Control Box 1230 , with the core sensors and actuators. Via connection (a), typically a CAN interface, the control box 1230 configures the radar unit 1310 and receives data. Connection (b) gives the control box acceleration information in 2 or 3 axes. The data link (c) provides information about a leading truck's 410 acceleration, or is used to provide that same information to a following truck 420 . The brake valve 1340 (d) provides data on brake pressure, and is used to apply pressure via a command from the control box 1230 . The accelerator command 1390 is sent via an analog voltage or a communications signal (CAN or otherwise). The control box performs calculations to process the sensor information, information from the GUI, and any other data sources, and determine the correct set of actuator commands to attain the current goal (example: maintaining a constant following distance to the preceding vehicle).
FIG. 15 shows one embodiment of the coordination and linking functionality. First the system identifies a vehicle available for coordination 1510 (example: within a certain range, depending on the route of the two vehicles). Once one of the vehicles has accepted 1522 or 1524 , the other can then accept, meaning that the pair has agreed to coordinate for possible linking 1530 . Depending on vehicle positioning, weight of load, vehicle equipment, and other factors, a vehicle within linking range may be identified as a Following Vehicle Available for Linking 1542 or a Leading Vehicle Available for Linking 1544 . If neither of these is the case, the system returns to coordination mode. Once a Following Vehicle Available for Coordination has Accepted the link 1552 , the Self Vehicle then also accepts the link 1553 , initiating the link. Upon completion of the link, the vehicles are now linked 1562 . Similarly, once a Leading Vehicle Available for Coordination has Accepted the link 1554 , the Self Vehicle then also accepts the link 1555 , initiating the link. Upon completion of the link, the vehicles are now linked 1564 .
Safety in the event of emergency maneuvers by the leading vehicle 410 is ensured by the use of the communication link between the two vehicles. This link may send some or all of the following: Brake application pressure, brake air supply reservoir pressure, engine torque, engine RPM, compression (Jake) brake application, accelerator pedal position, engine manifold pressure, computed delivered torque, vehicle speed, system faults, battery voltage, and radar/lidar data.
The data link 1260 has very low latency (approximately 10 ms in one embodiment), and high reliability. This could be, but is not limited to, WiFi, radio modem, Zigbee, or other industry standard format. This link could also be a non-industry-standard format. In the event of a data link loss, the trailing vehicles should immediately start slowing, to ensure that if the front vehicle happens to brake immediately when the link is lost, the gap can be maintained safely.
In addition to safe operation during the loss of the data link 1260 , the system should be safe in the event of failure of components of the system. For most failures, the trailing vehicles 420 start braking, until the driver takes control. This ensures that in the worst case where the front vehicle 410 starts to brake immediately when a system component fails, the system is still safe. The modified brake valve 1340 is also designed such that in the event of a complete failure, the driver can still brake the vehicle.
Ordering of the vehicles: The system arranges the vehicles on the road to ensure safety. This order may be determined by vehicle weight/load, weather/road conditions, fuel savings or linking time accrued, braking technology on the vehicle, destination or other factors. The system will (graphically or otherwise) tell the drivers which vehicle should be in the front. For example, to mitigate fatigue, the system may cause the trucks to exchange positions on a periodic basis.
FIG. 16 shows some additional safety features the system may have to prevent other types of accidents unrelated to the close following mode. One such feature is to use the video stream from the front looking camera to detect drifting within or out of the lane. This is done by looking at the edges or important features on the leading vehicle 410 , and calculating the lateral offset from that vehicle. When it is detected, the system can react with a braking jerk (a short braking application to get the driver's attention), slowing down, or a braking jerk in the leading vehicle. The system can also use the front mounted radar to detect obstacles or stationary vehicles in the road, even when not in close-following mode. When these are detected, it can apply a braking jerk, slow the vehicle, or provide visual or auditory warnings. The system can also use the accelerator pedal signal to determine when the driver is not engaged with the vehicle (or other driver states) and react accordingly, such as slowing the vehicle or disabling the system.
To facilitate rapid deployment, a simpler version of the system enables vehicles to be a leading vehicle, shown in FIG. 14 . The components on this version are a subset of those on the full system, so there is no automation. There are several embodiments of this reduced set of functionality, with different subsets of the components from the full system. One minimal system simply performs two functions: Transmits sufficient data to the trailing vehicle to allow close following, and alerts the front driver to a linking request and allows him/her to accept or decline it. As such, this version has only the data link functionality 1460 . It connects to the brake pressure sensor and electrical power. This system may also have additional components, including an accelerometer 1450 and/or an extremely simply user interface and/or long range data communication 1440 .
The full system may also provide other fuel economy optimizations. These may include grade-based cruise control, where the speed set-point is determined in part by the grade angle of the road and the upcoming road. The system can also set the speed of the vehicles to attain a specific fuel economy, given constraints on arrival time. Displaying the optimum transmission gear for the driver 1410 can also provide fuel economy benefits.
The system may also suggest an optimal lateral positioning of the trucks, to increase the fuel savings. For example, with a cross wind, it may be preferable to have a slight offset between the trucks, such that the trailing truck is not aligned perfectly behind the leading truck. This lateral position may be some combination of a relative position to the surrounding truck(s) or other vehicles, position within the lane, and global position.
The data link between the two vehicles is critical to safety, so the safety critical data on this link has priority over any other data. Thus the link can be separated into a safety layer (top priority) and a convenience layer (lower priority). The critical priority data is that which is used to actively control the trailing vehicle. Examples of this may include acceleration information, braking information, system activation/deactivation, system faults, range or relative speed, or other data streams related to vehicle control.
The lower priority convenience portion of the link can be used to provide data to the driver to increase his pleasure of driving. This can include social interaction with the other drivers, video from the front vehicle's camera to provide a view of the road ahead. This link can also be used when the vehicle is stationary to output diagnostic information gathered while the vehicle was driving.
Because the system is tracking the movements of the vehicles, a tremendous amount of data about the fleet is available. This information can be processed to provide analysis of fleet logistics, individual driver performance, vehicle performance or fuel economy, backhaul opportunities, or others.
The system will have an “allow to merge” button to be used when the driver wants another vehicle to be able to merge in between the two vehicles. The button will trigger an increase in the vehicle gap to a normal following distance, followed by an automatic resumption of the close following distance once the merging vehicle has left. The length of this gap may be determined by the speed of the vehicles, the current gap, an identification of the vehicle that wishes to merge, the road type, and other factors. The transition to and from this gap may have a smooth shape similar to that used for the original linking event. Using Dv as the relative distance to allow a vehicle to cut in, and Da as the desired distance in semi-autonomous following mode, and a time Tt for the transition to occur, the target distance may be D g =D a +(D v −D a )*(1−cos(pi*t/T d ))/2 for t less than or equal to T d .
For vehicles with an automatic transmission, the system can sense the application of the clutch pedal by inferring such from the engine speed and vehicle speed. If the ratio is not close to one of the transmission ratios of the vehicle, then the clutch pedal is applied or the vehicle is in neutral. In this event the system should be disengaged, because the system no longer has the ability to control torque to the drive wheels. For example this calculation may be performed as a series of binary checks, one for each gear: Gear_1=abs(RPM/WheelSpeed—Gear1Ratio)<Gear1Threshold and so on for each gear. Thus if none of these are true, the clutch pedal is engaged.
The system can estimate the mass of the vehicle to take into account changes in load from cargo. The system uses the engine torque and measured acceleration to estimate the mass. In simplest form, this says that M total=Force_Wheels/Acceleration. This may also be combined with various smoothing algorithms to reject noise, including Kalman filtering, Luenberger observers, and others. This estimate is then used in the control of the vehicle for the trajectory generation, system fail-safes, the tracking controller, and to decide when full braking power is needed. The mass is also used to help determine the order of the vehicles on the road.
Many modifications and additions to the embodiments described above are possible and are within the scope of the present invention. For example, the system may also include the capability to have passenger cars or light trucks following heavy trucks. This capability may be built in at the factory to the passenger cars and light trucks, or could be a subset of the components and functionality described here, e.g., as an aftermarket product.
The system may also include an aerodynamic design optimized for the purpose of convoying, as shown in FIG. 17 . This may be the design of the tractor or trailer, or the design of add-on aerodynamic aids that optimize the airflow for the convoy mode. This design may correspond to a specific speed, at which the airflow will be optimized for the convoy mode.
For example, a hood may deploy, e.g., slide forward, from the roof of the follower vehicle. Portions of the hood may be textured (like an aerodynamic golf ball surface) or may be transparent so as not to further obscure the follower driver's view. In another example, the existing aerodynamic cone of a follower truck may be repositioned, and/or the cone profile dynamically reconfigured, depending on vehicular speed and weather conditions. This aerodynamic addition or modification may be on the top, bottom, sides, front, or back of the trailer or tractor, or a combination thereof
This aerodynamic design may be to specifically function as a lead vehicle 1710 , specifically as a following vehicle 1720 , or an optimized combination of the two. It may also be adjustable in some way, either automatically or manually, to convert between optimized configurations to be a lead vehicle, a following vehicle, both, or to be optimized for solitary travel.
The data link between the two vehicles may be accomplished in one of several ways, including, but not limited to: A standard patch antenna, a fixed directional antenna, a steerable phased-array antenna, an under-tractor antenna, an optical link from the tractor, an optical link using one or more brake lights as sender or receiver, or others.
The data link, or other components of the system, may be able to activate the brake lights, in the presence or absence of brake pedal or brake application.
Other possible modifications include supplemental visual aids for drivers of follower vehicles, including optical devices such as mirrors and periscopes, to enable follower drivers to get a better forward-looking view which is partially obscured by the lead vehicle.
Any portion of the above-described components included in the system may be in the cab, in the trailer, in each trailer of a multi-trailer configuration, or a combination of these locations.
The components may be provided as an add-on system to an existing truck, or some or all of them may be included from the factory. Some of the components may also be from existing systems already installed in the truck from the factory or as an aftermarket system.
The present invention is also intended to be applicable to current and future vehicular types and power sources. For example, the present invention is suitable for 2-wheeler, 3-wheelers, 4 wheelers, 16-wheelers, gas powered, diesel powered, two-stroke, four-stroke, turbine, electric, hybrid, and any combinations thereof. The present invention is also consistent with many innovative vehicular technologies such as hands-free user interfaces including head-up displays, speech recognition and speech synthesis, regenerative braking and multiple-axle steering.
The system may also be combined with other vehicle control systems such as Electronic Stability Control, Parking Assistance, Blind Spot Detection, Adaptive Cruise Control, Traffic Jam Assistance, Navigation, Grade-Aware Cruise Control, Automated Emergency Braking, Pedestrain detection, Rollover-Control, Anti-Jacknife control, Anti-Lock braking, Traction Control, Lane Departure Warning, Lanekeeping Assistance, Sidewind compensation. It may also be combined with predictive engine control, using the command from the system to optimize future engine inputs.
In sum, the present invention provides systems and methods for a Semi-Autonomous Vehicular Convoying. The advantages of such a system include the ability to follow closely together in a safe, efficient, convenient manner.
While this invention has been described in terms of several embodiments, there are alterations, modifications, permutations, and substitute equivalents, which fall within the scope of this invention. Although sub-section titles have been provided to aid in the description of the invention, these titles are merely illustrative and are not intended to limit the scope of the present invention.
It should also be noted that there are many alternative ways of implementing the methods and apparatuses of the present invention. It is therefore intended that the following appended claims be interpreted as including all such alterations, modifications, permutations, and substitute equivalents as fall within the true spirit and scope of the present invention. | The present invention relates to systems and methods for facilitating participants of vehicular convoys to closely follow one another through partial automation. Following closely behind another vehicle has significant fuel savings benefits, but is unsafe when done manually by the driver. On the opposite end of the spectrum, fully autonomous solutions require inordinate amounts of technology, and a level of robustness that is currently not cost effective. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of U.S. patent application Ser. No. 13/335,749, now U.S. Pat. No. 9,027,287, and claims the benefit of priority to Provisional Patent Application No. 61/428,778 filed Dec. 30, 2010.
TECHNICAL FIELD OF INVENTION
The present invention relates to a new rig mast, substructure, and transport trailer for use in subterranean exploration. The present invention provides rapid rig-up, rig-down and transport of a full-size drilling rig. In particular, the invention relates to a self-erecting drilling rig in which rig-up of the mast and substructure may be performed without the assistance of a crane. The rig components transport without removal of the drilling equipment including top drive with mud hose and electrical service loop, AC drawworks, rotary table, torque wrench, standpipe manifold, and blow out preventers (BOP), thus reducing rig-up time and equipment handling damage.
BACKGROUND OF THE INVENTION
In the exploration of oil, gas and geothermal energy, drilling operations are used to create boreholes, or wells, in the earth. Drilling rigs used in subterranean exploration must be transported to the locations where drilling activity is to be commenced. These locations are often remotely located. The transportation of such rigs on state highways requires compliance with highway safety laws and clearance underneath bridges or inside tunnels. This requirement results in extensive disassembly of full-size drilling rigs to maintain a maximum transportable width and transportable height (mast depth) with further restrictions on maximum weight, number and spacing of axles, and overall load length and turning radius. These transportation constraints vary from state to state, as well as with terrain limitations. These constraints can limit the size and capacity of rigs that can be transported and used, conflicting with the subterranean requirements to drill deeper, or longer reach horizontal wells, more quickly, requiring larger rigs.
Larger, higher capacity drilling rigs are needed for deeper (or horizontally longer) drilling operations, since the hook load for deeper operations is very high, requiring rigs to have a capacity of 500,000 lbs. and higher. Constructing longer, deeper wells requires increased torque, mud pump capacity and the use of larger diameter tubulars in longer strings. Larger equipment is required to handle these larger tubulars and longer strings. All of these considerations drive the demand for larger rigs. Larger rigs require a wider base structure for strength and wind stability, and this requirement conflicts with the transportability constraint and the time and cost of moving them. Larger rigs also require higher drill floors to accommodate taller BOP stacks. Once transported to the desired location, the large rig components must each be moved from a transport trailer into engagement with the other components located on the drilling pad. Moving a full-size rig and erecting a conventional mast and substructure generally requires the assistance of large cranes at the drilling site. The cranes will be required again when the exploration activity is complete and it is time to take the rig down and prepare it for transportation to a new drilling site.
Once the cranes have erected the mast and substructure, it is necessary to reinstall much of the machinery associated with the operation of the drilling rig. Such machinery includes, for example, the top drive with mud hose and electrical service loop, AC drawworks, rotary table, torque wrench, standpipe manifold, and BOP.
Rigs have been developed with mast raising hydraulic cylinders and with secondary substructure raising cylinders for erection of the drilling rig without the use, or with minimal use, of cranes. For example, boost cylinders have been used to fully or partially raise the substructure in combination with mast raising cylinders. These rigs have reduced rig transport and rig-up time; however, substructure hydraulics are still required and the three-step lifting process and lower mast lifting capacity remain compromised in these configurations. Also, these designs incorporate secondary lifting structures, such as mast starter legs which are separated completely from the mast for transportation. These add to rig-up and rig-down time, weight, and transportation requirements, encumber rig floor access, and may still require cranes for rig-up. Importantly, the total weight is a critical concern.
Movement of rig masts from transport trailers to engagement with substructures remains time consuming and difficult. Also, rig lifting supports create a wider mast profile, which limits the size of the structure support itself due to transportation regulations, and thus the wind load limit of the drilling rig. In particular, it is very advantageous to provide substructures having a height of less than 8 (eight) feet to minimize the incline and difficulty of moving the mast from its transport position into its connectable position on top of the collapsed substructure. However, limiting the height of the collapsed substructure restricts the overall length of retracted raising cylinders in conventional systems. It further increases the lift capacity requirement of the raising cylinder due to the disadvantageous angle created by the short distance from ground to drilling floor in the collapsed position.
For the purpose of optimizing the economics of the drilling operation, it is highly desirable to maximize the structural load capacity of the drilling rig and wind resistance without compromising the transportability of the rig, including, in particular, the width of the lower mast section, which bears the greatest load.
Assembly of drilling rigs for different depth ratings results in drilling rig designs that have different heights. Conventional systems often require the use of different raising cylinders that are incorporated in systems that are modified to accommodate the different capacity and extension requirements that are associated with drilling rigs having different heights from ground to drill floor. This increases design and construction costs, as well as the problems associated with maintaining inventories of the expensive raising cylinders in multiple sizes.
It is also highly desirable to devise a method for removing an equipment-laden lower mast section from a transport trailer into engagement with a substructure without the use of supplemental cranes. It is also desirable to minimize accessory hydraulics, and the size and number of telescopic hydraulic cylinders required for rig erection. It is also desirable to minimize accessory structure and equipment, particularly structure and equipment that may interfere with transportation or with manpower movement and access to the rig floor during drilling operations. It is also desirable to ergonomically limit the manpower interactions with rig components during rig-up for cost, safety and convenience.
It is also highly desirable to transport a drilling rig without unnecessary removal of any more drilling equipment than necessary, such as the top drive with mud hose and electrical service loop, AC drawworks, rotary table, torque wrench, standpipe manifold, and BOP. It is highly desirable to transport a drilling rig without removing the drill line normally reeved between the travelling block and the crown block. It is also highly desirable to remove the mast from the transport trailer in alignment with the substructure, and without the use of cranes. It is also desirable to maintain a low height of the collapsed substructure. It is also desirable to have a system that can adapt a single set of raising cylinders for use on substructures having different heights.
Technological and economic barriers have prevented the development of a drilling rig capable of achieving these goals. Conventional prior art drilling rig configurations remain manpower and equipment intensive to transport and rig-up. Alternative designs have failed to meet the economic and reliability requirements necessary to achieve commercial application. In particular, in deeper drilling environments, high-capacity drilling rigs are needed, such as rigs having hook loads in excess of 500,000 lbs., and with rated wind speeds in excess of 100 mph. Quick rig-down and transportation of these rigs have proven to be particularly difficult. Highway transport regulations limit the width and height of the transported mast sections as well as restricting the weight. In many states, the present width and height limit is 14 feet by 14 feet. Larger loads are subject to additional regulations including the requirement of an escort vehicle.
In summary, the preferred embodiments of the present invention provide unique solutions to many of the problems arising from a series of overlapping design constraints, including transportation limitations, rig-up limitations, hydraulic raising cylinder optimization, craneless rig-up and rig-down, and static hook load and rated wind speed requirements.
SUMMARY OF THE INVENTION
The present invention provides a substantially improved drilling rig system. In one embodiment, a drilling mast transport skid is provided comprising a frame positionable on a transport trailer. A forward hydraulically actuated slider, and a rear hydraulically actuated slider are located on the frame. The sliders are movable in perpendicular relationship to the frame. An elevator is movably located between the rear slider and the mast supports (or equivalently between the rear slider and frame) for vertically elevating the mast relative to the frame. A carriage is movably located between the frame and the forward slider for translating the forward slider along the length of the frame. A mast section of a drilling rig may be positioned on the sliders, such that controlled movement of the sliders, the elevator and the carriage can be used to position the mast section for connection to another structure.
In another embodiment, a slide pad is located on an upper surface of at least one of the sliders, so as to permit relative movement between the mast section and the slider when articulating the slider.
In another embodiment, an elevator is located on each side of the rearward slider, between the rearward slider and the mast support, such that each elevator is independently movable between a raised and lowered position for precise axial positioning of the mast section.
In another embodiment, a roller set between the carriage and the frame provides a rolling relationship between the carriage and the frame. A motor is connected to the carriage. A pinion gear is connected to the motor. A rack gear is mounted lengthwise on the frame, and engages the pinion gear, such that operation of the motor causes movement of the forward slider lengthwise along the frame.
In one embodiment, a drilling rig is provided, comprising a collapsible substructure including a base box, a drill floor and a pair of raising cylinders pivotally connected at one end to the base box and having an opposite articulating end. The raising cylinders are selectively extendable relative to their pivotal connection at the base box. A mast is provided, and has a lower mast section comprising a framework having a plurality of cross-members that define a transportable width of the lower mast section. The lower mast section has a plurality of legs, having an upper end attached to the framework, and an opposite lower end. A connection on the lower end of at least two legs is provided for pivotally connecting the lower mast section to the drill floor.
A pair of wing brackets is deployably secured to the lower mast section framework. The wing brackets are pivotal or slidable between a stowed position within the transport width of the lower mast section and a deployed position that extends beyond the transport width of the lower mast section. The raising cylinder is connectable to the wing brackets and extendable to rotate the lower mast section from a generally horizontal position to a raised position above the drill floor to a substantially vertical position above the drill floor, or to a desired angle that is less than vertical.
In another embodiment, each wing bracket of the drilling rig further comprises a frame having a pair of frame sockets on its opposite ends. The frame sockets pivotally connect the frame to the lower mast section. The wing brackets pivot to fit substantially within a portal in the lower mast section in the stowed position.
In another embodiment, the pivotal connection of the frame to the mast defines a pivot axis of the wing bracket about which the wing bracket is deployed and stowed. The pivotal connection between the lower mast section legs and the drill floor defines a pivot axis of the mast. In a preferred embodiment, the pivot axis of the wing bracket is substantially perpendicular to the pivot axis of the mast.
In another embodiment, each wing bracket of the drilling rig further comprises a frame and an arm extending from the frame towards the interior of the lower mast section. An arm socket is located on the end of the arm opposite to the frame. A bracket locking pin is attached to the lower mast section and is extendable through the arm socket to lock the wing bracket in the deployed position.
In another embodiment, each wing bracket of the drilling rig further comprises a frame and a lug box attached to the frame. The lug box is receivable of the articulating end of the raising cylinder. A lug socket is located on the lug box. A raising cylinder lock pin is extendable through the articulating end of the raising cylinder and the lug socket to lock the raising cylinder in pivotal engagement with the wing bracket.
In another embodiment, each wing bracket of the drilling rig further comprises a wing cylinder attached between the interior of the lower mast section and the arm of the wing bracket. Actuation of the wing cylinder moves the wing bracket between the deployed and stowed positions, without the need to have workers scaling the mast to lock the wing in position.
In one embodiment, a drilling rig assembly is provided comprising a collapsible substructure that is movable between the stowed and deployed positions. The collapsible substructure includes a base box, a drill floor framework and a drill floor above the drill floor framework, and a plurality of legs having ends pivotally connected between the base box and the drill floor. The legs support the drill floor above the base box in the deployed position. A raising cylinder has a lower end pivotally connected at one end to the base box and an opposite articulating end. The raising cylinder is selectively extendable relative to the pivotal connection at the base box. A cantilever is provided, having a lower end and an upper end, and being pivotally connected to the drill floor framework, the upper end movable between a stowed position below the drill floor and a deployed position above the drill floor. The upper end of the cantilever is connectable to the articulating end of the raising cylinder when the cantilever is in the deployed position, such that extension of the raising cylinder raises the substructure into the deployed position.
In one embodiment, the raising cylinder can be selectively connected to a lower mast section of a drilling mast that is pivotally connected above the drill floor such that extension of the raising cylinder raises the lower mast section from a generally horizontal position to a generally vertical position above the drill floor. In another embodiment, the raising cylinder raises the lower mast section from a generally horizontal position to a position above the drill floor that is within 50 degrees of vertical to permit slant drilling operations.
In another embodiment, a cantilever cylinder is pivotally connected at one end to the drill floor framework and has an opposite end pivotally connected to the cantilever. The cantilever cylinder is selectively extendable relative to its pivotal connection at the drill floor framework. Extension of the cantilever cylinder rotates the cantilever from the stowed position below the drill floor to the deployed position above the drill floor. Refraction of the cantilever cylinder refracts the cantilever from the deployed position above the drill floor to the stowed position below the drill floor.
In another embodiment, the substructure includes a box beam extended horizontally beneath the drill floor and a beam brace affixed to the box beam. The cantilever engages the beam brace upon rotation of the cantilever into the fully deployed position. Extension of the raising cylinder transfers the lifting force for deployment of the substructure to the box beam through the cantilever and beam brace.
In another embodiment, when the substructure is in the collapsed position and the raise cylinder is connected to the cantilever, the centerline of the raise cylinder forms an angle to the centerline of a substructure leg that is greater than 20 degrees. In another embodiment, when the substructure is in the collapsed position, the distance from the ground to the drill floor is less than 8 feet.
In another embodiment, connection of the upper end of the cantilever to the articulating end of the raising cylinder forms an angle between the cantilever and the raising cylinder of between 70 and 100 degrees, and extension of the raising cylinder to deploy the substructure reduces the angle between the cantilever and the raising cylinder to between 35 and 5 degrees.
In another embodiment, an opening is provided in the drill floor that is sufficiently large so as to permit passage of the cantilever as it moves between the stowed and deployed positions. A backer panel is attached to the cantilever and is sized for complementary fit into the opening of the drill floor when the cantilever is in the stowed position.
In another embodiment, the mast has front legs and rear legs. The front legs are connectable to front leg shoes located on the drill floor. The rear legs are connectable to rear leg shoes located on the drill floor. In another embodiment, the lower end of the raising cylinder is pivotally connected to the base box at a location beneath and between the front leg shoes and the rear leg shoes of the drill floor of the erected substructure. The lower end of the cantilever is pivotally connected to the drill floor framework at a location beneath the drill floor.
In one embodiment, a drilling rig assembly is provided, comprising a collapsible substructure movable between the stowed and deployed positions. The collapsible substructure includes a base box and a drill floor framework having a drill floor above the drill floor framework. The substructure further includes a plurality of legs having ends pivotally connected to the base box and drill floor framework, such that the legs support the drill floor above the base box in the deployed position of the substructure. A mast is included, having a lower mast section pivotally connected above the drill floor and movable between a generally horizontal position to a position above the drill floor.
A cantilever has a lower end and an upper end, the lower end being pivotally connected to the drill floor framework. The upper end is movable between a stowed position below the drill floor and a deployed position above the drill floor. A raising cylinder is pivotally connected at one end to the base box and has an opposite articulating end. The raising cylinder is selectively extendable relative to the pivotal connection at the base box. The articulating end of the raising cylinder is connectable to the mast such that extension of the raising cylinder moves the mast from a generally horizontal position above the drill floor to a generally vertical position above the drill floor. The articulating end of the raising cylinder is also connectable to the upper end of the cantilever such that extension of the raising cylinder raises the drilling substructure into the deployed position.
In another embodiment, the raising cylinder can be selectively connected to a lower mast section of a drilling mast that is pivotally connected above the drill floor such that extension of the raising cylinder raises the lower mast section from a generally horizontal position to a generally vertical position above the drill floor. In another embodiment, the partial extension of the raising cylinder is selectable for raising the mast to an angular position of at least 50 degrees of the vertical for slant drilling operations.
In another embodiment, a pair of wing brackets is pivotally attached to the lower mast section and capable of attachment to the raising cylinder. The raising cylinder may be connected to the wing brackets and extended to rotate the lower mast section from a generally horizontal position to a generally vertical position above the drill floor. In another embodiment, the partial extension of the raising cylinder is selectable for raising the mast to an angular position of at least 50 degrees of the vertical for slant drilling operations.
In another embodiment, the wing brackets are pivotal between a deployed position and a stowed position. A lug socket is located on each bracket and is connectable to the raising cylinder. In the stowed position, the wing brackets are contained within the width of the lower mast section. In the deployed position, the wing brackets extend beyond the width of the lower mast such that the sockets are in alignment with the articulating end of the raising cylinder.
In one embodiment, a drilling rig assembly is provided comprising a raising cylinder. The raising cylinder has a first angular position for connection to a deployable wing bracket connected to a mast section. The raising cylinder has a second angular position for detachment from the deployable wing bracket at the conclusion of raising a mast into the vertical position. The raising cylinder has a third angular position for connection to a retractable cantilever connected to a substructure in a stowed (collapsed) position. The raising cylinder has a fourth angular position for detachment of the raising cylinder from the retractable cantilever at the conclusion of raising a subsection into the deployed (vertical) position. In a preferred embodiment, the first angular position is located within 10 degrees of the fourth angular position, and the second angular position is located within 10 degrees of the third angular position.
In another embodiment, the raising cylinder has a pivotally connected end about which it rotates and an articulating end for connection to the deployable wing bracket and the retractable cantilever. The articulating end of the raising cylinder forms a first lifting arc between the first angular position and the second angular position. The articulating end of the raising cylinder forms a second lifting arc between the first angular position and the second angular position. The first and second lifting arcs intersect substantially above the pivotally connected end of the raising cylinder.
In another embodiment, the raising cylinder rotates in a first rotational direction while raising the mast sections. The raising cylinder rotates in a second rotational direction opposite to the first rotational direction while raising the substructure.
In another embodiment, the raising cylinder is a multi-stage cylinder having a maximum of three stages. In another embodiment, the wing brackets are deployed about a first pivot axis. The cantilevers are deployed about a second pivot axis that is substantially perpendicular to the first pivot axis.
In one embodiment, a drilling rig assembly is provided comprising a collapsible substructure movable between the stowed and deployed positions. The collapsible substructure includes a base box and a drill floor framework with a drill floor above the drill floor framework. A plurality of substructure legs have ends pivotally connected to the base box and the drill floor for supporting the drill floor above the base box in the deployed position.
A lower mast section of a drilling mast is provided comprising a lower section framework having a plurality of cross-members that define a transportable width of the lower mast section. A plurality of legs is pivotally connected to the lower section framework for movement between a stowed position and a deployed position. A connection is provided on the lower end of at least two legs for pivotally connecting the lower mast section above the drill floor.
A raising cylinder is pivotally connected at one end to the base box and has an opposite articulating end. The raising cylinder is selectively extendable relative to the pivotal connection at the base box. A wing bracket is pivotally connected to the lower mast section of a drilling mast and movable between a stowed position and a deployed position. The wing bracket is connectable to the articulating end of the raising cylinder when the cantilever is in the deployed position, such that extension of the raising cylinder raises the lower mast section into a generally vertical position above the drill floor.
In another embodiment, the legs are movable between a stowed position within the transport width and a deployed position external of the transport width. The wing brackets are also movable between a stowed position within the transport width and a deployed position external of the transport width.
In another embodiment, the legs are pivotally movable about a first axis. The wing brackets are pivotally movable about a second axis that is substantially perpendicular to the first axis.
In another embodiment, a cantilever is pivotally connected to the drill floor and is movable between a stowed position below the drill floor and a deployed position above the drill floor. The cantilever is connectable to the articulating end of the raising cylinder when the cantilever is in the deployed position, such that extension of the raising cylinder raises the drill floor into the deployed position.
In another embodiment, the cantilever is deployed about a third pivot axis substantially perpendicular to each of the first pivot axis and the second pivot axis.
In one embodiment, a method of assembling a drilling rig provides for steps comprising: setting a collapsible substructure onto a drilling site; moving a lower mast section into proximity with the substructure; pivotally attaching the lower mast section to a drill floor of the substructure; pivotally deploying a pair of wings outward from a stowed position within the lower mast section to a deployed position external of the lower mast section; connecting an articulating end of a raising cylinder having an opposite lower end to the substructure to each wing; extending the raising cylinder so as to rotate the lower mast section from a substantially horizontal position to an erect position above the drill floor; pivotally deploying a pair of cantilevers upward from a stowed position beneath the drill floor to a deployed position above the drill floor; connecting the articulating end of the raising cylinder to each deployed cantilever; and extending the raising cylinder so as to lift the substructure from a stowed, collapsed position to a deployed, erect position.
In another embodiment, the raising cylinders are adjusted as a central mast section and an upper mast section are sequentially attached to the lower mast section.
As will be understood by one of ordinary skill in the art, the sequence of the steps disclosed may be modified and the same advantageous result obtained. For example, the wings may be deployed before connecting the lower mast section to the drill floor (or drill floor framework).
BRIEF DESCRIPTION OF THE DRAWINGS
The objects and features of the invention will become more readily understood from the following detailed description and appended claims when read in conjunction with the accompanying drawings in which like numerals represent like elements.
The drawings constitute a part of this specification and include exemplary embodiments to the invention, which may be embodied in various forms. It is to be understood that in some instances various aspects of the invention may be shown exaggerated or enlarged to facilitate an understanding of the invention.
FIG. 1 is an isometric view of a drilling system having certain features in accordance with the present invention.
FIG. 2 is an isometric exploded view of a mast transport skid having certain features in accordance with the present invention.
FIG. 3 is an isometric view of the mast transport skid of FIG. 2 , illustrated assembled.
FIG. 4 is an isometric view of a first stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
FIG. 5 is an isometric view of a second stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
FIG. 6 is an isometric view of a third stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
FIG. 7 is an isometric view of a fourth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
FIG. 8 is an isometric view of the wing bracket illustrated in accordance with an embodiment of the present invention.
FIG. 9 is an isometric view of the wing bracket of FIG. 8 , illustrated in the deployed position relative to a lower mast section.
FIGS. 10, 11 and 12 are side views illustrating a fifth, sixth and seventh stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
FIG. 13 is a side view of an eighth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
FIG. 14 is a side view of a ninth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
FIG. 15 is an isometric view of a retractable cantilever, shown in accordance with the present invention.
FIG. 16 is a side view of a tenth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
FIG. 17 is a side view of an eleventh stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
FIG. 18 is a side view of a twelfth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
FIG. 19 is a side view of a thirteenth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention.
FIG. 20 is a diagram of the relationships between the mast and substructure raising components of the present invention.
FIG. 21 is a diagram of certain relationships between the raising cylinder, the deployable cantilever, and the substructure of the present invention.
FIG. 22 is a diagram of drilling rig assemblies of three different sizes, each using the same raising cylinder pair in combination with the deployable cantilever and deployable wing bracket.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The following description is presented to enable any person skilled in the art to make and use the invention, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein.
FIG. 1 is an isometric view of a drilling rig assembly 100 including features of the invention. As seen in FIG. 1 , drilling assembly 100 has a lower mast section 220 mounted on top of a substructure 300 .
Mast leg pairs 230 are pivotally attached to lower mast section 220 at pivot connections 226 . Mast leg cylinders 238 may be connected between lower mast section 220 and mast legs 230 for moving mast legs 230 between a transportable stowed position and the illustrated deployed position. The wider configuration of deployed mast legs 230 provides greater drilling mast wind resistance and more space on a drilling floor for conducting drilling operations.
A pair of wing brackets 250 is pivotally connected to lower mast section 220 immediately above pivot connections 226 . Wing brackets 250 are movable between a transportable stowed position and the illustrated deployed position.
Collapsible substructure 300 supports mast sections 200 , 210 (not shown) and 220 . Substructure 300 includes a base box 310 located at ground level. A drill floor framework 320 is typically comprised of a pair of side boxes 322 and a center section 324 . A plurality of substructure legs 340 is pivotally connected between drill floor framework 320 and the base box 310 . A box beam 326 (not visible) spans side boxes 322 of drill floor framework 320 for structural support. A drill floor 330 covers the upper surface of drill floor framework 320 .
A pair of cantilevers 500 is pivotally attached to drill floor framework 320 . Cantilevers 500 are movable between a transportable stowed position and a deployed position. In the stowed position, cantilevers 500 are located beneath drill floor 330 . In the deployed position, cantilevers 500 are raised above drill floor 330 .
A pair of raising cylinders 400 is provided for raising connected mast sections 200 , 210 and 220 into the vertical position above substructure 300 , and also for raising substructure 300 from a transportable collapsed position to the illustrated deployed position. Raising cylinders 400 are also provided for lowering substructure 300 from the illustrated deployed position to a transportable collapsed position, and for lowering connected mast sections 200 , 210 and 220 into the horizontal position above collapsed substructure 300 .
Raising cylinders 400 raise and lower connected mast sections 200 , 210 and 220 by connection to wing brackets 250 . Raising cylinders 400 raise and lower substructure 300 by connection to cantilevers 500 .
FIG. 2 is an isometric exploded view of an embodiment of transport skid 600 . Transport skid 600 is loadable onto a standard low-boy trailer as is well known in the industry. Transport skid 600 has a forward end 602 and a rearward end 604 . Transport skid 600 supports a movable forward slider 620 and a rearward slider 630 .
Forward slider 620 is mounted on a carriage 610 . A forward hydraulic cylinder 622 is connected between carriage 610 and forward slider 620 . A pair of front slider pads 626 may be located between forward slider 620 and frame sides 606 .
Carriage 610 is located on skid 600 and movable in a direction between forward end 602 and rearward end 604 , separated by skid sides 606 . In one embodiment, a roller set 612 provides a rolling relationship between carriage 610 and skid 600 .
A motor 614 is mounted on carriage 610 . A pinion gear 616 is connected to motor 614 . A rack gear 618 is mounted lengthwise on skid 600 . Pinion gear 616 engages rack gear 618 , such that operation of motor 614 causes movement of carriage 610 lengthwise along skid 600 .
Rearward slider 630 is mounted on a rearward base 632 . A rearward hydraulic cylinder 634 is connected between rearward slider 630 and rearward base 632 . A pair of rear slider pads 636 may be located between rearward slider 630 and skid sides 606 . In one embodiment, bearing pads 638 are located on the upper surface of rearward slider 630 for supporting mast section 220 .
In one embodiment, an elevator 640 is located on each side of rearward slider 630 , between rearward slider 630 and skid 600 , each being movable between a raised and lowered position.
FIG. 3 is an isometric view of mast transport skid 600 of FIG. 2 , illustrated assembled. Forward slider 620 is movable in the X-axis and Y-axis relative to skid 600 . Actuation of motor 614 causes movement of forward slider 620 along the X-axis. Actuation of forward cylinder 622 causes movement of forward slider 620 along the Y-axis.
Rearward slider 630 is movable independent of forward slider 620 . Rearward slider 630 is movable in the Y-axis and Z-axis relative to skid 600 . Actuation of rearward cylinder 634 causes movement of rearward slider 630 along the Y-axis. Actuation of elevators 640 causes movement of rearward slider 630 along the Z-axis. In one embodiment, elevators 640 are independently operable, thus adding to the degrees of freedom of control of rearward slider 630 .
FIGS. 4 through 7 illustrate the initial stages of the rig-up sequence performed in accordance with the present invention. FIG. 4 is an isometric view of a first stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. Lower mast section 220 is carried on forward slider 620 and rearward slider 630 of transport skid 600 . Transport skid 600 is mounted on a trailer 702 connected to a tractor 700 .
A plurality of structural cross-members 222 (not shown) defines a mast framework width 224 (not shown) of lower mast section 220 . At this stage of the sequence, mast legs 230 are in the retracted position, and within framework width 224 . Also at this stage, wing brackets 250 are in the retracted position, and also within framework width 224 . By obtaining a stowed position of mast legs 230 and wing brackets 250 , the desired transportable framework width 224 of lower mast section 220 is achieved. Substructure 300 is in the collapsed position, on the ground, and being approached by tractor 700 and transport skid 600 .
FIG. 5 is an isometric view of a second stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. At this stage, tractor 700 and trailer 702 are backed up to a position of closer proximity to substructure 300 , which is on the ground in a collapsed position. Having moved mast legs 230 past the point of interference with raising cylinders 400 , legs 230 are deployed by mast leg cylinders 238 (not shown), which rotates legs about the axis Z of pivot connection 226 .
Each mast leg pair 230 has a front leg 232 and a rear leg 234 . Shoe connectors 236 are located at the base of legs 230 . Front shoes 332 and rear shoes 334 are located on drilling floor 330 for receiving shoe connectors 236 of front legs 232 and rear legs 234 , respectively. A pair of inclined ramps 336 is located on drilling floor 330 , inclining upwards towards front shoes 332 .
Elevators 640 are actuated to raise rearward slider 630 and thus mast legs 230 of lower mast 220 along the Z-axis ( FIG. 3 ) above obstacles related to substructure 300 as tractor 700 and trailer 702 are backed up to a position of closer proximity to substructure 300 (see FIG. 4 ). In this position (referring also to FIG. 2 ), forward cylinder 622 of forward slider 620 and rearward cylinder 634 of rearward slider 630 are actuated to finalize Y-axis ( FIG. 3 ) alignment of mast legs 230 of lower mast section 220 with inclined ramps 336 ( FIGS. 4 and 5 ). The option of like or opposing translation of forward slider 620 and rearward slider 630 along the Y-axis is especially beneficial for this purpose. Using this alignment capability, shoe connectors 236 of front legs 232 are aligned with inclined ramps 336 .
FIG. 6 is an isometric view of a third stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. In this stage, rearward slider 630 is lowered by elevators 640 (not visible), positioning shoe connectors 236 of front legs 232 onto inclined ramps 336 . This movement disengages rearward slider 630 from lower mast section 220 .
Carriage 610 is translated from forward end 602 towards rearward end 604 . In one embodiment, this movement is accomplished by actuating motor 614 . Motor 614 rotates pinion gear 616 which is engaged with rack gear 618 , forcing longitudinal movement of carriage 610 and forward slider 620 along the X-axis ( FIG. 3 ). As a result, lower mast section 220 is forced over substructure 300 , as shoe connectors 236 slide up inclined ramps 336 .
FIG. 7 is an isometric view of a fourth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. As shoe connectors 236 reach the top of inclined ramps 336 , they align with, and are connected to, front leg shoes 332 .
In the embodiment described, wing brackets 250 ( FIG. 9 ) are pivotally connected to lower mast section 220 proximate to, and above, pivot connections 226 ( FIG. 7 ). Wing brackets 250 are movable between a transportable stowed position and the illustrated deployed position.
A wing cylinder 252 ( FIG. 9 ) may be connected between lower mast section 220 and each wing bracket 250 for facilitating movement between the stowed and deployed positions. Connection sockets 254 are provided on the ends of wing brackets 250 for connection to raising cylinder 400 . As shown in FIGS. 7 and 9 , wing brackets 250 are moved into the deployed position by actuating wing cylinders 252 ( FIG. 9 ).
Raising cylinder 400 is pivotally connected to base box 310 . In a preferred embodiment, raising cylinder 400 has a lower end 402 pivotally connected to base box 310 at a location between the pivotal connections of substructure legs 340 to base box 310 (see FIG. 18 ). Raising cylinder 400 has an opposite articulating end 404 (see FIG. 9 ). In a preferred embodiment, raising cylinder 400 is a multi-stage telescoping cylinder capable of extension of a first stage 406 , a second stage 408 and a third stage 410 . A positioning cylinder 412 may be connected to each raising cylinder 400 for facilitating controlled rotational positioning of raising cylinder 400 .
In the stage of the rig-up sequence illustrated in FIG. 7 , raising cylinders 400 are pivotally moved into alignment with deployed wing brackets 250 for connection to sockets 254 . Notably, raising cylinders 400 bypass the transported framework width 224 of lower mast section 220 in order to connect to wing brackets 250 on the far side of lower mast section 220 . It is thus required that mast raising cylinders 400 be separated by a distance slightly greater than framework width 224 . Lower mast section 220 is now supported by wing brackets 250 . This is accomplished by the present invention without the addition of separately transported and assembled mast sections.
As described above, an embodiment of the invention further includes a retractable push point for raising substructure 300 significantly above drill floor 330 and significantly forward of lower mast section 220 .
Lower mast section 220 is lifted slightly by extension of first stage 406 of raising cylinder 400 , disengaging lower mast section 220 from transport skid 600 , allowing tractor 700 and trailer 702 to depart.
As seen in FIG. 7 , mast legs 230 are pivotally deployed about first pivot axis Z (at 226 ), and wing brackets 250 are pivotally deployed about second pivot axis 264 that is substantially perpendicular to first pivot axis Z (at 226 ).
FIG. 8 is an isometric view of wing bracket 250 in accordance with an embodiment of the present invention. FIG. 9 is an isometric view of wing bracket 250 in the deployed position relative to lower mast section 220 . Referring to the embodiment of wing bracket 250 illustrated in FIG. 8 , wing bracket 250 is comprised of a framework 260 designed to fit within a portal 228 in lower mast section 220 (see FIG. 9 ). Frame 260 has a pair of sockets 262 for pivotal connection to lower mast section 220 within portal 228 . The pivotal connection defines an axis 264 about which wing bracket 250 is deployed and stowed. In one embodiment, axis 264 is substantially perpendicular to first pivot axis Z (at 226 ) about which legs 230 are deployed and stowed.
A lug box 256 extends from frame 260 . Socket 254 is located on lug box 256 . An arm 270 extends inward towards the interior of lower mast section 220 . A bracket socket 272 is located near the end of arm 270 .
Referring to FIG. 9 , wing cylinder 252 extends between lower mast section 220 and arm 270 to deploy and stow wing bracket 250 . In the deployed position, a bracket locking pin 274 extending through portal 228 passes through bracket socket 272 ( FIG. 8 ) to lock wing bracket 250 in the deployed position. With wing bracket 250 locked in the deployed position, raising cylinder 400 is extended. Lug box 256 receives articulating end 404 of raising cylinder 400 . A raising cylinder locking pin 258 is hydraulically operable to pass through articulating end 404 and socket 254 to lock raising cylinder 400 to wing bracket 250 .
FIGS. 10, 11 and 12 are side views illustrating a fifth, sixth and seventh stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. Referring to FIGS. 10 through 11 , it is seen that subsequent tractor 700 and trailer 702 carry central mast section 210 for connection to lower mast section 220 , and carry upper mast section 200 for connection to central mast section 210 . At this time, the weight of the collective mast sections is born by the raising cylinder 400 as transmitted through the wing brackets 250 . Raising cylinder 400 can be extended to align connected mast sections with each incoming mast section. For example, raising cylinder 400 can be extended to align connected mast sections 210 with 220 , and 200 with 210 .
FIGS. 13 and 14 are side views illustrating an eighth and ninth sequence for a drilling system, as performed in accordance with the present invention. In these steps, lower mast section 220 (and connected central and upper mast sections 210 and 200 ) is raised into a vertical position. In FIG. 13 , lower mast section 220 is illustrated pivoted upwards by extension of first stage 406 and second stage 408 of raising cylinder 400 . In FIG. 14 , lower mast section 220 is illustrated pivoted into the fully vertical position by extension of third stage 410 of raising cylinder 400 .
FIG. 15 is an isometric view of cantilever 500 , shown in accordance with the present invention. Cantilever 500 has a lower end 502 for pivotal connection to drill floor framework 320 of substructure 300 . Cantilever 500 has an upper end 504 for connection to articulating end 404 of raising cylinder 400 . A load pad 508 is provided for load bearing engagement with a beam brace 328 (not shown) located on substructure 300 . A backer panel 510 provides a complementary section of drill floor 330 when cantilever 500 is in the stowed position.
Cantilever 500 is movable between a transportable stowed position and a deployed position. In the stowed position, cantilever 500 is located beneath drill floor 330 . In the deployed position, upper end 504 of cantilever 500 is raised above drill floor 330 for connection to articulating end 404 of raising cylinder 400 . A cantilever cylinder 506 (not shown) may be provided for moving cantilever 500 between the transportable stowed position and the deployed position.
FIGS. 16, 17, 18, and 19 are side views illustrating tenth, eleventh, twelfth, and thirteenth stages of the rig-up sequence for a drilling system, illustrating the erection of substructure 300 , as performed in accordance with the present invention. In FIG. 16 , raising cylinder 400 has been detached from wing brackets 250 , and articulating end 404 of raising cylinder 400 has been retracted. Wing brackets 250 may remain in the deployed position during drilling operations.
Cantilever 500 has been moved from the stowed position beneath drill floor 330 into the deployed position in which upper end 504 of cantilever 500 is above drill floor 330 . Cantilever 500 may be moved between the stowed and deployed positions by actuation of cantilever cylinder 506 . Upper end 504 of cantilever 500 is connected to articulating end 404 of raising cylinder 400 . In this position, load pad 508 of cantilever 500 is in complementary engagement with beam brace 328 for transmission of lifting force as applied by raising cylinder 400 .
FIG. 17 is a side view of an eleventh stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. In the view, first stage 406 of raising cylinder 400 is fully extended and second stage 408 ( FIG. 18 ) is being initiated. As a result of the force being applied on cantilever 500 , as transferred to beam brace 328 , drill floor framework 320 is raising off of base box 310 as substructure 300 is moved towards an erected position.
FIG. 18 is a side view of a twelfth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. In this view, first stage 406 and second stage 408 of raising cylinder 400 have been extended to lift drill floor framework 320 over base box 310 as substructure 300 is moved into the fully deployed position with substructure legs 340 supporting the load of mast sections 200 , 210 , 220 , and drill floor framework 320 . Conventional locking pin mechanisms and diagonally oriented beams are used to prevent further rotation of substructure legs 340 , and thus maintain substructure 300 in the deployed position.
FIG. 19 is a side view of a thirteenth stage of the rig-up sequence for a drilling system, as performed in accordance with the present invention. In this view, articulating end 404 of raising cylinder 400 is disconnected from upper end 504 of cantilever 500 . Raising cylinder 400 is then retracted. Cantilever 500 is moved into the stowed position by actuation of cantilever cylinder 506 . In the stowed position, backer panel 510 of cantilever 500 becomes a part of drill floor 330 , providing an unobstructed space for crew members to perform drilling operations.
FIG. 20 is a diagram of the relationships between lower mast section 220 and substructure 300 raising components 250 , 400 and 500 of the present invention. More specifically, FIG. 20 illustrates one embodiment of preferred kinematic relationships between deployable wing bracket 250 , deployable cantilever 500 and raising cylinder 400 .
In one embodiment, upper end 504 of cantilever 500 is deployed to a location above drill floor 330 that is also forward of front leg shoes 332 . In one embodiment, pivotally connected end 402 of raising cylinder 400 is connected to substructure 300 at a location beneath and generally between front leg shoes 332 and rear leg shoes 334 of drill floor 330 of erected substructure 300 . Also in this embodiment, lower end 502 of cantilever 500 is pivotally connected at a location beneath drill floor 330 and forward of front leg shoes 332 .
As was seen in an embodiment illustrated in FIG. 7 , mast legs 230 are pivotally deployed about a first pivot axis, and wing brackets 250 are pivotally deployed about a second pivot axis that is substantially perpendicular to the first pivot axis of mast legs 230 . Cantilever 500 is deployed about a third pivot axis that is substantially perpendicular to the first and second pivot axes of mast legs 230 and wing brackets 250 , respectively.
As seen in FIG. 1 , there is a pair of raising cylinders 400 , each raising cylinder 400 connectable to a cantilever 500 and a wing 250 . In a preferred embodiment, the pair of raising cylinders 400 rotates in planes that are parallel to each other. In another preferred embodiment, cantilevers 500 rotate in planes that are substantially within the planes of rotation of the raising cylinders. This configuration has a number of advantages related to the alignment and connection of upper end 504 of cantilever 500 to articulating end 404 of raising cylinder 400 . This embodiment also optimizes accessibility of the deployed cantilevers 500 of sufficient size to carry the significant sub-lifting load beneath and above the very limited space on drill floor 330 and within drill floor framework 320 . This embodiment also provides deployed engagement of load pad 508 with a beam brace 328 located on substructure 300 , without placing a misaligned load of the pivotal connections of cantilevers 500 and cylinders 400 . It will be understood by one of ordinary skill in the art that a modest offset of the planes would behave as a substantial mechanical equivalent of these descriptions.
As was seen in an embodiment illustrated in FIGS. 4-8 , mast legs 230 are pivotally deployed about a first pivot axis Z (at 226 ), and wing brackets 250 are pivotally deployed about a second pivot axis 264 that is substantially perpendicular to first pivot axis Z (at 226 ) of mast legs 230 . Cantilever 500 is deployed about a third pivot axis that is substantially perpendicular to the first and second pivot axes of mast legs 230 and wing brackets 250 , respectively. This embodiment is advantageous in that mast legs 230 may be pivoted about an axis that reduces the transport width of the mast. It is further advantageous in that the wings remain gravitationally retracted during transportation, and when deployed.
One such plane of rotation is illustrated in FIG. 20 . As illustrated in FIG. 20 , when connected to deployed wing brackets 250 , articulating end 404 forms a first arc A 1 upon extension of raising cylinder 400 . Arc A 1 is generated in a first arc direction as mast sections 200 , 210 and 220 are raised.
When connected to deployed cantilever 500 , articulating end 404 forms a second arc A 2 upon extension of raising cylinder 400 . Arc A 2 is generated in a second arc direction opposite that of A 1 , as collapsed substructure 300 is raised.
A vertical line through the center of pivotally connected end 402 of cantilever 400 is illustrated by axis V. In a preferred embodiment, the intersection of first arc A 1 and second arc A 2 relative to axis V, is located within + or −10 degrees of axis V.
In one embodiment illustrated in FIG. 20 , the angular disposition of raising cylinder 400 has four connected positions. The sequential list of the connected positions is: a) retracted connection to wing brackets 250 ; b) extended connection to wing brackets 250 ; c) retracted connection to cantilever 500 ; and d) extended connection to cantilever 500 . In the embodiment illustrated in FIG. 20 , the angular disposition of raising cylinder 400 in position a is within 10 degrees of position d, and the angular disposition of raising cylinder 400 in position b is within 10 degrees of position c. The angular disposition of each position a, b, c, and d to vertical axis V is denoted as angles a′, b′, c′, and d′, respectively.
Having connected positional alignments within approximately 10 degrees optimizes the power and stroke of raising cylinder 400 . Also, having connected positional alignments b and c within approximately 10 degrees speeds alignment and rig-up of drilling system 100 .
FIG. 21 is a diagram of the relationship between raising cylinder 400 , deployable cantilever 500 and substructure leg 340 . In this diagram, substructure leg 340 is relocated for visibility of the angular relationship to raising cylinder 400 , as represented by angle w. Angle w is critical to the determination of the load capacity requirement of raising cylinder 400 . Without the benefit of the higher push point provided by deployable cantilever 500 , angle w would be approximately 21 degrees of lees for the embodiment shown. By temporarily raising the push point or pivotally connected end 402 above drill floor 330 , w is increased, lowering the load capacity requirement of raising cylinder 400 .
Provided in combination with deployable wing brackets 250 , the configuration of drilling rig assembly 100 of the present invention permits the optimal sizing of mast raising cylinders 400 , as balanced between retracted dimensions, maximum extension and load capacity, all within the fewest hydraulic stages. Specifically, mast raising cylinders 400 can achieve the required retracted and extended dimensions to attach to wing brackets 250 and extend sufficiently to fully raise mast sections 200 , 210 and 220 , while also providing an advantageous angular relationship between substructure legs 340 and raising cylinder 400 such that sufficient lift capacity is provided to raise substructure 300 . This is all accomplished with the fewest cylinder stages possible, including first stage 406 , second stage 408 and third stage 410 .
As seen in the embodiment illustrated in FIG. 21 , connection of upper end 504 of cantilever 500 to articulating end 404 of raising cylinder 400 , when substructure 300 is in the stowed position, forms an angle x between cantilever 500 and raising cylinder 400 of between 70 and 100 degrees. Extension of raising cylinder 400 to deploy substructure 300 reduces the angle between cantilever 500 and raising cylinder 400 to between 5 and 35 degrees.
FIG. 22 is a diagram of drilling rig assemblies 100 of three different sizes, each using the same raising cylinder pair 400 in combination with the same deployable cantilever 500 and deployable wing bracket 250 .
As seen in FIG. 22 , the configuration of drilling rig assembly 100 of the present invention has the further benefit of enabling the use of one size of raising cylinder pair 400 in the same configuration with wing brackets 250 and cantilever 500 to raise multiple sizes of drilling rig assemblies 100 . As seen in FIG. 22 , a substructure 300 for a 550,000 lb. hook load drilling rig 100 is shown having a lower ground to drill floor 330 height than does substructures 302 and 304 . Drilling rig designs for drilling deeper wells may encounter higher subterranean pressures, and thus require taller BOP stacks beneath drill floor 330 . As illustrated, the same wing brackets 250 , cantilever 500 and the raising cylinders 400 can be used with substructure 302 for a 750,000 lb. hook load drilling rig 100 , or with substructure 304 for a 1,000,000 lb. hook load drilling rig 100 .
As also illustrated in FIG. 22 , the configuration of drilling rig assembly 100 of the present invention has a drill floor 330 height to ground of distance “h” which is less than 8 feet. This has the significant advantage of minimizing the incline and difficulty of moving mast sections 200 , 210 , 220 along inclined ramps 336 from the transport position into connection with front shoes 332 on top of collapse substructure 300 . This is made possible by the kinematic advantages achieved by the present invention.
As described, the relationships between the several lifting elements have been shown to be extremely advantageous in limiting the required size and number of stages for raising cylinder 400 , while enabling craneless rig-up of masts ( 200 , 210 , 220 ) and substructure 300 . As further described above, the relationships between the several lifting elements have been shown to enable optimum positioning of a single pair of raising cylinders 400 to have sufficient power to raise a substructure 300 , and sufficient extension and power at full extension to raise a mast ( 200 , 210 , 220 ) without the assistance of intermediate booster cylinder devices and reconnecting steps, and to permit such expedient mast and substructure raising for large drilling rigs.
Referring back to FIGS. 4 through 7, 9, 13 through 14, and 16 through 19 , a method of assembling a drilling rig 100 is fully disclosed. The disclosure above, including the enumerated figures, provides for steps comprising: setting collapsible substructure 300 onto a drilling site; moving lower mast section 220 into proximity with substructure 300 ( FIGS. 4-6 ); pivotally attaching lower mast section 220 to a drill floor 330 of substructure 300 ( FIG. 7 ); pivotally deploying a pair of wing brackets 250 outward from a stowed position within lower mast section 220 to a deployed position external of lower mast section 220 ( FIGS. 7 and 9 ); connecting articulating ends 404 of a pair of raising cylinders 400 (having opposite pivotally connected end 402 connected to substructure 300 ) to each wing bracket 250 ( FIG. 7 ); extending raising cylinders 400 so as to rotate lower mast section 220 from a substantially horizontal position to an erect position above drill floor 330 ; pivotally deploying a pair of cantilevers 500 upward from a stowed position beneath drill floor 330 to a deployed position above drill floor 330 ; connecting articulating ends 404 of raising cylinders 400 to each deployed cantilever 500 ; and extending raising cylinders 400 so as to lift substructure 300 from a stowed, collapsed position to a deployed, erect position.
In another embodiment, shown in FIGS. 10 through 12 , raising cylinders 400 are adjusted as central mast section 210 and upper mast section 200 are sequentially attached to lower mast section 220 .
As will be understood by one of ordinary skill in the art, the sequence of the steps disclosed may be modified and the same advantageous result obtained. For example, the wing brackets may be deployed before connecting the lower mast section to the drill floor (or drill floor framework).
Having thus described the present invention by reference to certain of its preferred embodiments, it is noted that the embodiments disclosed are illustrative rather than limiting in nature and that a wide range of variations, modifications, changes, and substitutions are contemplated in the foregoing disclosure and, in some instances, some features of the present invention may be employed without a corresponding use of the other features. Many such variations and modifications may be considered desirable by those skilled in the art based upon a review of the foregoing description of preferred embodiments. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | The present invention discloses a high-capacity drilling rig system that includes novel design features that alone and more particularly in combination facilitate a fast rig-up and rig-down with a single set of raising cylinders and maintains transportability features. In particular, a transport trailer is disclosed having a first support member and a drive member which align the lower mast portion with inclined rig floor ramps and translate the lower mast legs up the ramps and into alignment for connection. A pair of wing brackets is pivotally deployed from within the lower mast width for connection to the raising cylinder for raising the mast from a horizontal position into a vertical position. A cantilever is pivotally deployed from beneath the rig floor to a position above it for connection to the raising cylinder for raising the substructure from a collapsed position into the erect position. | 4 |
BACKGROUND OF THE INVENTION
The present invention relates generally to IC (integrated circuit) card assemblies and more particularly to an improved adapter card assembly, such as for CF (CompactFlash) and PCMCIA (Personal Computer Memory Card International Association) card assemblies.
Small, lightweight and transportable computing devices are becoming ubiquitous. Such devices have a wide variety of functions, and it is often desired by the user to be able to adapt the function of the computing device to serve varying needs. To accommodate the ability of a user to alter the capabilities of a computing devices many of today's personal computers, computer peripherals and other electronic products such as digital cameras, have receptacles or ports for receiving removable IC cards. Such IC cards augment or replace traditional immovable memory, mass storage and input/output devices with removable cards that contain one or more integrated circuits. The IC cards may feature on-card functions, or may provide interfaces to other external devices. Because they are removable, IC cards let the user expand the memory, storage, communications and other capabilities of a computer or other electronic device without opening the case of the device.
IC cards typically conform to software and hardware specifications, including form factor standards which cover physical dimensions, pin assignments, and so on. A popular standard is that established by the Personal Computer Memory Card International Association (PCMCIA). Another standard with growing popularity is the CompactFlash (CF) standard. As advances have been made which permit smaller and more compact IC cards, new standards for IC cards have been introduced to the market.
Most electronic devices are capable of receiving IC cards of just one standard. For example, an older device may be able to receive only a PCMCIA card, while a newer device may be able to receive only a CF card. Obviously, this presents many compatibility difficulties. A user may own several devices which require different IC card standards, and thus will not be able to interchange a single IC card among all of the devices. A user may replace an older device that uses one standard with a newer device that uses a different standard, thereby rendering the IC cards for the older device useless with the new device. As a result of these types of compatibility problems, adapters have been developed which allow an IC card of one standard to be used with a device which requires a card of another standard.
Currently available IC card adapters are not without problems of their own. In particular, currently available adapters use materials and assembly techniques common to IC cards, and as a result have the same types of problems as IC cards. For example, the adapter connectors usually nest in plastic frames which are then joined to metal covers by complicated manufacturing steps such as insert molding, ultrasonic welding, or thermoset adhesive, used alone or in combination. Usually, the connector bodies are bonded with adhesive to the metal covers to prevent the metal covers from flexing excessively and separating from the connector. However, under the stress of mechanical or thermal shock, vibration or flexure, present adapter assemblies can fail. Common modes of failure include fracturing of ultrasonic welds and adhesive separation.
Of course, it is readily apparent that each manufacturing step adds cost to the assembly. In IC cards, the material and assembly costs are low compared to the cost of the electronic components used in the IC card. However, the same is not true of adapter cards which contain few or no electronic devices other than connectors. Therefore, an adapter design utilizing less expensive components and simplifying the required assembly will provide a disproportionately large cost savings.
In addition to the complicated assembly requirements of currently available IC card adapters, the metal covers currently used in such adapters create a host of problems. Metal covers on the adapters increase the incidence of host equipment damage and program execution errors associated with ESD (electrostatic discharge) through the metal covers. It is also known that EMI (electromagnetic interference) emissions from the assembly occur when the metal covers act as an antenna. Another limitation attributed to metal covers is that they can cause wearing or skiving of a host connector due to the typically sharp edges of the covers. When this occurs, insulative debris are produced which can interfere with electrical contact interfaces in the connectors.
Unfortunately, a suitable solution to the problems associated with IC card adapter assemblies related to complicated assembly of excessive parts, bonding or welding requirements, electrostatic discharge, electromagnetic interference damage to host connectors and resulting debris, fracturing and separation failures and disassembly damage has not been satisfactorily addressed by the prior art.
Therefore, what is needed is an adapter apparatus for facilitating IC card adapter assembly. It is also highly desirable to provide added structural integrity to limit failures and shortcomings associated with the use of such adapter assemblies.
SUMMARY OF THE INVENTION
The present invention provides an apparatus and method of assembly of an IC card adapter. The apparatus comprises a printed circuit board having a first edge attached to solder tails extending from a back surface of a first connector and an opposing second edge attached to solder tails extending from a front surface of a second connector. The printed circuit board, first connector and second connector form a subassembly which is provided with a first keyed interlock surface. A lower molded housing is adapted to receive the subassembly. The lower housing includes a second keyed interlock surface for oriented engagement with the first keyed interlock surface of the subassembly. The keyed interlock surfaces of the subassembly and lower housing provide proper orientation between the subassembly and the lower housing, and also secure the subassembly within the lower housing. The lower housing also includes a first latching member. An upper molded housing is provided with a second latching member adapted for engagement with the first latching member of the lower housing, such that when engaged, the lower and upper housings define a cavity enclosing the printed circuit board.
The primary advantage of the present invention is that it provides lower manufacturing and assembly costs by reducing the number of components in the apparatus and reducing number of operations required to assemble the apparatus. The invention also provides improved electrical performance, and improved resistance to mechanical failure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a prior art IC card adapter assembly.
FIG. 2 illustrates a common failure mode of the IC card adapter assembly of FIG. 1.
FIG. 3 is an isometric view of the inventive IC card adapter assembly.
FIG. 4a is an exploded view of the adapter assembly of FIG. 3.
FIG. 4b is an isolated view of the lower housing shown in FIG. 4a.
FIG. 5 is a cross sectional view of the latching means of the adapter assembly of FIG. 3.
FIGS. 6a and 6b are cross sectional views of latching means which introduce dimensional variance.
FIG. 7 is a cross sectional view of a portion of the adapter assembly of FIG. 3.
FIG. 8 is a cross sectional view taken along line 8--8 of FIG. 3.
FIG. 9 is a cross sectional view taken along line 9--9 of FIG. 3.
FIG. 10 is a cross sectional view of a portion of an alternative configuration of the adapter assembly.
FIG. 11 is a schematic side view of an alternative configuration of the adapter assembly.
DETAILED DESCRIPTION OF THE INVENTION
A portion of a common prior art construction for IC card and IC card adapter assemblies is shown in FIGS. 1 and 2. FIGS. 1 and 2 show connector 10, well known in the art, for connection to an external host connector 12 (shown in FIG. 2). Front surface 14 of connector 10 includes a plurality of pin receiving connections (not shown) for connection to external host connector 12. Rear surface 16 of connector 10 is electrically connected to a circuit board 18 by contacts 20. Circuit board 18 is protected by metal covers 22 which are secured to upper and lower surfaces 24, 26 of connector 10 by an adhesive 28. The height H of connector 10 is controlled by form factor standards (e.g., PCMCIA and CF), and is 0.130 inches. Upper and lower surfaces 24, 26 include reduced thickness portions 30, 32, which reduce the thickness of connector 10 to approximately 0.106 inches, which is the practical minimum thickness due to the required connector body wall thickness. The remaining space (0.024 inches) is all that remains to accommodate the thickness of covers 22 and adhesive 28, such that the completed assembly has a smooth and continuous outer surface. Metal covers 22 usually have a thickness of about 0.008 inches, while adhesive 28 is about 0.004 inches thick. The objective of adhesively bonding metal covers 22 to connector 10 is to avoid bowing or lifting of covers 22 which would cause skiving or stubbing on pin header shroud 34 of external host connector 12, as is illustrated in FIG. 2. Such bowing or lifting can be caused by numerous factors, including mechanical and thermal shock, and poor adhesive bonding.
As discussed above, there are a host of disadvantages associated with metal covers. As a result, there have been attempts to substitute molded plastic covers for the metal covers of FIGS. 1 and 2, and thereby overcome many of the disadvantages of metal covers. However, such attempts have not been entirely successful. As noted above, the height H of connectors is limited by the appropriate standard (e.g., PCMCIA and CF), and it has proven extremely difficult to successfully mold a plastic cover which is thin enough (approximately 0.008 inches) to work with the construction shown in FIGS. 1 and 2. Accordingly, a novel and inventive construction is required.
Referring to FIG. 3, illustrated is an isometric view of the inventive IC card adapter assembly 40. The components of adapter assembly 40 are best seen in FIG. 4a, which shows an exploded view of the adapter assembly 40 of FIG. 3. Adapter assembly 40 includes molded lower housing 42 and upper housing 44, both formed of a dielectric material, first connector 46, second connector 48, and circuit board 50. First connector 46 and second connector 48 are adapted to conform, for example, to PCMCIA and CF standards, respectively, while circuit board 50 functions to translate signals from one connector to the other. Of course, first and second connectors 46, 48 may be selected to conform to any other desired standards, depending upon the user's preference.
First connector 46 and second connector 48 are well known in the art. First connector 46 includes a frontal surface 52, a rear surface 54, a pair of spaced apart connector surfaces including an upper surface 56 and a lower surface 58, and opposed side surfaces 60. Frontal surface 52 includes a plurality of pin receiving connections 62, well known in the art, for connection to an external host connector device. Rear surface 54 includes a plurality of solder tails 64 for making electrical contact with circuit board 50. Side surfaces 60 each include a guide rail 66. A latching mechanism 67 is incorporated into side surfaces 60 for securing first connector 46 within the assembly.
Second connector 48 includes a frontal surface 68, a rear surface 70, and opposed side surfaces 72. Frontal surface 68 includes a plurality of solder tails 74 for making electrical contact with circuit board 50. Rear surface 70 includes a plurality of pin connections 76, well known in the art, for connection to an IC card. Side surfaces 72 each include a locking tab 78.
Together, first connector 46, second connector 48 and circuit board 50 form a subassembly 80 which is enclosed by lower housing 42 and upper housing 44.
Lower housing 42 (seen unobstructed in FIG. 4b) and upper housing 44 both include thin walls 82 which extend between side rails 84 and serve to protect circuit board 50. As best seen in FIG. 4b, side rails 84 of lower housing 42 include recesses 86, which are sized to capture locking tabs 78 of second connector 48. Side rails 84 also include detents 87 for cooperating with latching mechanisms 67 on first connector 46. When locking tabs 78 of second connector 48 are captured within recesses 86 and latching mechanism 67 of first connector 46 engage detents 87 in side rails 84, the subassembly 80 consisting of first and second connectors 46, 48, respectively, and circuit board 50 is prevented from moving within adapter assembly 40 as adapter assembly 40 is inserted into a host device, or as IC cards are inserted to adapter assembly 40.
Lower housing 42 and upper housing 44 further include ribs 88 which extend across wall 82. Ribs 88 function to stiffen wall 82 so that wall 82 does not give or feel flimsy to the touch. Ribs 88 may be arranged such that they contact circuit board 50 without detrimental effect, thereby imparting additional support to circuit board 50 and wall 82. Preferably, ribs of lower housing 42 and upper housing 44 oppose one another to better support lower and upper housings 42, 44 and circuit board 50. Another benefit of ribs 88 is that they function as flow enhancers during the molding process.
Lower housing 42 and upper housing 44 are secured together by latching means 90 which are integrally molded into the side rails 84 of lower housing 42 and upper housing 44. Latching means 90 extend along the length of side rails 84 and are best seen in cross section in FIG. 5. It should be noted that FIG. 5 is greatly simplified to clearly illustrate the latching means and other structures. To prevent separation of lower housing 42 and upper housing 44, lower housing 42 is provided with angled engaging surface 92, while upper housing 44 is provided with mating angled engaging surface 94 and tensioning member 96. It is common for latches to have such angled engaging surfaces to prevent separation caused by flexure, physical impact, and material creep. However, the angled engaging surfaces 92, 94 usually result in undesired "play" between assembled parts. As illustrated in FIGS. 6a and 6b, if clearance "A" is provided to allow latching of the two members, the resulting assembly thickness will vary, with the thickness ranging from "B" to "A+B". In the case of IC cards or IC adapter assemblies, even small variations in thickness can result in out-of-spec products, which is not acceptable.
The latching means 90 of the present invention overcomes the above described difficulty by providing tensioning member 96 on upper housing 44. Tensioning member 96 is formed so as to contact lower housing 42 and keep angled engaging surfaces 92, 94 in constant contact, such that there is no "play" between lower housing 42 and upper housing 44. Tensioning member 96 effectively creates a cantilever arm 98 on upper housing 44 that may be flexed to latch engaging surfaces 92, 94, but which does not allow any play between the components. Tensioning member 96 must be positioned a suitable distance from engaging surface 94 such that the material of upper housing 44 is not over-stressed when it is flexed to engage the lower and upper housings 42, 44. It is expected that those skilled in the art will recognize a number of possible variations of the latching means of FIG. 5, but which provide the same function. Such variations are contemplated to be within the scope of the present invention.
Integrally molded into side rails 84 of lower housing 42 are channels 100. Channels 100 are sized to slidably receive guide rails 66 of first connector 46. Because first connector 46 is not adhesively bonded to lower housing 42 and upper housing 44, channels 100 aid in aligning and securing first connector 46 within adapter assembly 40. First connector 46 is further secured in lower housing 42 by cooperative engagement of latching mechanism 67 on first connector 46 and detents 87 on side rails 84. If desired, cooperating guide rails 66 and channels 100, as well as latching mechanisms 67 and detents 87, may be made asymmetrical such that the components can engage in only the desired orientation.
To further aid in securely holding first connector 46 within adapter assembly 40, the portion of lower housing 42 and upper housing 44 which is adjacent first connector 46 is provided with a unique structure. As best seen in FIG. 7, and contrasted to the prior art adapter shown in FIGS. 1 and 2, upper housing 44 and lower housing 42 stop behind the body of first connector 46. It is thus not necessary for lower housing 42 and upper housing 44 to overlap the body of first connector 46, and the previously discussed problems related to the difficulty of molding suitably thin plastic covers are avoided. The body of first connector 46 may thus be the full thickness required by the appropriate standard (such as PCMCIA or CF) and no allowance needs to be made for the thickness of the side walls and adhesive, as in the prior art.
Lower housing 42 and upper housing 44 are provided with a thickened lip 102 which may rest on contacts 64. Lips 102 provides additional support to front edges 104 of lower and upper housings 42, 44 and provide a solid tactile feel. Lip 102 also straightens any inward bow of molded upper and lower housings 42, 44, helps resist warping of lower housing 42 and upper housing 44, and discourages tampering with the assembly by blocking any tools attempting to pry under the housings. A lead-in radius or chamfer 106 is provided adjacent first connector 46, thereby reducing the possibility of lower or upper housing 42, 44, catching on any surface during use. Preferably, ribs 88 which contact circuit board 50 are located as close as possible to front edges 104 to further support and stiffen lower housing 42 and upper housing 44.
To assemble adapter assembly 40, subassembly 80 (consisting of first connector 46, second connector 48, and circuit board 50) is positioned such that guide rails 66 of first connector 46 are aligned with channels 100 in lower housing 42. Guide rails 66 are slid into channels 100 until locking tabs 78 on second connector 48 are captured by recesses 86 of lower housing 42 and latching mechanisms 67 of first connector 46 are engaged with detents 87. Upper housing 44 is then snapped onto lower housing 42 and secured by latching means 90. Cross-sectional views of the assembled adapter assembly 40 are shown in FIGS. 8 and 9, taken along lines 8--8 and 9--9, respectively, of FIG. 3.
It will be appreciated by those skilled in the art that variations may be made to the assembly described herein. An alternate connector and housing configuration is shown in FIG. 10. FIG. 10 shows a connector 110 connected to circuit board 112 by solder tails 114. Upper and lower surfaces 116, 118, respectively, of connector 110 are provided with protruding tongues 120 which engage with grooves 122 on upper and lower housings 124, 126, respectively. The engagement of tongues 120 with grooves 122 provides a barrier to debris which could otherwise enter the interior of the assembly, prevents outward bowing of housings 124, 126. To assemble connector 110 and housings 124, 126, connector 110 and circuit board 112 are slidably engaged with lower housing 126 in the direction of arrow 128, as described above with respect to the configuration of FIGS. 1-9. Groove 122 of upper housing 124 is then engaged under mating tongue 120 of connector 110 and upper housing 124 is rotated in the direction of arrow 130 to engage lower housing 126 in the manner described with respect to the configuration of FIGS. 1-9.
The preferred embodiment describes a snap-fitting engagement between the upper and lower housings. However, those skilled in the art will recognize that other types of engagement between upper and lower housings could also work. For example, the upper and lower housings could be secured together by press fitting, ultrasonic welding, or chemical bonding, depending upon the requirements of the user. Such techniques are considered within the scope of the present invention.
An alternate configuration for securing the connector and housings is shown in FIG. 11. A connector 140 is provided with tongues 142 for engaging grooves 143 of upper and lower housings 144, 146. Upper and lower housings 144, 146 are provided with interlock tabs 148, 150, respectively, which are designed for cooperative engagement with each other. After connector 140 and lower housing 146 are engaged with each other in the manner described above, upper housing 144 is positioned relative to lower housing 146 as shown in FIG. 11 and slid axially in the direction of arrow 152. As upper housing 144 approaches connector 140, interlock tabs 148 of upper housing 144 slide under interlock tabs 150 of lower housing 146. At the same time, groove 143 of upper housing 144 engages tongue 142 on connector 140. Upon full engagement of interlock tabs 148, 150, upper and lower housings 144, 146 are locked together. Upper and lower housings 144, 146 may additionally be provided with a latching means 154 at back end 156 of the assembly. Latching means 154 can be configured to interact with and secure a second connector(not shown) within the assembly, or may also extend across back end 156 of the assembly to provide a closed end if no second connector is used. The second connector may bean input/output (I/O) device such as a CF or PCMCIA connector, as described above, or could alternatively be any other type of signal communication device, such as an infrared transceiver or a telephone jack. It should be noted that FIG. 11 is intended to schematically illustrate the interlock tabs 148, 150 of the alternate configuration, and does not show all features of the assembly.
As it can be seen, there are many advantages to the present invention. One advantage is lower manufacturing cost. There is no need for insert molding, and the need for metal cover tooling, stamping, and forming is eliminated.
Another advantage is lower assembly cost. The inventive assembly disclosed herein reduces assembly steps and time. For example, there is no adhesive bonding of covers to connectors, no ultrasonic welding of molded components, no sheet insulator material needed under metal covers to reduce component shorting, and to need for ground contacts between covers and the circuit board.
A further advantage is improved electricals. Dielectric covers, a feature of the device described herein, are known to reduce the incidence of host equipment damage or program execution errors associated with ESD through metal covers. It is also known the EMI emissions from the card can occur when the metal cover acts as an antenna. The antenna effect is reduced by substituting plastic covers, with the best attenuation of EMI occurring with the use of materials with the highest practical dielectric constant.
A still further advantage is improved mechanicals. Under mechanical or thermal stress or shock, vibration or flexure, assemblies can sometimes fail due to fracturing of ultrasonic welds, and adhesive separation. The inventive assembly described herein avoids these assembly methods and thus the associated failures. Another failure mode is caused by movement of the circuit board away from the connector body, taking the soldered contacts with it. In the present invention, the use of molded ribs to support the circuit board and locking mechanisms to prevent movement of the connectors avoid separation of contacts from the connector body. The elimination of metal covers also eliminates the potential for wearing or skiving of the host connector by the typically sharp edges of metal covers. A further advantage gained by eliminating metal covers is weight reduction, which is very important for manufacturers of hand-held portable devices such as digital cameras and palmtop computers. Yet another advantage of the inventive adapter is its ease of distinctive coloration for product differentiation or brand identification.
Although illustrative embodiments of the invention have been shown and described herein, a wide range of modifications, change and substitution is contemplated in the foregoing disclosure and in some instances, some features of the present invention may be employed without a corresponding use of the other features. For example, although the invention has been shown and described in connection with an IC card adapter assembly, many of the features described herein are equally applicable to and useful in IC cards themselves. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention. | An IC card adapter includes a printed circuit board attached on a first edge to solder tails extending from a first connector and on an opposing second edge to solder tails extending from a second connector. The printed circuit board, first connector and second connector form a subassembly. The subassembly is provided with a first keyed interlock surface which mates with a second keyed interlock surface on a lower molded housing adapted to receive the subassembly. The first and second keyed interlock surfaces orient the subassembly and lower housing. The lower molded housing also includes a first latching member which snap-fits with a second latching member on an upper molded housing. When the lower and upper housings are engaged, they define a cavity which encloses the printed circuit board. | 8 |
TECHNICAL FIELD
[0001] The present disclosure relates to light-emitting devices based on a conjugated polymer with intermixed mobile ions as the active material positioned between two electrodes, which can allow for long operational lifetimes and efficient light emission. The light-emitting devices can be fabricated on flexible substrates and in flexible configurations.
BACKGROUND
[0002] The vision of a simultaneous efficient, durable, flexible, and low-cost light-emitting device is highly attractive from both an end-user and a producer perspective, but at the same time poses a significant scientific and technological challenge that remains effectively non-resolved as of now. Emerging fluorescent organic semiconductors can, in contrast to their more conventional inorganic counterparts, be processed by relatively simple methods at low temperatures, and are as such compatible with the employment of flexible substrates and low-cost roll-to-roll production. Accordingly, light-emitting devices based on organic semiconductors in the form of small molecules (SMs) or conjugated polymers (CPs) are attracting enormous scientific and commercial interest, with the current prime focus being aimed at the development of organic light-emitting diodes (OLEDs).
[0003] SM-based OLEDs exhibit an interesting attribute in that the properties of the active material can be tuned by controllable chemical doping of different layers within a multi-layer stack, and the performance of such appropriately designed devices have recently reached rather impressive levels. However, a notable drawback with SM-based OLEDs is that they are not typically amenable to solution processing and roll-to-roll fabrication, with a concomitant penalty in the simplicity and cost of fabrication. CP-based OLEDs, on the other hand, are compatible with a straightforward and low-cost solution processing of the polymeric active material, but suffer from the fact that doping is not realizable in practice. As a consequence, it is necessary to employ a low-work function and highly reactive cathode material in CP-OLEDs in order to attain good device performance, which has a negative impact on the device functionality from a fabrication and stability perspective.
[0004] An alternative, and frequently overlooked, organic light-emitting device is the light-emitting electrochemical cell (LEC). Its unique operation is based on that mobile ions are intimately intermixed with the organic semiconductor, and that these ions redistribute during device operation in order to allow for efficient electronic charge injection, transport and recombination. Moreover, CP-based LECs can be processed directly from solution using potentially cheap materials (based on common elements such as C, H, O, N, etc.), and accordingly offer most of the initially outlined requirements for the high-performance light-emitting device of the future. However, the significant drawback of the current generation of LECs, which rationalizes the as-of-yet limited interest from industry and academia, is related to a non-adequate operational lifetime.
[0005] There is prior art in the field of functional LECs with long lifetime, high power conversion efficiency, and/or flexible design.
[0006] US2008/0084158 and Shao, Y., G. C. Bazan, and A. J. Heeger, Long - lifetime polymer light - emitting electrochemical cells . Advanced Materials, 2007. 19(3): p. 365-+, discloses a significant operational lifetime for LEC devices of 100-1000 h. They disclose a dilute concentration of the electrolyte constituent (an ionic liquid) in the active material. These disclosures, however, are based on the theory that phase separation has a greatly limiting effect on the lifetime of the LEC. According to these disclosures, the improved lifetime is due to the fact that the two constituent materials in the active material (an ionic liquid and a conjugated polymer) form a single phase, since they are both hydrophobic.
[0007] Cao, Y., et al., Efficient, fast response light - emitting electrochemical cells: Electroluminescent and solid electrolyte polymers with interpenetrating network morphology . Applied Physics Letters, 1996. 68(23): p. 3218-3220., discloses a similar “single phase” approach when a surfactant is added to an active material mixture based on {MEH-PPV+PEO+LiCF 3 SO 3 }. They attained LEC devices with operational lifetimes of approximately 100 h at significant brightness. Importantly, the authors employ conventional high concentrations of the LiCF 3 SO 3 salt and the ion-dissolving and ion-transporting PEO polymer.
[0008] In the herein exploited field of LEC devices with an active material mixture comprising a hydrophobic conjugated polymer blended with a dilute concentration of a hydrophilic electrolyte (here the salt KCF 3 SO 3 blended with the ion-dissolving and ion-transporting solid-state solvent PEO), which form a phase-separated active material, there appears to be very little prior art.
[0009] deMello, J. C., et al., Ionic space - charge effects in polymer light - emitting diodes . Physical Review B, 1998. 57(20): p. 12951-12963. discloses a low concentration of salt in some of their LEC devices, but the concentration of the ion-dissolving and ion-transporting solid-state solvent was kept high, and the total electrolyte content was therefore high. This disclosure further focuses on the operational mechanism of the devices and did, for instance, not report any data on the operational lifetime.
[0010] State-of-the-art OLEDs with solely MEH-PPV as the active material and with a power conversion efficiency of less than or approximately equal to 2 lm/W was demonstrated in Spreitzer, H., et al., Soluble phenyl - substituted PPVs—New materials for highly efficient polymer LEDs . Advanced Materials, 1998. 10(16): p. 1340-+, Hsiao, C. C., et al., High - efficiency polymer light - emitting diodes based on poly 2- methoxy -5-(2- ethylhexyloxy )-1,4- phenylene vinylene with plasma - polymerized CHF 3- modified indium tin oxide as an anode . Applied Physics Letters, 2006. 88(3), Wu, X. F., et al., High - quality poly 2- methoxy -5-(2′- ethylhexyloxy )- p - phenylenevinylene synthesized by a solid - liquid two - phase reaction: Characterizations and electroluminescence properties . Journal of Polymer Science Part a-Polymer Chemistry, 2004. 42(12): p. 3049-3054, and Malliaras, G. G., et al., Electrical characteristics and efficiency of single - layer organic light - emitting diodes . Physical Review B, 1998. 58(20): p. 13411-13414, It is noteworthy that this high-performance OLEDs employ a low-work function and thus highly reactive metal for the cathode (typically Ca), while the herein disclosed LEC devices with MEH-PPV in the active material exhibit a similar or better power conversion efficiency while employing a stable Al cathode.
[0011] In Santos, G., et al., Opto - electrical properties of single layer flexible electroluminescence device with ruthenium complex . Journal of Non-Crystalline Solids, 2008. 354(19-25): p. 2571-2574, there is disclosed the first flexible SM-based LEC, but with a very modest brightness level of 1 cd/m 2 and a very low power efficiency of 0.003 lm/W.
[0012] Hence, there is a need for improved or alternative light-emitting devices, and in particular of such devices which have a longer operational life and/or which presents an increased versatility in terms of applications for use.
SUMMARY
[0013] It is a general object of the present disclosure, to provide a light-emitting device which alleviates or eliminates at least some of the disadvantages with prior art devices. Particular objects include providing light-emitting devices, systems, and/or operating schemes which enable longer operational life of the device.
[0014] The invention is defined by the appended independent claims, with embodiments being set forth in the appended dependent claims, in the following description and in the drawings.
[0015] According to a first aspect, there is provided a light-emitting device comprising a first electrode, a second electrode, and a light-emitting active material contacting and separating the first and second electrodes. The active material comprises a combination of a conjugated polymer and an electrolyte, said electrolyte comprising ions, allowing for electrochemical doping of the conjugated polymer. A ratio between the ions and the conjugated polymer is selected to allow for the formation of:
[0016] (i) a doped region at the respective electrode interface, which allows for injection and transport of electronic charge carriers into and through the doped regions, respectively, at zero or low overpotential, and
[0017] (ii) an effectively undoped region, separating the doped regions, wherein injected electronic charge carriers are recombineable under excitation of the conjugated polymer and the polymer is de-excitable under the emission of light. The ratio between the ions and the conjugated polymer is low enough for the undoped region to remain effectively undoped and free from said ions, as substantially all ions in the active material are locked up in the doped regions.
[0018] For a specific particular combination of materials, geometry and temperature, the ratio (typically mass ratio) between the ions and the conjugated polymer can be determined by routine experiments, such as the ones described herein. The undoped region, will remain undoped, if the ion access is depleted before the doping fronts, which start growing from the respective electrode, meet.
[0019] The present disclosure is based on the understanding that a factor limiting the operational life of light-emitting devices are side reactions occurring in the active material. Hence, by limiting the amount of ions and other electrolyte constituents available in the active material, the occurrence and effect of such side reactions can be reduced, thereby increasing the operational life of the light-emitting device.
[0020] Compared with the prior art, a mixture of a hydrophobic conjugated polymer and a hydrophilic electrolyte is employed, thus forming an active material mixture that is prone to phase separation, and yet, similar or better operational lifetimes can be attained. Thus, a single phase active material is possible, but not a requirement, for long operational lifetimes in LEC, and commonplace hydrophilic electrolytes (essentially all electrolytes except ionic liquids) in general may be functional. This obviously expands the number of electrolytes that can be employed significantly.
[0021] Hence, the conjugated polymer may be hydrophobic and the electrolyte may be hydrophilic, or the conjugated polymer may be hydrophilic and the electrolyte may be hydrophobic. Thus, the two components may form a bi-phase or a multi-phase mixture.
[0022] The conjugated polymer and the electrolyte may form a phase separated mixture, components of which being separated on a scale ranging from 1 nm to 1 mm.
[0023] The components may be separated on a scale ranging from about 50 nm to about 100 μm, or about 400 nm to about 10 μm.
[0024] In the alternative, the combination may be a single phase combination.
[0025] The inventive concept described above may be combined also with a single phase device, i.e. a device comprising a hydrophilic conjugated polymer and a hydrophilic electrolyte, or a hydrophobic conjugated polymer and a hydrophobic electrolyte. In particular, the selections of materials for substrates, electrodes, conjugated polymer, and electrolyte may be the ones described herein. Also the concentrations of the constituent materials in the electrolyte may be as described herein as well as the drive scheme.
[0026] The ratio between the ions and the conjugated polymer may be selected to provide a width of the undoped region which effectively eliminates detrimental interactions between the excited conjugated polymer and the dopants in the doped regions and the ions.
[0027] In an embodiment where the electrodes at least partially overlap each other, the ratio between the ions and the conjugated polymer may be selected to result in said width of the effectively undoped region being about 10 nm to 200 nm, or about 10-100 nm or about 10-50 nm or about 20 nm.
[0028] In such an embodiment, the ratio between the mass of salt providing the ions and the mass of conjugated polymer may be selected as about 0.01-3 times, or about 0.1-3, or about 0.5-2 or about 0.5-1 times z, which may be calculated according to the formula:
[0000]
=
x
doping
·
(
d
tot
-
d
pn
)
·
M
salt
2
·
d
tot
·
M
CPru
,
[0029] wherein x doping is a doping concentration in the doped regions, d tot is an interelectrode distance, d pn is a width of the undoped region (in the interelectrode direction), M salt M is a molar mass of the salt, and M CPru is a molar mass of a repeat unit of the conjugated polymer. All of the parameters in the formula, with the exception of d pn , can be determined or measured by routine experiments, such as the ones described herein. Thus, one specific z value correlates to one specific d pn , which is selected, as given by the above formula.
[0030] The ratio between the mass of ions and mass of the conjugated polymer may be about 0.005-0.10, or about 0.01-0.06.
[0031] In another embodiment, the electrodes may be substantially co-planar, and the ratio between the ions and the conjugated polymer is selected to result in said width of the effectively undoped region being about 10 nm to 70 μm, or about 100 nm to 70 μm, or about 1 μm to 70 μm, or about 10 μm to 70 μm, or about 10 μm to 20 μm.
[0032] In either case, the ratio between the ions and the conjugated polymer may be selected to provide a brightness of more than 100 cd/m 2 for at least 20 hours of continuous operation, for at least 40 hours of continuous operation, for at least 60 hours of continuous operation, for at least 80 hours of continuous operation, for at least 100 hours of continuous operation, for at least 150 hours of continuous operation or for at least 200 hours of continuous operation, or for at least one month of continuous operation; or a brightness of more than 20 cd/m 2 is maintained for at least four months; a brightness of more than 400 cd/m 2 is maintained for at least four days; or a brightness of more than 1000 cd/m 2 is maintained for at least 24 hours.
[0033] The conjugated polymer may be selected from the group consisting of poly(para-phenylene vinylene (PPV), polyfluorenylene (PF), poly(1,4-phenylene) (PP), polythiophene (PT), and neutral and ionic derivatives thereof.
[0034] Particularly, the conjugated polymer may be poly[2-methoxy-5-(2-ethyl-hexyloxy)-1,4-phenylenevinylene].
[0035] The conjugated polymer may comprise a phenyl-substituted PPV copolymer, such as superyellow.
[0036] The electrolyte may comprise a gel electrolyte.
[0037] In the alternative, or as a complement, the electrolyte may comprise a substantially solid electrolyte.
[0038] In the alternative, or as a complement, the electrolyte may comprise a substantially liquid electrolyte.
[0039] The device may further comprise a spacer, arranged to maintain a predetermined distance between the electrodes. When using a liquid or semisolid (gel) electrolyte, spacers may, depending on the design of the device, be used to keep the electrodes at a desired distance from each other, and to avoid short circuiting of the device.
[0040] The electrolyte may comprise a salt.
[0041] The salt may comprise at least one metal salt, comprising a cation, such as Li, Na, K, Rb, Mg, or Ag, and a molecular anion, such as CF 3 SO 3 , ClO 4 , or (CF s SO 2 ) 2 N.
[0042] The electrolyte may comprise at least one ionic liquid.
[0043] The electrolyte in the active material may comprise an ion-dissolving material. A concentration of the ion-dissolving material may be large enough to allow for dissociation of the ions, and small enough to provide a brightness of more than 100 cd/m 2 for at least 20 hours of continuous operation, for at least 40 hours of continuous operation, for at least 60 hours of continuous operation, for at least 80 hours of continuous operation, for at least 100 hours of continuous operation, for at least 150 hours of continuous operation or for at least 200 hours of continuous operation, or for at least one month of continuous operation; or a brightness of more than 20 cd/m 2 is maintained for at least four months; a brightness of more than 400 cd/m 2 is maintained for at least four days; or a brightness of more than 1000 cd/m 2 is maintained for at least 24 hours.
[0044] For a particular combination of materials, geometry and temperature, the concentration of the salt and the ion-dissolving material can be determined by routine experiments, such as the ones described herein.
[0045] In particular embodiments, a mass ratio between the ion-dissolving material and the conjugated polymer may be about 0.01-0.25, about 0.01-0.20, about 0.01-0.17, about 0.05-0.25, about 0.05-0.20, about 0.05-0.17, about 0.08-0.25, about 0.08-0.20 or about 0.085-0.17.
[0046] The ion-dissolving material may comprise at least one polymer material.
[0047] The polymer material may be selected from a group consisting of poly(ethylene oxide), poly(propylene oxide), methoxyethoxy-ethoxy substituted polyphosphazane, and polyether based polyurethane, or combinations thereof.
[0048] The ion-dissolving material may comprise at least one non-polymer ion-dissolving material, such as a crown ether.
[0049] The active material may comprise a surfactant, or a polymeric non-ion-dissolving material, such as polystyrene.
[0050] In one particular embodiment, the electrolyte may comprise KCF 3 SO 3 dissolved in poly(ethylene oxide).
[0051] The device may be formed on a substrate.
[0052] The substrate may be effectively non-flexible, e.g. a glass or a glass-like material.
[0053] The substrate may be effectively flexible. By “effectively flexible” is meant that the substrate is so flexible as to allow some visible bending without rupturing.
[0054] The substrate may comprise a polymeric material, such as poly(ethylene terephthalate), poly(ethylene naphthalate), poly(imide), poly(carbonate), or combinations or derivatives thereof.
[0055] The substrate may comprise a metal foil, such as steel, Ti, Al, Inconel alloy, or Kovar.
[0056] The substrate may comprise paper or paper-like material.
[0057] One or both electrodes may be directly or indirectly deposited on the substrate.
[0058] One or both of the first and second electrodes may be conducting and transparent or semi-transparent.
[0059] Specifically, the electrode may comprise a semi-transparent oxide, such as indium-tin oxide, or a thin film of a semi-transparent metal, such as Au, Ag, Pt, or Al.
[0060] In the alternative, or as a complement, one or both of the first and second electrodes is coated with a thin layer of a conducting polymer, such as poly(3,4-ethylenedioxythiophene)-poly(styrene sulfonate).
[0061] One or both of the first and second electrodes may comprise a metal. The metal may comprise a stable metal, such as Al, Ag or Au.
[0062] According to a second aspect, there is provided a method for generating light, comprising a light-emitting device as described above, and a power source, connected to the first and second electrodes. A power source may be any means suitable for generating a power that can be used with the device, e.g. a battery or a converted mains voltage
[0063] The power source may be arranged to provide a pre-biasing of the light-emitting device.
[0064] By such pre-biasing, it is possible to provide a more “clean” cathodic interface and a more centered p-n junction; the former is attractive since it may inhibit the formation of an overpotential at the cathodic interface. The consequences may be a longer operational life of the device and a higher power conversion efficiency. The latter may be attractive since it inhibits the quenching of the light emission by the metallic electrodes. The consequence may thus be a higher power conversion efficiency.
[0065] The power source is arranged to provide the pre-bias at a voltage and/or current and time period sufficient to form an effective p-n junction.
[0066] As a non-limiting example, the p-n junction may be effective where the light emission zone is at least 10 nm away from the electrode interface and where a major portion of the applied overpotential drops over the light-emission zone.
[0067] For example, the pre-biasing may be provided during a time period of less than 1 hour, less than 30 minutes, less than 20 minutes, less than 15 minutes, less than 10 minutes, less than 5 minutes, less than 1 minute, less than 30 seconds, less than 15 seconds, less than 5 seconds or less than 1 second.
[0068] The pre-biasing may be provided only when the light-emitting device is in a substantially pristine or relaxed state.
[0069] The power source may be arranged to provide a nominal drive voltage and a pre-biasing voltage, which is higher than the nominal drive voltage. A typical nominal drive voltage may be about 2-4 V, e.g. 2 V, 3 V or 4 V.
[0070] For example, the pre-bias voltage may be about 10%-1000% higher than the nominal drive voltage, about 10%-500% higher than the nominal drive voltage, about 10%-100% higher than the nominal drive voltage, about 30%-100% higher than the nominal drive voltage, or about 30%-50% higher than the nominal drive voltage.
[0071] The power source may be arranged to provide a nominal drive current and a pre-biasing drive current, which is higher than the nominal drive current.
[0072] A typical nominal drive current density may be about 100 A/m 2 .
[0073] For example, the pre-biasing current may about 2-100 times that of the nominal drive current, about 2-50 times that of the nominal drive current, about 2-20 times that of the nominal drive current, or about 5-20 times that of the nominal drive current.
[0074] The power source may be arranged for driving the light-emitting device substantially galvanostatically. As galvanostatic drive circuits are well known, this would constitute a suitable drive scheme.
[0075] The power source may be arranged to be permanently connected to the light-emitting device.
[0076] According to a third aspect, there is provided use of the above described device or system for generating light.
[0077] According to a fourth aspect, there is provided a method for operating the above described device, comprising pre-biasing the light-emitting device. The pre-bias may be provided at a voltage and time period sufficient to form an effective p-n junction.
[0078] For example, the pre-biasing may be provided during a time period of less than 1 hour, less than 30 minutes, less than 20 minutes, less than 15 minutes, less than 10 minutes, less than 5 minutes less than 1 minute, less than 30 seconds, less than 15 seconds, less than 5 seconds or less than 1 second.
[0079] The pre-biasing may be provided when the light-emitting device is in a substantially pristine or relaxed state.
[0080] A pre-biasing voltage may be provided, which is higher than a nominal drive voltage of the light-emitting device.
[0081] In the alternative, or as a complement, a pre-biasing current may be provided, which is higher than a nominal drive current of the light-emitting device.
[0082] The light-emitting device may be driven substantially galvanostatically.
[0083] The pre-biasing may be provided in connection with a use or testing of the component, which it forms part of.
BRIEF DESCRIPTION OF THE DRAWINGS
[0084] For a more complete understanding, reference is now made to the following descriptions taken in conjunction with the accompanying drawing.
[0085] FIG. 1 illustrates the long-term operation of an ITO/PEDOT/{MEH-PPV:PEO:KCF 3 SO 3 }/AI sandwich cell with an active material mass ratio of 1:0.085:0.03. The device was operated at T=295 K and in galvanostatic mode. An initial “pre-bias” current, I pre-bias =0.005 A, was applied for t=0.5 h, and it was followed by long-term uninterrupted operation at I=0.001 A. The inset illustrates the conformability of a similar device mounted on a flexible PET substrate during operation.
[0086] FIG. 2 . illustrates chemical structures of poly[2-methoxy-5-(2-ethyl-hexyloxy)-1,4-phenylenevinylene] (MEH-PPV), polyethylene oxide (PEO), KCF 3 SO 3 and “superyellow”.
[0087] FIG. 3 . is a schematic depiction of the device architecture in: FIG. 2 a : a planar surface cell configuration, FIG. 2 b : a vertical sandwich cell configuration.
[0088] FIG. 4 . are photographs of planar Au/MEH-PPV+PEO+KCF 3 SO 3 /Au LECs with an interelectrode gap of 1 mm during operation at V=5 V and T=360 K. The MEH-PPV:PEO:KCF 3 SO 3 mass ratios are included in the heading of each set of photographs. The positive and negative electrodes are identified in photograph I, and the doped MEH-PPV corresponds to the dark regions progressing from the electrode interfaces.
[0089] FIG. 5 . illustrate current vs. time for planar Au/{MEH-PPV+PEO+KCF 3 SO 3 }/Au LECs with an interelectrode gap of 1 mm during operation at V=5 V and T=360 K. The MEH-PPV:PEO:KCF 3 SO 3 mass ratios are included in the inset.
[0090] FIG. 6 . schematically illustrate a non-biased pristine LEC ( FIG. 5 a ), and the doping (FIGS. b and c), and light-emission ( FIG. 5 d ) processes in an LEC device. The initial doping formation and progression stops at ion depletion ( FIG. 5 d ), so that an appropriately sized undoped p-n junction can be designed with a width corresponding to twice the exciton diffusion distance ( FIG. 5 d ). The electric double layers at the charge-injecting interfaces are omitted for clarity.
[0091] FIG. 7 . illustrates the temporal evolution of the brightness of ITO/{MEH-PPV:PEO:KCF 3 SO 3 }/Al sandwich cells with different KCF 3 SO 3 salt concentration in the active material, as specified in the upper inset. The lower inset presents data for a device with no salt in the active material. All devices were driven at V=3 V and T=360 K.
[0092] FIG. 8 . illustrates the temporal evolution of the brightness of ITO/{MEH-PPV:PEO:KCF 3 SO 3 }/Al sandwich cells with different PEO concentration in the active material, as specified in the upper inset. The devices were driven at V=3 V and T=360 K.
[0093] FIG. 9 . illustrates doping front propagation and subsequent light emission in planar Au/{MEH-PPV+PEO+KCF 3 SO 3 }/Au surface cells with a 1 mm interelectrode gap during operation at T=360 K and V=5 V (top panel) and V=15 V (bottom panel), respectively. The time of applied voltage is indicated in the bottom part of each photograph.
[0094] FIG. 10 . illustrates average positions of the p-type and the n-type doping front, respectively, as a function of time (normalized to the time at which the p-n junction forms) for planar Au/{MEH-PPV+PEO+KCF 3 SO 3 }/Au surface cells with a 1-mm inter-electrode gap during operation at various applied voltages.
[0095] FIG. 11 . are optical microscopy images of the anodic (left) and cathodic (right) interfaces after 12 h operation at V=30 V and T=360 K of a planar Au/{MEH-PPV+PEO+KCF 3 SO 3 }/Au surface cell with a 1-cm inter-electrode gap. The white line just to the left of the Au electrode on the right appears to be the product of a cathodic electrochemical side reaction.
[0096] FIG. 12 . illustrate cyclic voltammetry data recorded using a working electrode (WE) of Au (top graphs) and Au coated with a thin film of MEH-PPV (lower graphs). The electrolyte solution was 0.1 M TBAPF 6 in CH 3 CN (left graphs) and 0.1 M KCF 3 SO 3 +2 M PEO in CH 3 CN (right graphs), respectively. A silver wire was used as the quasi-reference electrode, and it was calibrated vs. the Fc/Fc + reference redox couple at the end of each measurement. The counter electrode was Pt, and the scan rate was 25 mV/s.
[0097] FIG. 13 . is a schematic electron-energy level diagram for an LEC, with the reduction level for the {KCF 3 SO 3 +PEO} electrolyte positioned within the band gap of the (MEH-PPV) conjugated polymer (CP). The electronic and ionic response during (b) the “initial stage” operation, when the p-type doping of the CP at the anode is balanced by an electrochemical side-reaction of the electrolyte at the cathode, and during (c) the “later stage” operation, when the subsequent p-type doping is balanced by n-type doping. The larger circles represent ions, the smaller open and solid circles represent holes and electron, respectively, and the arrows represent electronic charge injection resulting in electrochemical doping. For clarity, the electric double layers at the interfaces are omitted.
[0098] FIG. 14 . illustrates the temporal evolution of the brightness of sandwich cells comprising an Al cathode and an {MEH-PPV:PEO:KCF 3 SO 3 } active material with a mass ratio of 1:0.085:0.03. The long-term operation was performed at V=3 V. Specifics for each anode structure and the initial measurement protocol are identified in the upper inset. The lower inset presents the power efficiency as a function of time.
[0099] FIG. 15 . illustrates the temporal evolution of the brightness (left) and the voltage (right) of an ITO/PEDOT/{MEH-PPV:PEO:KCF 3 SO 3 }/AI sandwich cell with an active material mass ratio of 1:0.085:0.03. The device was operated at T=295 K and in galvanostatic mode. The initial “pre-bias” current, I pre-bias =0.005 A, was applied for t=0.5 h, and it was followed by long-term operation at I=0.001 A.
[0100] FIG. 16 . are photographs of ITO/{MEH-PPV:PEO:KCF 3 SO 3 }/Al sandwich cells, with an active material mass ratio of 1:0.085:0.03, mounted on flexible PET substrates. The photographs of the flexed devices were taken during operation at T=295 K and I=0.005 A.
[0101] FIG. 17 . illustrates the temporal evolution of the brightness of an ITO/PEDOT/{superyellow:PEO:KCF 3 SO 3 }/Al sandwich cell with an active material mass ratio of 1:0.085:0.03. The device was operated at T=295 K and in galvanostatic mode. The initial “pre-bias” current, I pre-bias =0.01 A, was applied for t=0.4 h, and it was followed by long-term operation at I=0.001 A.
[0102] FIG. 18 . are photographs of ITO/{superyellow:PEO:KCF 3 SO 3 }/Al sandwich cells, with an active material mass ratio of 1:0.085:0.03, mounted on flexible PET substrates. The photographs of the flexed devices were taken during operation at T=295 K.
DESCRIPTION OF EMBODIMENTS
[0103] In the following disclosure, it will be shown that it is possible to design and fabricate CP-based LECs (from here on LECs) with a record-long operational lifetime exceeding one month of uninterrupted operation at significant and efficient light emission. The approach is based on a combination of a careful tuning of the composition of the active material and the employment of an appropriate operational protocol. It is shown that these two approaches allow for the design of a doping structure resembling that of a SM-OLED, while at the same time minimizing lifetime-limiting chemical and electrochemical side reactions. It is also demonstrated the first functional flexible LEC, with a similar impressive device performance.
[0104] A generic device and method which result in a significant improvement of the operational lifetime and the power conversion efficiency of light-emitting electrochemical cells (LECs) will now be presented. Specifically, by employing a by design low concentration of a hydrophilic electrolyte (here {PEO+KCF 3 SO 3 }) blended with a hydrophobic conjugated polymer (here either MEH-PPV or superyellow), and by employing an appropriate operational protocol where the distinguishing feature is a high prebias during the initial operation, it is possible to demonstrate operational lifetimes of ˜1000 h at a significant brightness of >100 cd/m 2 and relatively high power conversion efficiency (2 lm/W for MEH-PPV, 6 lm/W for superyellow). The temporal evolution of the brightness and the voltage for such a durable LEC with MEH-PPV as the conjugated polymer is presented in FIG. 1 . Moreover, the first functional flexible LEC with a similar promising device performance is disclosed, and such a conformable device during operation is presented in the inset.
[0105] The origin to the improved device performance over previous LEC devices is an effective inhibition of undesired side reactions. Below it is rationalized
[0106] i) why chemical side reactions in the light-emitting region of the device will be eliminated/minimized via the optimization of the electrolyte content in the active material, and
[0107] ii) why electrochemical side reactions at the electrode interfaces will be eliminated/minimized via the employment of an appropriate operational protocol. First, the former achievement (i) will be described in detail.
[0108] The influence of the ion concentration on the device performance of planar LECs in a “surface cell” configuration was investigated (see FIG. 3 a for a schematic of the device configuration). The device structure consists of an active material mixture 13 of the conjugated polymer poly[2-methoxy-5-(2-ethylhexyloxy)-1,4-phenylenevinylene] (MEH-PPV, see FIG. 2 a ), the ion-solvating and ion-transporting polymer poly(ethylene oxide) (PEO, see FIG. 2 b ) and the salt KCF 3 SO 3 (see FIG. 2 c ) positioned on top of, or below, two Au electrodes 11 and 12 with a 1 mm inter-electrode gap; the electrode/active material assembly is positioned on top of a substrate 10 . For experimental details regarding the preparation and operation of surface cells, see appendix 1.
[0109] FIG. 4 presents photographs recorded during the operation of four representative planar surface cell devices with (from top to bottom) gradually decreasing salt concentration. The devices were operated under UV light (which excites the photoluminescence, PL, of MEH-PPV) in a dark room, so that the doped MEH-PPV in the gap can be distinguished as dark regions (with doping-quenched PL). The positive electrode 20 is marked with + and the negative electrode 21 with − in photograph I. All devices exhibit both p-type doping formation 23 at the positive electrode and n-type doping formation 24 at the negative electrode (see photographs III and IV). A continuous light-emitting p-n junction 25 is only formed in the topmost two “ion-rich” devices (photograph VI in FIGS. 4 a and b ), while the most “ion-poor” device do not exhibit any p-n junction formation as the two doping fronts come to a complete stop at a significant distance from each other ( FIG. 4 d ). (Note that schematics illustrating the p-type and n-type doping processes in LECs are presented in FIG. 6 .)
[0110] FIG. 5 presents current vs. time graphs recorded in parallel with the photographs in FIG. 4 . Each graph represents an average of data from 6-10 devices. A notable increase in current with time is only observed in the two ion-rich devices, which exhibit light-emitting p-n junction formation.
[0111] By integrating the current from the initial appearance of doping up to the time of the p-n junction formation in the two ion-rich devices and up to the time when the doping front motion stop in the ion-poor devices, and dividing this charge with the observed volume of the doped regions (as extracted from FIG. 4 and thickness measurements executed with atomic force microscopy), we find that the doping concentration in the p-type and n-type doped regions is essentially the same independent of ion concentration; x p ≈0.09±0.02 dopants/MEH-PPV repeat unit and x n =0.13±0.03 dopants/MEH-PPV repeat unit. This observation is consistent with that the current, and thus the effective device resistance, is the same for the two ion-rich devices at the time of p-n junction formation (see FIG. 5 ). The ion-poor devices contain a significant un-doped region with low conductivity, and the effective device resistance is accordingly invariably significantly higher.
[0112] The conclusions that follows from these observations are that the doping fronts propagate at essentially constant doping concentration until either (i) they meet and a light-emitting p-n junction forms (see FIGS. 4 a and 4 b ), or (ii) all ions in the active material are consumed in electrochemical doping at which point the doping front progression will stop without junction formation (as observed in FIGS. 4 c and 4 d ).
[0113] This new knowledge provides a guideline for the appropriate design of the doping structure in more conventional and practical “sandwich cell” LECs (herein, as schematically presented in FIG. 3 b , comprising a thin layer of active material 13 ′ with a total thickness of d tot ˜150 nm sandwiched between a transparent indium-tin oxide, ITO, anode 11 ′ on a glass substrate 10 and an Al cathode 12 ′). The proposed doping design scenario is depicted in FIG. 6 . The concept is that efficient electronic charge injection and transport are dependent on the existence of distinct doped regions next to the electrodes (cathode 30 and anode 31 in FIG. 6 a ), while the efficient radiative recombination of injected holes and electrons is benefiting from the existence of an undoped p-n junction region 37 with a width of d pn of the order of 20 nm. The size of the latter is motivated by that the recombination of holes and electrons will take place in the undoped p-n junction region, that the effective diffusion distance of an exciton (a bound electron-hole pair) is approximately 10 nm, and that doping effectively quenches the fluorescence of CPs. Moreover, by locking up all cations 33 and anions 34 in the active material 32 as counter-ion dopants in the distinct doped regions, the interaction between on the one hand the excitons formed in the p-n junction region and on the other hand the ions located in the doped regions and/or the dopants is minimized, which could be beneficial for the operational lifetime.
[0114] The proposed scenario during turn on of such an optimized LEC is depicted in FIG. 6 . p-type and n-type doping formation and progression ( 36 and 35 , respectively) take place at constant doping concentration (see FIGS. 6 b and 6 c ) until ion depletion sets in and the designed p-n junction 37 is formed (see FIG. 6 d ). With such a doping structure in place, one can expect that the interactions between the excitons 38 formed in the p-n junction region on the one hand and non-existing uncompensated ions and/or far-away dopants in the doped regions will be minimized, as depicted in FIG. 6 d . In other words, the width of the p-n junction is designed to minimize the leakage of diffusing excitons into the doped regions, without compromising the efficiency of electronic injection and transport. Moreover, such a minimization of the salt concentration will effectively decrease the interactions between excitons and ions/dopants, which could decrease undesired side reactions in the p-n junction region and concomitantly improve the operational lifetime.
[0115] The “ideal” ratio between the mass of salt and the mass of CP in the active material (z ideal ), which allows for this desired doping structure, can be calculated with the following general equation (for derivation, see appendix 2):
[0000]
(
1
)
[0116] where x doping is the doping concentration in the doped regions, d tot is the total length of the active material (equal to the interelectrode distance), d pn is the length (in the interelectrode direction) of the undoped region, M salt is the molar mass of the salt, and M CPru is the molar mass of a repeat unit of the conjugated polymer.
[0117] By plugging in relevant values in Eq. (1), it is found that the ideal z value that allows for the formation of the desired doping structure with d pn =20 nm is z=z ideal =0.03 for sandwich cells with d tot ˜150 nm and with an active material of {MEH-PPV+PEO+KCF 3 SO 3 }.
[0118] FIG. 7 presents the brightness as a function of time for sandwich-cell LECs with a mass ratio between the KCF 3 SO 3 salt and the MEH-PPV in the active material ranging from z=0.25 to z=0.03, as specified in the upper inset. (Details on the preparation of sandwich cell devices are included in example 1.) A device with z=0 was also tested under the same conditions, but no light emission could be detected (see lower inset), which is as expected considering the significant barrier for electron injection from an Al cathode into the undoped MEH-PPV. The devices were operated at V=3 V and T=360 K; the employment of the elevated temperature, which is found to lower the operational lifetime by a factor of ˜2, is motivated by that it allowed us to screen a significant number of devices within a reasonable time frame (all presented data are averages recorded on at least two pristine devices). Both the operational lifetime (defined as the time at which the brightness drops below 100 cd/m 2 ) and the power efficiency (˜0.2 lm/W; data not shown) are relatively independent on the salt concentration, which demonstrate that an functional doping structure can be attained at a low z=0.03, but that the main culprit behind the limited operational lifetime of LECs is not originating in side reactions stemming solely from an excess of salt; more specifically the main lifetime-limiting reaction is not due directly to interactions between excitons and uncompensated ions and/or dopants.
[0119] However, the active material of LECs typically contains a third ion-solvating and ion-transporting component (here, PEO) in addition to the CP and the salt, and so attention is now shifted to the influence of the PEO concentration on LEC performance. It is chosen to keep the mass ratio between the KCF 3 SO 3 salt and MEH-PPV constant at the low value of z=0.03 and to vary the mass ratio between PEO and MEH-PPV from y=1.35 (a typical value used in devices) to y=0.085.
[0120] FIG. 8 reveals that the concentration of PEO has a profound influence on the device performance. it is found that the operational lifetime increases in a monotonous and drastic fashion with decreasing amount of PEO from ˜2 h at y=1.35 to ˜65 h at y=0.085. The power efficiency is still rather modest, even though the low-PEO content devices (y≦0.34) exhibit a larger power efficiency at ˜0.5-0.7 lm/W as compared to ˜0.2 lm/W for the device with the high PEO content of y=1.35 (data not shown).
[0121] Furthermore, the open planar surface-cell structure with the same active material constituents was utilized in an attempt to identify the chemical signatures and the spatial position of life-time limiting side reactions in LECs, as described in W{dot over (a)}gberg, T., et al., On the limited operational lifetime of light - emitting electrochemical cells . Advanced Materials, 2008. 20(9): p. 1744-1746. By optically probing post-mortem devices, it was found that the vinyl group and the fluorescence capacity of the MEH-PPV polymer are strongly and irreversibly damaged at the end of LEC operation, but only in a limited spatial region at, or in the close vicinity, of the p-n junction.
[0122] Thus, considering the results presented in FIGS. 7 and 8 it is highly plausible that the main lifetime-limiting reaction is related to the spatial co-existence and chemical interaction between an exciton on an MEH-PPV chain and the {PEO+KCF 3 SO 3 } electrolyte. It is further proposed that this irreversible chemical reaction is initiated by an electron transfer from the LUMO of the photo-excited MEH-PPV to an unoccupied energy level in the {PEO+KCF 3 SO 3 } electrolyte, and that the subsequent chemical reactions include a chemical attack of the exposed vinyl group of the MEH-PPV polymer. The effective decrease in the interaction between MEH-PPV excitons in the p-n junction region and the electrolyte, when the electrolyte content in the active material is decreased from a conventional high fraction (here, y=1.35, z=0.25) to a significantly lower fraction (y=0.085, z=0.03), rationalizes the dramatic 30-fold increase in device lifetime, as observed in FIG. 8 .
[0123] Attention is now shifted to the second part (ii), namely the influence of the operational protocol on device performance. FIG. 9 presents sequences of photographs of the doping front progression and the subsequent light emission for two representative planar Au/{MEH-PPV+PEO+KCF 3 SO 3 }/Au surface cell devices with a 1 mm inter-electrode gap. The positive anode 20 is positioned to the left and the negative cathode 21 is positioned to the right in the photographs. The doped regions 23 and 24 appear as dark areas originating at the electrode interfaces (marked with dashed lines). The device presented in the upper panel of photographs was biased at V=5 V, and the device presented in the lower panel was biased at V=15 V. The presented photographs were selected such that the p-type doping front had progressed the same distance in the inter-electrode gap in the two photographs marked with the same letter.
[0124] It is clear that the n-type doping onset, compared to the p-type doping onset, is delayed in both devices (as observed also in the devices in FIG. 4 ); see the two photographs b) in FIG. 9 , where p-type doping 23 but not n-type doping 24 is apparent. Moreover, this delay of the n-type doping onset is significantly more prominent in the device biased at V=5 V, as seen in the first signs of n-type doping 24 already in photograph c) in the device biased at V=15 V but only in photograph d) in the device biased at V=5 V. The delay of the n-type doping onset has the direct consequence that the light-emitting p-n junction 25 is formed closer to the negative cathode 21 in the device biased at V=5 V (see photographs e and f).
[0125] Two other interesting and consistent observations in all the devices investigated (>40 in total) concern the shape of the doping front. First, the shape of the p-type front becomes more jagged with time and with increasing voltage, which is a direct consequence of the ion-transport limited turn-on process. Second, and here more relevant, the initial n-type front exhibits a spike-like appearance that is absent in the initial p-type front. This issue will be returned to later.
[0126] FIG. 10 presents the average positions of the p-type doping front and the n-type doping front as a function of time (normalized to the time at which the p-n junction forms) at various applied voltages. Three general trends are apparent: (i) the onset time for p-type doping is essentially independent of the applied voltage; (ii) the delay in the n-type doping onset is more significant at lower applied voltage; and (iii) the average position of the light-emitting p-n junction (as observed at time=1.0) is shifted towards the negative cathode with decreasing applied voltage, from 0.59 mm away from the positive anode in devices with a 1-mm inter-electrode gap at V=20 V to 0.76 mm at V=5 V.
[0127] A similar behavior with decreasing temperature is observed, as it is found that the delay in the n-type doping onset, as compared to the p-type doping onset, increases significantly and that the p-n junction shifts cathodically at lower temperatures (data not shown). Since it is well-established that these active materials exhibit a strongly temperature-dependent ionic conductivity, we attribute the increasing delay in the n-type doping onset, and the resulting cathodic shift of the p-n junction, to reduced ionic conductivity.
[0128] Balanced redox must be maintained at the two electrode interfaces in an LEC during the doping progression. (Although, it is in principle possible that limited Faradaic doping at one electrode can be compensated by non-Faradaic electric double-layer formation at the other electrode, it has been shown in J. H. Shin, S. Xiao, and L. Edman, Polymer light - emitting electrochemical cells: The formation and effects of doping - induced micro shorts . Advanced Functional Materials, 2006. 16(7): p. 949-956, that this effect is too minor to explain, e.g., the significant delay in n-type doping onset in the wide-gap devices studied in FIGS. 9 and 10 .[10]) Thus, it must be that another electrochemical reaction than n-type doping of the CP can take place at the cathodic interface, and it is chosen to collectively term such reactions as “electrochemical side-reactions”.
[0129] Direct visual evidence for an electrochemical side-reaction at the cathodic interface in devices which exhibit significant time difference between the onset of p-type and n-type doping is provided by optical microscopy images. FIG. 11 shows the anodic interface 40 (left) and the cathodic interface 41 (right) of a planar Au/{MEH-PPV+PEO+KCF 3 SO 3 }/Au surface cell with an extremely large inter-electrode gap of 1 cm after long-term operation at V=30 V. While the anodic interface 40 retains a “clean” appearance after the long-term operation, a bright “degradation layer” 43 has emerged at the cathodic interface between the negative Au electrode and the {MEH-PPV+PEO+KCF 3 SO 3 } active material 42 . It is interesting to find that the degradation layer is easiest to discern in devices that exhibit slow doping kinetics, i.e., devices operated at a low overpotential and/or low temperature (when the ionic conductivity of the active material is very low), and with large inter-electrode gaps.
[0130] Insight into the electronic structure of the various components in the LEC, i.e., the Au electrode, the MEH-PPV polymer, and the {KCF 3 SO 3 +PEO} electrolyte, is provided by cyclic voltammetry (CV). FIG. 12 shows CV data recorded employing either bare Au (top graphs) or Au coated with a thin film of MEH-PPV (lower graphs) as the working electrode, and using either TBAPF 6 in CH 3 CN (left graphs) or {KCF 3 SO 3 +PEO} in CH 3 CN (right graphs) as the electrolyte solution. The top left graph demonstrates that the bare Au electrode is electrochemically inert in the probed voltage range (spanning between −2.6 V and +0.8 V vs. the Fc/Fc + couple), while the lower left graph demonstrates that MEH-PPV can be reversibly n-type doped (reduced) at −2.3 V vs. Fc/Fc + and reversibly p-type doped (oxidized) at +0.1 V vs. Fc/Fc + . When the electrolyte is changed from TBAPF 6 to {KCF 3 SO 3 +PEO} the situation changes in that an irreversible reduction reaction emerges in both the bare Au-electrode system (top right graph) and in the MEH-PPV-coated Au-electrode system (bottom right graph). Based on these data, the conclusion may be drawn that the {KCF 3 SO 3 +PEO} electrolyte is irreversibly reduced at a lower potential than MEH-PPV is reversibly n-type doped.
[0131] FIG. 13 presents the proposed operational mechanism of the LECs, in the form of a schematic electron-energy diagram. In agreement with the CV data, we include in FIG. 13( a ) a reduction level of the {KCF 3 SO 3 +PEO} electrolyte at a lower energy than the conduction band edge of MEH-PPV (corresponding approximately to the n-type doping level). During the “initial stage” operation, as presented in FIG. 13( b ), the electrochemical redox balance in the LEC is maintained by p-type doping (oxidation) of MEH-PPV at the anode and reduction of the electrolyte at the cathode. The latter reaction corresponds to the electrochemical side-reaction, which manifests itself in the lack of n-type doping progression during the initial stage operation (see FIGS. 9 and 10) and in the form of the degradation layer at the interface between the negative Au electrode and the active material (see FIG. 11 ). During the “later stage” operation, the p-type doping at the anode is instead balanced by n-type doping at the cathode, and it is during this process that n-type doping emerges in FIGS. 9 and 10 .
[0132] A question that deserves attention at this stage is related to the transition between the electrochemical-side reaction and the n-type doping at the Au cathode, and why it takes place earlier at higher applied voltage and/or increased ionic conductivity of the active material. It is proposed that the side-reaction is the thermodynamically-preferred cathodic reaction (which is supported by the CV data), but that the n-type doping is the kinetically-preferred cathodic reaction at the Au cathode interface. This has the consequence that when very little overpotential is available at small drive voltage or because all overpotential is dropping over a low-ionic conductance undoped region, the thermodynamically-preferred side-reaction wins, since the n-type doping reaction simply is not energetically accessible. The situation changes at higher drive voltage or when the ionic conductance of the undoped region (separating the p-type and n-type regions) increases (because its ionic conductivity increases or because it decreases in size during later stages of the doping process) since there is then sufficient overpotential available at the cathodic interface to allow for both the side-reaction and n-type doping. In such a scenario, the kinetically-favoured reaction, the n-type doping, takes over. Moreover, during the later-stage operation when the effective cathodic interface is located at the n-type doping front, and not at the Au cathode, the acquired data indicate that n-type doping is the dominant process.
[0133] Two directly apparent consequences of the electrochemical side-reaction are that the n-type doping onset is delayed and that the p-n junction shifts towards the cathode. One can also expect that the electrochemical side-reaction will produce reactant residues on the surface of the Au cathode (as visualized in FIG. 11 ), which subsequently will at least partially block the initial n-type doping. The existence of a partial passivation layer on the Au cathode surface, but not on the Au anode surface, following the side-reaction is also consistent with the observation that the initial n-type doping front exhibits a spike-like appearance that is absent in the initial p-type front (see FIG. 9 ). The existence of an insulating degradation layer between the negative Au electrode and the active material could have implications for the voltage distribution in a turned-on LEC containing a light-emitting p-n junction, as it is reasonable to expect that it will cause a significant portion of the overpotential to shift from, e.g., the p-n junction to the degradation layer.
[0134] Thus, in order to minimize the extent of the cathodic side reaction, and improve the device performance, it is relevant to apply a large potential (a “pre-bias”) during the initial doping formation process. Thereafter, when the p-n junction has formed, it is appropriate to decrease the applied potential to allow for long-term operation. In FIG. 14 the effects of this operational protocol on the performance of sandwich cells is illustrated.
[0135] The sandwich-cell devices were identical to those presented in FIGS. 7 and 8 , but a notable difference is that the testing was performed at room temperature instead of at an elevated temperature of T=360 K. The lowering of T resulted in an improvement in the operational lifetime by a factor of approximately two. Moreover, the well-established procedure of coating the surface of the ITO anode with a thin planarizing layer of the conducting polymer PEDOT was employed in order to investigate whether the roughness of the ITO surface might influence the device performance; but we find that this additional layer only results in a marginal improvement. The cumulative effects on the device performance by the lowering of T and the introduction of the PEDOT layer at the anodic interface are presented in FIG. 14 (compare the open squares with the stars).
[0136] It is chosen to “pre-bias” the sandwich cell devices at V pre-bias =4 V during the initial doping process, and subsequently when significant light emission is attained and the doping completed (at t˜0.5 h) lower the voltage to V=3 V. The results of the employment of a large pre-bias (solid circles in FIG. 14 ) are clearly encouraging: the operational lifetime increases from ˜125 h to ˜175 h, and the power efficiency increases markedly from a high value of ˜0.5-0.6 lm/W to ˜1.9 lm/W (see inset in FIG. 14 ).
[0137] It is expected that the high pre-bias during device turn-on will result in an increased amount of n-type doping at the expense of a cathodic side reaction involving the {PEO+KCF 3 SO 3 } electrolyte. The consequential and desired outcome during long-term operation is a more “clean” cathodic interface and a more centered p-n junction; the former is attractive since it inhibits the formation of an overpotential at the cathodic interface, while the latter is desired since it will effectively eliminate documented problems related to exciton quenching by a nearby metal electrode, as described in Lee, K. W., et al., Photophysical properties of tris ( bipyridyl ) ruthenium ( II ) thin films and devices . Physical Chemistry Chemical Physics, 2003. 5(12): p. 2706-2709, and the formation of doping-induced short-circuits, as described in, J. H. Shin, S. Xiao, and L. Edman, Polymer light - emitting electrochemical cells: The formation and effects of doping - induced micro shorts . Advanced Functional Materials, 2006. 16(7): p. 949-956, and in Johansson, T., et al., Light - emitting electrochemical cells from oligo ( ethylene oxide )- substituted polythiophenes: Evidence for in situ doping . Chemistry of Materials, 1999. 11(11): p. 3133-3139. The inhibition of these processes directly correlate to increased power conversion efficiency, while particularly the elimination of doping shorts and cathodic side reactions can be expected to result in an improved operational lifetime. Accordingly, it is plausible to rationalize the observed improved device performance following a high pre-bias to the alleviation of electrochemical side reactions. Moreover, a high pre-bias may also be attractive from a turn-on time perspective, and we find that the device pre-biased at V pre-bias =4 V reaches a brightness of 100 cd/m 2 >70 times faster than an identical device, which was invariably biased at V=3 V.
[0138] Inspired by the strong influence of the operation protocol on device performance, it is chosen to investigate the effects of the biasing mode. FIG. 15 presents brightness and voltage as a function of time for a sandwich cell operated at constant current (galvanostatic mode) instead of at constant voltage (potentiostatic mode, as was the case in FIGS. 7-8 and 14 ). In order to minimize cathodic side reactions and speed up the turn-on time, we set the initial pre-bias current to a high value of I pre-bias =0.005 A for 0.5 h, directly after which the current was lowered to I=0.001 A. The results are highly promising: the initial power efficiency is >2 lm/W and the operational lifetime reaches an impressive value of ˜1000 h, i.e., >40 days. It is also notable that the applied voltage never exceeds V=4 V during the more than month-long uninterrupted operation at I=0.001 A.
[0139] It is plausible that the improved device performance in FIG. 15 is due to the resulting high initial voltage of V=6 V during the first few seconds of high-current operation at I pre-bias =0.005 A. The high pre-bias will further prohibit undesired cathodic electrochemical side reactions, as compared to the lower initial bias of V=3-4 V, which was applied during the potentiostatic operation in FIGS. 7 , 8 and 14 . It is further noted that self-heating effects can be rather prominent in the p-n junction region of an LEC during steady-state operation, due to non-radiative decay of excitons and Joule heating (the junction is undoped and as such the most resistive portion of the device); and that the better performance in galvanostatic mode as compared to potentiostatic mode, in part, also possibly can be attributed to a better heat management of the p-n junction region, as described in Wagberg, T., et al., On the limited operational lifetime of light - emitting electrochemical cells . Advanced Materials, 2008. 20(9): p. 1744-+, and Zhang, Y. G. and J. Gao, Lifetime study of polymer light - emitting electrochemical cells . Journal of Applied Physics, 2006. 100(8).
[0140] Furthermore, the first highly functional LEC devices on flexible ITO-coated PET substrates are demonstrated. FIG. 16 presents two photographs, which illustrate the conformability of such sandwich cells during operation. Under accelerated lifetime testing at a high applied current of I=0.01 A, it is found that the device performance (i.e., maximum brightness, power conversion efficiency, and operational lifetime) of such flexible LEC devices is on par with the performance of the best of the previously presented devices mounted on non-flexible glass-substrates.
[0141] Finally, it is demonstrated that it is possible to employ other active material constituents and attain a similar impressive device performance by using the aforementioned optimization of the active material composition and the high-prebias protocol. For instance, “superyellow” (see FIG. 2 d for chemical structure) was used instead of MEH-PPV as the conjugated polymer. FIG. 17 presents an initial brightness vs. time test for a sandwich cell device operated at I pre-bias =0.01 A for 0.4 h, directly after which the current was lowered to I=0.001 A. The power conversion efficiency of such yellow-emitting devices can reach 6 lm/W, and the initial operational lifetime data indicate that such superyellow-devices with an appropriate low electrolyte concentration and exposed to an appropriate operational protocol can exhibit an operational lifetime on par with similarly optimized MEH-PPV based devices. In FIG. 18 we present a fully functional flexible superyellow-based LEC device during operation.
[0142] To summarize, it is demonstrated that the composition of the active material and the protocol of operation have a profound influence on the device performance of LECs. Specifically, it is shown that a red-emitting LEC, comprising an active material mixture of {MEH-PPV:PEO:KCF 3 SO 3 } sandwiched between stable ITO and Al electrodes, can attain an impressive operational lifetime of ˜1000 h at a significant brightness of >100 cd/m 2 and a high power conversion efficiency of 2 lm/W, provided that the concentration of the {PEO:KCF 3 SO 3 } electrolyte is optimized and that a high pre-bias is applied during the initial operation. Two efficient routes towards alleviation of detrimental chemical and electrochemical side reactions, which may be used separately or together, have been demonstrated. Furthermore, a flexible LEC with a highly promising device performance has been demonstrated.
EXAMPLES
[0143] The present disclosure is further illustrated by the following specific Example, which should not be construed as limiting in the scope or content of the claimed invention in any way.
[0144] In a first example, the conjugated polymer poly[2-methoxy-5-(2-ethyl-hexyloxy)-1,4-phenylenevinylene] (MEH-PPV) was used as received. Poly(ethylene oxide) (PEO, M w =5×10 6 , Aldrich) and the salt KCF 3 SO 3 (98%, Alfa Aesar) were dried at a temperature (T) of 323 K and 473 K, respectively, under vacuum. Master solutions of 10 mg/mL concentration were prepared: MEH-PPV dissolved in chloroform (>99%, anhydrous, Aldrich), and PEO and KCF 3 SO 3 dissolved separately in cyclohexanone (99%, Merck). Blend solutions were prepared by mixing the master solutions together in a MEH-PPV:PEO:KCF 3 SO 3 mass ratio of 1:0.085:0.03, followed by stirring on a magnetic hot plate at T=323 K for at least 5 h. The indium tin oxide (ITO) glass substrates (1.5×1.5 cm 2 , 20±5 ohms/sq., TFD Inc) were cleaned by subsequent ultrasonic treatment in detergent, acetone, and isopropanol solutions. The active material was deposited by spin-coating the blend solution at 800 rpm, which resulted in a film thickness of ˜150 nm, as established by atomic force microscopy. The active material was thereafter dried on a hot plate at T=333 K for at least 5 h. Al electrodes were deposited by thermal evaporation at p<2×10 −4 Pa. For some devices, a thin layer of poly(3,4-ethylenedioxythiophene)-poly(styrene sulfonate) (PEDOT-PSS 1.3 wt % dispersion in H 2 O, Sigma Aldrich) was spin-coated on top of the ITO at 4000 rpm before the deposition of the active material. All of the above device preparation procedures, with the exception of the cleaning of substrates and the PEDOT deposition, were carried out in two interconnected N 2 -filled glove boxes (O 2 <3 ppm, H 2 O<0.5 ppm). Before testing, the devices were dried in-situ in a cryostat for 2 h at T=360 K and under high vacuum (p<10 −3 Pa). All measurements were performed under high vacuum (p<10 −3 Pa) in the same optical-access cryostat. A computer-controlled source-measure unit (Keithley 2400) in combination with a calibrated photo-diode (Hamamatsu, S9219-01) were employed for the optoelectronic characterization of the LEC devices.
[0145] In another example, the conjugated polymer “superyellow” was used instead of MEH-PPV. Superyellow is a soluble phenyl-substituted PPV co-polymer, which was purchased from Merck, and it was used as received. It was handled in the same manner as the MEH-PPV polymer in the above example.
[0146] In yet another example, a flexible ITO-coated poly(ethylene terephthalate) (PET) substrate (PET60, Visiontek Systems Ltd.) was used instead of a non-flexible ITO glass substrate. These substrates were used as received.
APPENDIX 1
Experimental Details Related to Surface Cells
[0147] Poly[2-methoxy-5-(2-ethyl-hexyloxy)-1,4-phenylenevinylene] (MEH-PPV, Aldrich, M n =40000-70000 g/mol) was used as received. Poly(ethylene oxide) (PEO, M w =5×10 6 , Aldrich) and the salt KCF 3 SO 3 (98%, Alfa Aesar) were dried at a temperature (T) of 473 K under vacuum. Master solutions of 10 mg/mL concentration were prepared: MEH-PPV dissolved in chloroform (>99%, anhydrous, Aldrich), and PEO and KCF 3 SO 3 dissolved separately in cyclohexanone (99%, Merck). A blend solution was prepared by mixing the master solutions together in a mass ratio of MEH-PPV:PEO:KCF 3 SO 3 =1:1.35:0.25, followed by stirring on a magnetic hot plate at T=323 K for at least 5 h. 1.5×1.5 cm 2 glass substrates were cleaned by subsequent ultrasonic treatment in detergent, acetone and isopropanol solutions. 100 nm-thick Au electrodes were deposited onto the cleaned glass substrates by thermal evaporation at p<2×10 −4 Pa. The inter-electrode gap was established by an Al shadow mask.
[0148] The blend solution was deposited by spin-coating at 800 rpm for 60 s, which resulted in active material films with a thickness of 150 nm. The films were thereafter dried on a hot plate at T=333 K for at least 5 h. Finally, immediately preceding a measurement, in-situ drying in the cryostat for 2 h at T=360 K and under vacuum (p<10 −3 Pa) took place. All of the above device preparation procedures except for the cleaning of substrates were carried out in an Ar-filled glove box (O 2 <3 ppm, H 2 O<0.5 ppm). The characterization of devices was performed under vacuum (p<10 −3 Pa) in an optical-access cryostat. A computer-controlled source-measure unit (Keithley 2400) was employed to apply voltage and to measure the resulting current. The photographs of the doping progression were recorded under UV (A=365 nm) illumination through the optical window of the cryostat, using a digital camera (Cannon EOS 20D) equipped with a macro lens.
[0149] Cyclic voltammetry (CV) measurements were carried out with a computer-controlled potentiostat/galvanostat (Autolab, PGSTAT302/FRA2, Eco Chemie) using the General Purpose Electrochemical Software (GPES, Eco Chemie). All the measurements were performed in an Ar-filled glove box (O 2 <3 ppm, H 2 O<0.5 ppm). The electrolyte solution was either 0.1 M tetrabutylammonium hexafluorophosphate (TBAPF 6 , 99.0%, Fluka) in acetonitrile (CH 3 CN, anhydrous, 99.8%, Aldrich) or 0.1 M potassium trifluoromethanesulfonate (KCF 3 SO 3 , 98%, Alfa Aesar) and 2 M (calculated as a number of repeat units of PEO per liter of solution) low-molecular-weight PEO (M w =400, Polysciences) in acetonitrile. Au working electrodes were deposited onto pre-cleaned glass substrates by thermal evaporation at p<2×10 −4 Pa. MEH-PPV films were spin-coated from the chloroform solution (10 mg/ml, >99%, anhydrous, Aldrich) onto the Au electrodes at 800 rpm for 60 s and thereafter dried on a hot plate at T=323 K for ˜1 h. A silver wire was used as the quasi-reference electrode. The silver wire was calibrated vs. the bis-(q-cyclopentadienyl)iron(II)/bis-β-cyclopentadienyl)iron(II) + ion (ferrocene/ferrocenium ion, Fc/Fc + ) reference redox couple (ferrocene, ≧98%; Fluka) at the end of each measurement by adding ˜10 −5 mol of ferrocene into the electrolyte solution and performing a sweep. A Pt rod was used as the counter electrode. The reduction/oxidation onset potentials were defined to correspond to the crossing point between the baseline and the half-peak-height tangent line. All the potentials are reported vs. the Fc/Fc + reference redox couple.
APPENDIX 2
Derivation of Equation (1)
[0150] The effective densities of the conjugated polymer (CP) and the salt (as well as the other components) in the active material (AM) can be related to their respective mass fractions by:
[0000]
ρ
i
=
m
i
m
tot
·
ρ
AM
(
1
)
[0000] where ρ AM is the density of the active material.
[0151] The densities of the CP and the repeat unit of the CP(CPru) are identical:
[0000] ρ CPru =ρ CP (2)
[0152] The number densities of the components in the active material are given by:
[0000]
N
i
=
N
A
M
i
·
ρ
i
(
3
)
[0000] where N A is Avogadro's constant and M i is the molar mass of component i.
[0153] We further note that for a univalent salt the following is true:
[0000] N cations =N anions =N salt (4)
[0154] At ion depletion, all ions of one type have accumulated in one distinct doping region, where they electrostatically compensate the dopants (anions compensate holes in the p-type region and cations compensate electrons in the n-type region). Further, the doping concentration, and therefore the ion concentration, in the doped region is constant. Thus, the concentrations of dopants and ions in each doped region are related to the volume of that doped region (V i , i=p, n) and the total volume of the active material (V tot ) by:
[0000]
N
p
=
N
anions
,
p
=
V
tot
V
p
·
N
salt
(
5
)
N
n
=
N
anions
,
n
=
V
tot
V
n
·
N
salt
(
6
)
[0155] If the cross-section area of the active material is constant, the expressions for the p-type and n-type doping concentrations can be rewritten as:
[0000]
N
p
=
d
tot
d
p
·
N
salt
=
ρ
salt
·
N
A
·
d
tot
M
salt
·
d
p
(
7
)
N
n
=
d
tot
d
n
·
N
salt
=
ρ
salt
·
N
A
·
d
tot
M
salt
·
d
n
(
8
)
[0000] where d tot is the total distance between the electrodes, and d p and d n are the total length of the p-type and n-type regions, respectively, in the inter-electrode direction.
[0156] The doping fraction in the doped regions (x i , i=p, n) can now be calculated with the following equation:
[0000]
x
i
=
N
i
N
CPru
(
9
)
[0157] By including the results from above and solving specifically for the p-type region, we find that:
[0000]
x
p
=
N
p
N
CPru
=
ρ
salt
·
N
A
·
d
tot
M
salt
·
d
p
ρ
CPru
·
N
A
M
CP
=
m
salt
m
CPru
·
M
CPru
·
d
tot
M
salt
·
d
p
(
10
)
[0158] We now solve for the ratio, z, between the mass of the salt and the mass of the conjugated polymer:
[0000]
(
11
)
[0159] If we set the doping concentrations in the two doped regions to be equal (in reasonable agreement with recent experimental observations for the herein investigated LEC devices, see J. Fang, et al. Identifying and alleviating electrochemical side - reactions in light - emitting electrochemical cells , Journal of the American Chemical Society, 2008, 130(13): p. 4562-4568) we find by symmetry that:
[0000] x p =═x n =x doping (12)
[0000] and
[0000]
d
p
=
d
n
=
d
tot
-
d
pn
2
(
13
)
[0000] where d pn is the width of the undoped p-n junction.
[0160] Under this specific condition, eq. (11) can be rewritten as:
[0000]
(
14
) | A light-emitting device comprises a first electrode, a second electrode, and a light-emitting active material contacting and separating the first and second electrodes. The device comprises a combination of a conjugated polymer and an electrolyte, said electrolyte comprising ions, allowing for electrochemical doping of the conjugated polymer. In the device, a ratio between the ions and the conjugated polymer is selected to allow for the formation of:
(i) a doped region at the respective electrode interface, which allows for injection and transport of electronic charge carriers into and through the doped regions, respectively, at zero or low overpotential, and (ii) an effectively undoped region, separating the doped regions, wherein injected electronic charge carriers are recombineable under excitation of the conjugated polymer and the polymer is de-excitable under the emission of light. The ratio between the ions and the conjugated polymer is low enough for the undoped region to remain effectively undoped and free from said ions, as substantially all ions in the active material are locked up in the doped regions. | 7 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to roller screeds, and more particularly relates to methods and apparatuses for creating a convex or concave finish to the surface screeded through utilizing such a roller screed.
[0003] 2. Background Information
[0004] Roller screeds comprise a frame having a power driven roller, typically comprising a number of joined strike tubes, that is moved across a freshly poured concrete surface thereby rolling said concrete surface into a flat, smooth finish. Typically, such a power screed would utilize a plurality of sections or modules whereby the power screed can be configured to have a desired length. Typical lengths of such modules are three, four, five, six, eight, and nine feet. However, utilizing such a modular construction easily allows for screed lengths exceeding fifty feet.
[0005] A typical roller screed is shown in U.S. Pat. No. 5,664,908 to Paladeni. Referring to FIG. 3 of Paladeni, a typical pair of screed modules is joined at a plate ( 62 ). Each of these modules having a roller or strike tube that is connected together through the use of a generally cylindrical spline ( 100 ). Power screws ( 66 ) and collars ( 68 ) are utilized to adjust the pitch of the two panels towards one another by drawing the dorsal side of the panel or panels nearer or farther from the plate ( 62 ). Through adjusting these screws within these collars, as Paladeni describes it, “ . . . the rotary screed 10 can be configured for long lengths because any sag that occurs in which the medial ends 80 of the strike tubes dip below the distal ends 82 can be adjusted by turning the power screws 66 .” (col. 4, In. 22-25).
[0006] The intended use of power screeds is to create extremely flat concrete surfaces. Paladeni discloses a device that is able to be adjusted to maintain the screed thereby allowing for a consistent, flat surface. However, it can also be desirable to create a concrete surface which is intentionally not flat. For instance, a user might desire to utilize these module sections to create varying degrees of slight, gradual pitch between one or more of the junctions between adjoining modules.
[0007] For instance, take a power screed having a pair of joining modules. These modules each having first ends which extend to second ends. These first ends joining at a junction. The second ends resting upon a rail or frame which contacts the ground surface. Thus, by raising the junction relative to the second ends, a convex surface will be created in the resulting concrete surface. Such a peak would be useful for causing water to roll off the concrete surface. Likewise, lowering the juncture relative to the second ends will create a concave surface. Such a concave surface is useful for collecting water in a trough.
[0008] It is known in the prior art to take such power screws and collars and tightening or loosing them to result in a very slight or gradual pitch being occurred in either a concave or convex surface resulting from the use of the roller tubes of the present invention. Such usage, while beneficial to the user, is not recommended by the manufacturer for the reason that application of such torque upon the spline greatly increases wear to the spline and associated assembly. This wear likewise causing an increased rate of failure of the spline assembly.
[0009] What is needed is a method of allowing for the creation of crowns or trenches in concrete surfaces whereby the spline is not placed in a position of damage. The present invention solves this need.
[0010] Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
[0011] The present invention is a method of and apparatus for creating upwards or downwards pitch in a roller screed and the apparatuses necessary to implement the same.
[0012] One embodiment of the present invention comprises an articulating rotary spline for joining a first roller to a second roller so that rotation of the first roller or the second roller results in rotation of the other roller. This spline comprising an elongated shaft having a first end extending to a second end. This shaft defining a first portion, a central portion, and second portion. A first annular groove is defined in the shaft between the central portion and the first portion. The first portion being generally prolate (cigar-shaped) in shape between the first end and the first annular groove. A plurality of longitudinal gear teeth are located on the spline first portion for interfitting relationship with corresponding longitudinal gear teeth within the first roller. Likewise, longitudinal gear teeth are located on the spline second portion for interfitting relationship with corresponding longitudinal gear teeth within the second roller.
[0013] Another embodiment of the present invention comprises an articulating rotary spline for joining a first roller to a second roller so that rotation of the first roller or the second roller results in rotation of the other roller. This spline comprising an elongated shaft having a first end extending to a second end. This shaft defines a first portion, a central portion, and a second portion. A first annular groove is defined in the shaft between the central portion and the first portion. A second annular groove is defined in the shaft between the central portion and the second portion. The first portion generally prolate in shape between the first end and the first annular groove. The second portion generally prolate in shape between the second end and the second annular groove. Longitudinal gear teeth are located on the spline first portion for interfitting relationship with corresponding longitudinal gear teeth within the first roller. Longitudinal gear teeth are located on the spline second portion for interfitting relationship with corresponding longitudinal gear teeth within the second roller.
[0014] Another embodiment of the present invention comprises an articulating rotary spline for joining a first roller to a second roller so that rotation of the first roller or the second roller results in rotation of the other roller. This spline comprising an elongated shaft having a first end extending to a second end. This shaft defining a first portion, a central portion, and a second portion. A first annular groove is defined in the shaft between the central portion and the first portion. A second annular groove is defined in the shaft between the central portion and the second portion. The first portion having a circumvolving first crest between the first annular groove and the first end. This first crest having a diameter greater than the first annular groove. The first crest having a diameter greater than the first end, wherein the first portion circumvolvingly tapers from the first annular grove to the first crest and the first portion circumvolvingly tapers from the first crest to the first end. The second portion having a circumvolving second crest between the second annular groove and the second end. This second crest having a diameter greater than the second annular groove. The second crest having a diameter greater than the second end, wherein the second portion circumvolvingly tapers from the second annular grove to the second crest and the second portion circumvolvingly tapers from the second crest to the second end. Longitudinal gear teeth are located on the spline first portion for interfitting relationship with corresponding longitudinal gear teeth within the first roller. Longitudinal gear teeth are also located on the spline second portion for interfitting relationship with corresponding longitudinal gear teeth within the second roller.
[0015] Still other objects and advantages of the present invention will become readily apparent to those skilled in this art from the following detailed description wherein I have shown and described only the preferred embodiment of the invention, simply by way of illustration of the best mode contemplated by carrying out my invention. As will be realized, the invention is capable of modification in various obvious respects all without departing from the invention. Accordingly, the drawings and description of the preferred embodiment are to be regarded as illustrative in nature, and not as restrictive.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] [0016]FIG. 1 is a side view of one embodiment of a power screed utilizing the present invention.
[0017] [0017]FIG. 2 is a partial, cut-away, side view of the embodiment of FIG. 1.
[0018] [0018]FIG. 3 is a side view of one embodiment of a spine utilized in the present invention.
[0019] [0019]FIG. 4 is an end view of FIG. 3.
[0020] [0020]FIG. 5 is a partial, cross-sectional view of the embodiment of FIG. 3.
[0021] [0021]FIG. 6 is a partial, cut-away, side view of the embodiment of FIG. 1 showing the configuration of the present invention to create a trough in the surface finished.
[0022] [0022]FIG. 7 is a partial, cut-away, side view of the embodiment of FIG. 1 showing the configuration of the present invention to create a ridge in the surface finished.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0023] While the invention is susceptible of various modifications and alternative constructions, certain illustrated embodiments thereof have been shown in the drawings and will be described below in detail. It should be understood, however, that there is no intention to limit the invention to the specific form disclosed, but, on the contrary, the invention is to cover all modifications, alternative constructions, and equivalents falling within the spirit and scope of the invention as defined in the claims.
[0024] Referring initially to FIG. 1, shown is one general embodiment of a roller screed 2 . The present invention is particularly considered relevant with respect to roller screeds, but could be utilized in any situation where two rotating shafts, tubes, rods, rollers, columns, pillars, poles, parts, portions, etc. are joined together. The general term “roller screed” is intended to include all of these other situations. A typical “roller screed” has a drive means 6 , such as an engine or a motor, for driving the rotation of one or more strike tubes 40 , 60 . These strike tubes suspended below a roller screed frame 4 .
[0025] The roller screed frame 4 , in the embodiment shown, has a pair of strike tubes 40 , 60 that join together at a middle bracket 12 . At least one elevation adjustment 14 is utilized to adjust the pitch of the two strike tubes relative to one another and/or in relation to the middle bracket. The first strike tube 40 has a first end 36 extending to a second end 38 . The second strike tube 60 has a first end 56 extending to a second end 58 . The invented pitch controller 10 is utilized to rotationally join the strike tube second ends 38 , 58 together.
[0026] Referring now to FIG. 2, the embodiment of FIG. 1 is shown in partial detail. The present invention is a pitch controller 10 for raising or lowering the strike tubes second ends ( 38 , 58 ) in relation to the strike tubes first ends ( 36 , 56 ). This raising or lowering is accomplished through manipulation of the elevation adjustment(s) 14 . In the embodiment shown, the elevation adjustment 14 shown comprises a threaded portion 16 able to be tightened or loosened into or out of a frame receiver 15 , thereby drawing the threaded portion 16 of the frame nearer or farther from said frame receiver 15 . This results in the raising or lowering of the first ends 36 , 56 , thereby creating a crown or a trough in the screeded concrete due to the orientation of the second ends 38 , 58 to one another. While this particular type of elevation adjustment is expressly disclosed as preferred, all other manners of elevation adjustment shown in the prior art are likewise included in this disclosure, as well as future manners of adjusting, including but not limited to screws, motors, engines, hydraulics, spacers, linkages, chains, cables, clamps, etc. A pinhole 17 for receiving a pin (not shown) is also preferably provided for allowing the threaded portion to be locked in place, inhibiting further rotation of the threaded portion.
[0027] The embodiment shown (FIG. 2) utilizes an articulating spline 20 for rotationally joining the strike tubes 40 , 60 together. The use of cylindrical splines is shown in the prior art, however the invented spline 20 differs from the prior art splines in shape.
[0028] The invented spline 20 is particularly shown in FIGS. 3 - 5 . Referring now to FIGS. 3 - 5 , the spline comprises an elongated shaft 26 having a first end 28 extending to a second end 30 . The shaft 26 defining a first portion 80 , a central portion 82 , and a second portion 84 . A first annular groove 90 is defined in said shaft 26 between said central portion 82 and said first portion 80 . This first portion 80 preferably being generally prolate (cigar-shaped) in shape between the first end 28 and the first annular groove 90 . A second annular groove 92 is defined in said shaft 26 between said central portion 82 , and said second portion 84 . This second portion 84 preferably being generally prolate in shape between the second end 30 and the second annular groove 92 .
[0029] It is preferred that a plurality of longitudinal gear teeth 70 on the spline first portion 80 for interfitting relationship with corresponding longitudinal gear teeth within the first strike tube coupling 46 (shown in FIG. 2) of the first strike tube (roller) 40 . Likewise, it is preferred that a plurality of longitudinal gear teeth 70 on the spline second portion 84 for interfitting relationship with corresponding longitudinal gear teeth within the second strike tube coupling 66 (shown in FIG. 2) of the second strike tube (roller) 60 .
[0030] This “prolate” shape could be further described as a first portion having a circumvolving first crest between the first annular groove and the first end. This first crest having a diameter greater than the first annular groove and greater than the first end, wherein the first portion circumvolvingly tapers from the first annular grove to the first crest and the first portion circumvolvingly tapers from the first crest to the first end. Likewise, the second portion having a circumvolving second crest between the second annular groove and the second end. The second crest having a diameter greater than the second annular groove and greater than the second end, wherein the second portion circumvolvingly tapers from the second annular grove to the second crest and the second portion circumvolvingly tapers from the second crest to the second end.
[0031] While the present invention is described and shown in the figures as having a spline that is symmetrical, this is not intended as a limitation. A roller screed could just as easily be provided with a spline having a standard cylindrical first end and a generally prolate second end, and other orientations and structures.
[0032] Referring back to FIG. 2, the spline 20 cooperates with a pair of bearing assemblies 18 , 18 ′ that are mounted on the middle bracket 12 . These bearings support the spline, which is rotationally mounted to the strike tubes. The first strike tube 40 having therein a first strike tube hub assembly 42 comprising a first strike tube hub 44 and a first strike tube coupling 46 . The hub 44 , connecting with said first strike tube 40 , has a centered orifice defined therein for receiving said coupling. The coupling 46 mounted within and extending through the hub 44 , this coupling having an interior portion that is configured with horizontal gear teeth configured to cooperate with the spline's gear teeth 70 . The second strike tube 60 has therein a second strike tube hub assembly 62 comprising a second strike tube hub 64 and a second strike tube coupling 66 . The hub 64 connects with said first strike tube 60 , having a centered orifice defined therein for receiving said coupling. The coupling 66 is mounted within and extends through the hub 64 . This coupling has an interior portion that is configured with horizontal gear teeth configured to cooperate with the spline's gear teeth 70 .
[0033] Referring now to FIG. 6, shown is the embodiment of FIG. 2 with the elevation adjustment causing the strike tubes first ends to be raised relative to the strike tubes second ends. The result is that the middle bracket 12 remains generally vertical, while the first ends are raised. This causes the top portions 48 , 68 of the first and second strike tube second ends to be drawn closer together, with the bottom portions 49 , 69 of the strike tube second ends drawn further apart, thereby providing for the creation of a trench within the concrete surface being screeded. Due to the prolate shape of the ends of the spline, the spline ends are allowed to generally rotate within the hubs, thereby causing no additional stress upon the junction caused by the elevation adjustment.
[0034] Referring now to FIG. 7, shown is the embodiment of FIG. 2 with the elevation adjustment causing the strike tubes first ends to be lowered relative to the strike tubes second ends. The result is that the middle bracket 12 remains generally vertical, while the first ends are lowered. This causes the top portions 48 , 68 of the first and second strike tube second ends to be pushed further apart, with the bottom portions 49 , 69 of the strike tube second ends drawn closer together, thereby providing for the creation of a crest or ridge within the concrete surface being screeded. Due to the prolate shape of the ends of the spline, the spline ends are allowed to generally rotate within the hubs, thereby causing no additional stress upon the junction caused by the elevation adjustment.
[0035] Thus, one embodiment of the present invention comprises a spline having one end generally prolate in shape. Another embodiment of the present invention comprises a spline having two generally prolate shaped ends. Another embodiment of the present invention comprises an improved screed utilizing the present invention. Another embodiment of the present invention is a novel manner of connecting two rotating parts. Other embodiments of the present invention are disclosed, explicitly or implicitly.
[0036] While there is shown and described the present preferred embodiment of the invention, it is to be distinctly understood that this invention is not limited thereto but may be variously embodied to practice within the scope of the following claims. From the foregoing description, it will be apparent that various changes may be made without departing from the spirit and scope of the invention as defined by the following claims. | An improved roller screed utilizing an articulated roller screed spline for allowing for the creation of crowns and trenches in widths of poured and finished concrete. The spline being generally prolate in shape. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to means for controlling clearance between rotating turbine parts and a surrounding shroud in a gas turbine engine.
2. Summary of the Prior Art
In an effort to maintain a high degree of efficiency, manufacturers of turbine engines have strived to maintain the closest possible clearance between rotating turbine parts and surrounding turbine shroud structure, because any gas which passes therebetween represents a loss of energy to the system. If a gas turbine were to operate only under steady-state conditions, it would be a relatively simple matter to establish the desired close clearance relationship between the rotating turbine parts and the turbine shroud. However, in reality, all turbine engines must initially be brought from a cold, standstill condition up to steady-state speed at relatively hot temperatures, and eventually return to the standstill condition. Operating conditions are even more complicated in turbine engines used to propel jet aircraft because the engines are frequently thrown into maximum acceleration or deceleration under both hot and cold engine temperature operation.
The problems in maintaining clearance between turbine blades and turbine shrouds under these conditions are caused by first, the mechanical expansion and shrinkage of the rotating turbine parts as brought about by changes in speed, and secondly, by relative thermal growth between rotating turbine blade tips and surrounding shrouds caused by differences in thermal inertia. One commonly used method of decreasing turbine tip clearance has been to properly select various materials with thermal properties that assist in matching radial growth responses at different engine operating conditions. Another method has been to actively direct and modulate variable temperature air on the outside of the turbine section of the engine. In this latter method, the air is directed on the turbine section during appropriate stages of engine operation to change the radial growth or shrinkage rate of the turbine shroud support in an effort to match the growth or shrinkage of the rotating turbine parts. These "active" clearance control systems generally require complex systems of pipes, valves, and controls to properly direct cooling air to the turbine section. The "active" system also requires significant amounts of compressor or fan air, much of which is underutilized because it is released outside the turbine section where it cannot be contained, thus causing a drain on engine performance.
It is, therefore, an object of the present invention to provide a gas turbine engine which allows decreases in clearance in a turbine section of the engine with a lesser drain on engine performance.
Another object of the invention is to control clearance between rotating turbine parts and surrounding shrouds during critical transient and steady-state phases of engine operation.
Another object of one embodiment of the present invention is to provide a turbine engine with a system that efficiently utilizes compressor air to decrease clearance between rotating turbine parts and a surrounding shroud during critical phases of engine operation.
These and other objects will become more readily apparent from reference to the following description taken in conjunction with the appended drawings.
SUMMARY OF THE INVENTION
In the present invention, a system is provided in a turbomachine for controlling clearance between rotating turbine parts and a surrounding turbine shroud. To accomplish this purpose, a plurality of control rings with internal passages are integrated into the turbine casing, and are expanded and contracted thermally with fluid flow through the internal passages during engine operation to control radial positioning of the turbine shroud. The expansion and contraction of the shroud is matched to the expansion and contraction of the rotating turbine parts to maintain close clearance when the engine is operated over the spectrum from full power to reduced power.
In one embodiment of the invention, the fluid used to cause expansion and contraction of the control rings is compressor discharge air that is taken from a region surrounding the combustor section of the engine. Conveniently, the temperature and pressure of this air closely matches what is desirable for this function. The system utilizes the amount and pressure of the compressor air, in combination with the size, location and structure of the control rings, to expand and contract the turbine shroud during appropriate periods of engine operation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic representation of a gas turbine engine which is partly in section and partly broken away;
FIG. 2 is an enlarged sectional view of a high pressure turbine of a gas turbine engine incorporating one embodiment of the present invention;
FIG. 3 is a graphic representation of turbine stator and rotor growth from engine idle to full throttle conditions; and
FIG. 4 is a graphic representation of turbine stator and rotor shrinkage from full throttle to engine idle conditions.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, there is shown in FIG. 1 a gas turbine engine 10 comprising a fan section 12, compressor 14, combustor 16, high pressure turbine 18 and low pressure turbine 20, all in flow series. Inside the high pressure turbine 18, turbine parts are mounted for rotation within turbine shrouds 22. These rotating turbine parts, shown in FIG. 1, are known to those skilled in the art as a turbine rotor section, generally designated at 24. Certain major components of the high pressure turbine 18 do not rotate, and these are known as the turbine stator 26.
Referring now to FIG. 2, the high pressure turbine 18 and associated structures are shown in greater detail with the present invention incorporated therein. The turbine stator section 26 comprises an inlet vane 28 and intermediate vane 30. The primary function of the vanes 28 and 30 is to properly direct the hot turbine gases against the blades 32 and 34 so that the inertial force of the gases causes turbine rotor section 24 to rotate. The efficiency of this transfer of inertial forces is a major factor in the overall efficiency of the engine. One means of improving the efficiency of this transfer is to decrease any flow of hot gases between tips of the turbine blades 32 and 34 and the surrounding turbine shroud 22. Any gases taking this path transfer very little inertial force to the blades. The volume of gases taking this undesirable flowpath is lessened by decreasing clearance between the turbine blade tips and the shrouds 22, and that is the purpose of the present invention.
The turbine tip clearance is decreased by radially expanding and contracting the turbine shrouds 22 to match the radial expansion and contraction of the tips of the turbine blades 32 and 34. Radial position of the shroud 22 is controlled by thermally expanding and contracting relatively massive ring structures 36, 37, 38, and 39 that extend radially outward from a turbine casing 40.
In the embodiment of the invention shown in FIG. 2, compressor discharge air is employed for the purpose of thermally expanding and contracting the rings 36, 37, 38 and 39. The compressor discharge air is derived from a region surrounding the combustor. In an alternate embodiment, interstage bleed air from upstream compressor stages could also be used to control all or selected rings. The path of the air through passages in the rings is generally shown by the dark arrows. The system utilizes the already available pressure of this compressor discharge air in combination with judiciously selected size, location and structure of the control rings and passages to properly control the thermal effect of the compressor air on the rings. The manner in which this is accomplished will be more fully described later in this description.
The radial movement of the control rings 36, 37, 38 and 39 is physically transferred to the turbine shroud 22 through shroud supports 42 and 43. Each shroud support physically interconnects with a portion of the shroud 22 in such a manner that an essentially box-like cross-sectional configuration is formed. Each of the rings 36, 37, 38 and 39 is carefully positioned radially outward of a radial side of this box-like configuration. This allows each ring to more directly affect expansion and contraction of a radial side of a shroud support, along with a corresponding portion of the shroud 22. The turbine shroud support components are either segmented or saw cut in design to avoid diverging from the radial position that the casing seeks as its ring temperature control function works. Thus, the box-like configuration in combination with the corresponding ring positioning permits very accurate control of the shroud position without causing the shroud portion to "tilt" and become unaligned with an adjacent blade tip. If a loss of alignment would occur, a portion of the turbine blade would "rub" against a portion of the shroud. Any "rubbing" of this nature would cause nonalignment of the turbine tips and corresponding turbine shroud and increase the turbine tip clearance during subsequent engine operation.
Operation
Initially, a gas turbine engine is started and operated at idle speed. During idle, the engine is not being called upon to deliver large amounts of power and engine efficiency is not critical. With this in mind, the turbine tip clearance can be set at a relatively high level. On the other hand, during high throttle and/or cruise operation, an engine must develop large amount of power over a long period of time. Under such conditions, efficiency is critical, and turbine tip clearance must be as low as is reasonably possible. Achieving a lower turbine tip clearance during cruise operation is accomplished by directing compressor discharge air that is cooler at cruise, through the control rings 36, 37, 38, and 39. Contraction of the rings occurs, and corresponding radial shrinkage of the turbine shroud 22 lessens turbine tip clearance and improves turbine efficiency.
This desirable effect during cruise operation is complicated by problems incurred during engine transients, such as acceleration and deceleration. During engine transients localized thermal effects of hot turbine gases and radial expansion caused by high rotational speed makes it particularly difficult to match radial growth of the turbine shroud with radial growth of the rapidly rotating turbine parts. While efficiency is relatively unimportant during these transients, it is essential for clearance that the shroud 22 does not physically interfere with the rotating turbine blades 32 and 34. Any interference would cause a "rub" that will remove or "rub off" a portion of the turbine blades 32, 34 and shrouds 22. When the engine is subsequently operated at cruise conditions, the turbine tip clearance would be increased because of the "rubbed off" portion of the blades and shrouds, resulting in a significant decrease in turbine efficiency.
To prevent "rubs" during engine transients, the present invention utilizes the phenomenon of relatively slow heating and cooling rates inherent to large, heavy ring structures located in cavities where the air circulation is weak. In the present invention, the rings 36, 37, 38 and 39, shown in FIG. 2, are located in a relatively weak air circulation region surrounding the turbine. By making the rings relatively massive, and by limiting any surrounding air circulation, heating and cooling rates of the turbine shroud during engine transients can be controlled. Specifically, by admitting small quantities of high pressure compressor discharge air from the region surrounding the combustor into the rings, and by circulating this air within the rings, the following desirable transient response characteristics will be achieved:
1. Engine Acceleration--When the engine is accelerated, the compressor air from the region surrounding the combustor is relatively hot because of the work done on it by compressing it and the heat transfer from the combustor 16. Circulation of this hot air through the rings 36, 37, 38 and 39 causes and controls thermal expansion that "moves" the turbine shroud 22 radially outward and away from the thermally expanding turbine. As embodied, there is very little effect, if any, during the early acceleration portion of the transient. This avoids a "rub" and any consequent damage to the turbine blades 32, 34 and shroud 22. FIG. 3 is a graphical depiction of calculated radial growth of turbine stator and rotor components during engine acceleration. The growth curve designated 46 represents stator growth in a prior art engine without the present invention. The curve designated 48 illustrates growth of a turbine stator with the present invention incorporated into the engine. The curve designated 50 represents turbine rotor growth in engines with or without the invention. The much closer match of growth rates in an engine incorporating the present invention is clearly evident in FIG. 3. This characteristic has significant advantages in that acceleration induced turbine inlet temperature "overshoot" is greatly reduced. This "overshoot" occurs when the control demands a specific engine power output when the clearances are relatively very large. Extra fuel is burned to produce the power at these inefficient clerance values. The extra fuel burned causes the high pressure turbine vanes and blades to run transiently at higher temperature levels than normal design values, which reduces component life. The present invention will significantly decrease this "overshoot."
2. Engine Deceleration --When the engine is decelerated from high to low power settings, the compressor discharge pressure drops off with engine speed to very low values. Consequently, the circulation strength of the air through the cooled rings 36, 37, 38 and 39 is reduced, and the cooling response rate of the rings is very slow, simply because the rings stay relatively hot in a low circulation environment, while the rest of the engine cools off. This delayed response pattern is very desirable because it keeps the turbine shroud 22 in a radially expanded position so that upon rapid reacceleration (reburst) the turbine blades 32 and 34 are less likely to incur a tip "rub" and damage the shroud 22.
FIG. 4 is a graphical representation of calculated radial shrinkage of turbine rotor and stator components during engine deceleration. The shrinkage curve designated 52 depicts stator shrinkage in a prior art engine, and the curve designated 54 depicts stator shrinkage in an engine incorporating the present invention. The curve designated 56 depicts rotor shrinkage on an engine with or without the invention. It can be readily appreciated from the FIG. 4 that the shrinkage of a stator in an engine incorporating the present invention is significantly slower thereby retaining greater tip clearance so that the engine can be reaccelerated without incurring blade tip rub.
The above-described features of the present invention allow blade tip clearance to be set very closely. Transient response differences between the stator and rotor that have previously required either the setting of larger clearances or have caused increased engine deterioration rates need no longer be accounted for. Improved performance and reduced deterioration levels are made possible by the present invention. Through selection of ring materials and circulation air temperatures which match those of the rotor hardware, very little increase in clearance between acceleration and steady-state power settings will be experienced. Through judicious design of the turbine casing and rings geometry, cooling airflow levels, and materials selection, the turbine shroud growth can be made to approximate rotor growth. This makes it possible to set more constant and relatively low steady-state operating clearances while avoiding any blade tip rubs during transient operation. All of these features are achieved without the addition of any external or internal cooling manifolds, piping or control system sensor devices.
While specific embodiments have been described, it will be apparent to those skilled in the art that various modifications thereto can be made without departing from the scope of the invention, as recited in the appended claims. Therefore, the scope of the invention is to be derived from the following claims. | A system is provided inside a turbomachine for controlling operational clearance between a turbine rotor and a surrounding turbine shroud. The system comprises a plurality of control rings, integrated into the turbine casing, that are thermally expanded and contracted to control radial positioning of the turbine shroud. Compressor air is directed through internal passages in the rings to cause the expansion and contraction. The system utilizes the pressure and temperature of compressor air, in combination with size, location, and structure of the control rings to match thermal growth of the control rings and turbine shroud to thermal growth of the turbine rotors, thereby controlling clearance. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This disclosure relates generally to a laminated internally threaded fastener,typically a nut, that can be manufactured from a variety of materials using a very inexpensive manufacturing process to produce laminae that are pre-threaded and easily assembled into a nut having properties equal or superior to a forged nut. Clearly, others have recognized the advantages of punching, stamping and stacking laminae to construct laminated nuts. Examples of patent art describing this technology and the advantages offered by this technology include the following references.
2. Description of the Prior Art
U.S. Pat. No. 3,233,262 to Vollman describes a laminated locknut that is assembled from a series of punched monoplanar laminae stacked within a cup-shaped housing and wherein the threads formed in certain laminae are displaced or axially out of phase relative to those formed in other laminae.
G.B. Patent 1,193,751 to Monticelli describes a resilient self-locking nut comprising a polygonal housing containing at least one resilient annular dished plate, internally contoured to be threaded onto a screw and externally contoured to rotate fast with the housing containing it and disposed between end plates which are flat on one side and contoured on the other to fit to the abutting surface of a resilient plate.
U.S. Pat. No. 2,581,641 to Forgaard discloses a nut comprising one or more elements of dished or conical form mounted in a pressure ring. The disclosure goes on to suggest that instead of using a pressure ring, the plates forming the element may be welded or otherwise secured together at the periphery, or elsewhere, so that the pressure ring can be dispensed with. However, the elements of the assembled nut are not individually threaded and must be stamped, then tapped after assembly.
U.S. Pat. No. 5,017,079 to Reynolds discloses a laminated nut wherein the laminae are characterized as conical spring disc washers that are held in a stacked, dished and aligned relationship so as to define a central opening that is tapped to match threads on an associated bolt. This laminated nut is further characterized by having a "cage" for holding the laminae in alignment and for providing a plurality of protrusions located at the base of the "cage". These protrusions are intended to prohibit tool engagement on the bottom side of the nut.
SUMMARY OF THE INVENTION
Notwithstanding the ingenuity and favorable features of the laminated nuts disclosed and suggested by the prior art, the fastening industry is always receptive to refinements in nut technology, especially when they contribute to savings in time and money. Accordingly, then, the laminated fastener disclosed herein is distinguished from and improves upon the prior art by providing an internally threaded fastener comprising a plurality of stacked laminae, each lamina having an internal bore with less than one full thread form at the helix plane and a periphery accommodating a wrenching tool.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a lamina having two half-thread segments and a hex-shaped perimeter.
FIG. 2 is a perspective view of a laminated internally threaded fastener comprising a two-lamina assembly of the lamina of FIG. 1.
FIG. 3 is a perspective view of a lamina with four half-thread segments with a square perimeter.
FIG. 4 is a perspective view of a laminated internally threaded fastener comprising a two-lamina assembly of the laminae of FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a hex-shaped lamina 10 is depicted. The particular shape of the lamina is significant only so far as in a typical embodiment all the laminae of a particular laminated threaded fastener or nut would be the same shape. A hex-shaped lamina is depicted primarily because hex-shaped nuts are some of the most popular fastening devices. Clearly, the disclosed invention relates to laminated threaded fasteners of all shapes. Typically, of course, the laminae will be generally annular in shape with facets to provide a wrenching surface.
Continuing to refer to FIG. 1, it is apparent that the hex-shaped fastener is further defined by an area that can be referred to as the perimeter plane 11. Its purpose is to form the structure of the nut and support the structural elements of the internal thread. The internal thread is complex in that it comprises several elements. However, all these elements can manifest themselves in a single lamina thereby giving rise to ease of manufacture and assembly.
In addition to a perimeter plane 11, each lamina will include orientation holes 12, denominated as "A" and "B" holes to facilitate assembly. Each hole 12 will also accommodate a joining device, mechanism or procedure to permit joining the stacked laminae one to another in a permanent or semi-permanent arrangement. In one embodiment of the presently disclosed fastener, it is envisioned that a small rivet or screw device will be employed to join the laminae to form the assembled nut. Other methods and devices that can be used to join the laminae include welding, adhesives and "cages" as demonstrated in the prior art. The holes 12 are identified as "A" and "B" holes because in a preferred embodiment of the disclosed nut each lamina will provide one-half of the thread form at the helix plane and in assembly it is essential that the stacking be in an "A" to "B" relationship. By stacking or assembling in such a 180 degree relationship, the one-half thread that is characteristic of each lamina is continued by the adjoining lamina to form a full thread over a 180 degree rotation with two half-threads, which are then available to form complete threads when assembled with other laminae.
Another embodiment of this disclosure is depicted in FIG. 3 which features a lamina with four threaded segments. Many of the aspects possessed by the two-segment lamina apply to the four-segment lamina with the readily apparent exception that there are two pairs of diametrically opposed, identical thread segments per lamina. The assembled thread form created when the four segment laminae are stacked creates a "double lead" thread, which comprises two distinct threads. The double lead thread design would have twice the thread lead of a conventional single lead thread with a correspondingly increased helix angle. One advantage of the double lead thread is that for each rotation of the nut or fastener, the axial advance is twice that of a conventional single lead thread. This would be advantageous in certain work situations where speed of assembly is important.
In the four-segment internally treaded lamina depicted in FIG. 3, there are two thread segments with upper thread faces which span approximately 90 degrees each and are diametrically opposed. They differ only in that one segment 18 i will form one thread of the double lead thread and 18 ii will form the other thread. There is also a similar relationship for lower thread faces 19 i and 19 ii.
The two-lamina assembly of FIG. 4 illustrates how the laminae are stacked to form full threads. On stacking the laminae, the orientation holes 1 2A are rotated about the threaded axis by either 90 degrees or 270 degrees to be in alignment with orientation holes 12B of the adjacent lamina. When the laminae are stacked thusly, the paired helix faces 13 are in contact and a complete thread segment is formed by the marriage of the upper thread face 18 i and the lower thread face 19 i. Likewise, another complete thread segment is formed comprising upper thread face 18 ii and lower thread face 19 ii. This second thread is diametrically opposed to the first and forms the other thread of the double lead thread.
This disclosure is also applicable to a lamina with triple lead threads, quadruple lead threads, and so on. In each case, the lamina would have twice the number of thread segments as the number of thread leads, and the stacking increment angle would be 360 degrees divided by the number of thread segments.
Referring once again to FIG. 1, it is apparent that the lamina itself, as well as the elements of the thread, can be formed by stamping, punching or injection molding material, typically metallic in nature. However, it is envisioned that fastening devices according to this disclosure can be fabricated from a variety of other materials including plastics and composites. Clearly, any material that is malleable enough to be formed into the desired shape can be employed to advantage in manufacturing laminated fasteners. Also sheet materials can be plated for corrosion resistance either prior or subsequent to forming. Since there are no thread roots in a laminated nut, there is less susceptibility to chemical action or embrittlement from plating residues at these locations.
Whether manufacturing the laminae by die-cast stamping, pressure forming or injection molding, it is apparent that all aspects of the lamina, including the shape, orientation holes and thread elements can be formed in one quick operation. The thread elements will typically include a helix plane 13 which will spiral upward and be supported or banked by an increasingly elevated ramp-up 17. The gradual elevation of the helix plane 13 follows the helix of the thread. The opposite side of the helix plane 13, as depicted in FIG. 1, is the root plane 14, which is adjacent the lower thread face 19. The lower thread face is paired with a diametrically situated upper thread face 18. Chambers 21 ease assembly and manufacture.
Not only is the threaded lamina, formed according the present disclosure, easier and less expensive to fabricate, it has been observed that formed threads are stronger than cut threads. The threaded aspect of the lamina can also contain additional features such as locking ramps, which can be coined anywhere on the face of the lamina, including areas which would not be accessible on traditionally tapped or rolled-thread nuts.
It has also been observed that laminated fastening devices have their own locking features. By torquing the topmost laminae, while holding the lower ones stationary, a laminated nut will twist then jam within itself, thus eliminating the need for a jam nut or lock washer in a locking-desired situation. And furthermore, by manufacturing the laminae with slight dishing curvatures, the nuts will be spring-like and self-locking, a valuable feature when encountering vibration. It should also be apparent that the assembled fastener made according to the teaching of this specification is compatible with and can be used in conjunction with sealing devices such as specially treated or coated washers and the like. These sealing devices can also manifest themselves as rubber, plastic or other compressible materials frequently seen in an annular configuration within and surrounded by a traditionally configured washer.
It should also be apparent that the assembled fastener made according to the teaching of this specification can be used with standard hand wrenches and power tools to replace and in lieu of conventional internally threaded fasteners.
All of the foregoing features and variations can be appreciated and realized when fabricating threaded fasteners from laminae formed according to the instant disclosure. And while the foregoing is a complete and detailed description of the preferred embodiments of the disclosed device, other variations and modifications may also be employed to implement the purpose of the invention; and, therefore, the instant elaboration should not be assumed to limit the scope of the invention which is intended to be defined by the following claims. | An internally threaded fastener assembled from formed laminae can be inexpensively and efficiently produced from a variety of materials in a multi-staged, die-operated, drawing press. Each lamina has an internal bore with less than one full thread form at the helix plane and is designed to be stacked in an aligned, alternating arrangement to provide full thread rotations along the interior of the assembled fastener. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to amusement devices and more particularly pertains to a new Two Person Rotating Amusement Apparatus for primarily entertaining children.
2. Description of the Prior Art
The use of amusement devices is known in the prior art. More specifically, amusement devices heretofore devised and utilized are known to consist basically of familiar, expected and obvious structural configurations, notwithstanding the myriad of designs encompassed by the crowded prior art which have been developed for the fulfillment of countless objectives and requirements.
Known prior art includes U.S. Pat. No. 5,203,827; U.S. Pat. No. 5,236,248; U.S. Pat. No. 5,199,933; U.S. Pat. No. 4,004,468; U.S. Pat. No. 4,450,733 and U.S. Pat. No. Des. 307,166. These devices are directed towards exercise bicycles, pedals for bicycles, and associated bicycle apparatus. None of these references, however, teach an amusement apparatus as set forth herein which is specifically designed solely for amusement purposes.
While these devices fulfill their respective, particular objectives and requirements, the aforementioned patents do not disclose a new Two Person Rotating Amusement Apparatus. The inventive device includes a support frame with handle bars attached thereto, a flywheel supported by the frame and driven by a drive sprocket, and large platforms secured to the drive sprocket. The surface of each platform is large enough to support both feet of a person thereon, and the handle bars are configured such that each person is able to grasp a portion thereof.
In these respects, the Two Person Rotating Amusement Apparatus according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of entertaining children.
SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of amusement devices now present in the prior art, the present invention provides a new Two Person Rotating Amusement Apparatus construction wherein the same can be utilized for primarily entertaining children.
The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new Two Person Rotating Amusement Apparatus apparatus and method which has many of the advantages of the amusement devices mentioned heretofore and many novel features that result in a new Two Person Rotating Amusement Apparatus which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art amusement devices, either alone or in any combination thereof.
To attain this, the present invention generally comprises a support frame with handle bars attached thereto, a flywheel supported by the frame and driven by a drive sprocket, and large platforms secured to the drive sprocket. The platforms are large enough to support both feet of a person on each platform, and the handle bars are configured such that each person is able to grasp a portion thereof. One person stands on each platform and holds onto the handle bar, and by cooperative effort cause the drive sprocket to rotate, thus rotating the flywheel. The riders will therefore move up and down and in a circular path on the platforms, aided by the inertia of the flywheel.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and which will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
It is therefore an object of the present invention to provide a new Two Person Rotating Amusement Apparatus apparatus and method which has many of the advantages of the amusement devices mentioned heretofore and many novel features that result in a new Two Person Rotating Amusement Apparatus which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art amusement devices, either alone or in any combination thereof.
It is another object of the present invention to provide a new Two Person Rotating Amusement Apparatus which may be easily and efficiently manufactured and marketed.
It is a further object of the present invention to provide a new Two Person Rotating Amusement Apparatus which is of a durable and reliable construction.
An even further object of the present invention is to provide a new Two Person Rotating Amusement Apparatus which is susceptible of a low cost of manufacture with regard to both materials and labor, and which accordingly is then susceptible of low prices of sale to the consuming public, thereby making such Two Person Rotating Amusement Apparatus economically available to the buying public.
Still yet another object of the present invention is to provide a new Two Person Rotating Amusement Apparatus which provides in the apparatuses and methods of the prior art some of the advantages thereof, while simultaneously overcoming some of the disadvantages normally associated therewith.
Still another object of the present invention is to provide a new Two Person Rotating Amusement Apparatus for primarily entertaining children.
Yet another object of the present invention is to provide a new Two Person Rotating Amusement Apparatus which includes a support frame with handle bars attached thereto, a flywheel supported by the frame and driven by a drive sprocket, and large platforms secured to the drive sprocket. The platforms are large enough to support both feet of a person on each platform, and the handle bars are configured such that each person is able to grasp a portion thereof. One person stands on each platform and holds onto the handle bar, and by cooperative effort cause the drive sprocket to rotate, thus rotating the flywheel. The riders will therefore move up and down and in a circular path on the platforms, aided by the inertia of the flywheel.
Still yet another object of the present invention is to provide a new Two Person Rotating Amusement Apparatus that is simple is design and easy to use.
Even still another object of the present invention is to provide a new Two Person Rotating Amusement Apparatus that keeps children entertained for hours at a time.
These together with other objects of the invention, along with the various features of novelty which characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated preferred embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a side view of a new Two Person Rotating Amusement Apparatus according to the present invention.
FIG. 2 is a front view thereof.
FIG. 3 is a cross sectional view taken along line 3--3 of FIG. 2.
FIG. 4 is a cross sectional view taken along line 4--4 of FIG. 1.
FIG. 5 is an exploded view of a pedal cover assembly.
FIG. 6 is a view of an alternate embodiment of the handle bars.
FIG. 7 is a view of another embodiment of the handle bars.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to the drawings, and in particular to FIGS. 1 through 7 thereof, a new Two Person Rotating Amusement Apparatus embodying the principles and concepts of the present invention and generally designated by the reference numeral 10 will be described.
More specifically, it will be noted that the Two Person Rotating Amusement Apparatus 10 comprises a support frame 20, an apparatus 30 for causing and maintaining rotation, and handle bars 60 attached to the frame 20.
As best illustrated in FIGS. 1 through 7, it can be shown that the support frame 20 comprises two spaced, front support bars 21,22 extending upward at an angle from a front support plate 23. The front support plate 23 supports the front of the frame on a floor or other flat ground. A rear support bar 24 extends at an angle upward from a rear support plate 25, and its opposite end is disposed between the front support bars 21,22 and appropriately attached thereto, such as by welding. The frame should be designed so as to stabily support the weight of at least two adolescent children.
The apparatus 30 includes a flywheel 31 supported for rotation between the bars 21,22 on an axle 32. The axle 32 is supported in the bars 21,22 for rotation relative thereto, such as by ball bearings. The axle 32 also includes a small gear 33 fixed thereto, such that when the gear 33 is rotated, the flywheel 31 simultaneously rotates. A flywheel diameter of about 20 inches has been found to work well in the apparatus 10.
Drive sprocket gear 34 is affixed to axle 35, which is rotationally supported by the rear support bar 24, such as with ball bearings. A drive chain 36 extends between the gear 34 and the gear 33, such that rotation of the gear 34 causes the gear 33 and the flywheel 31 to rotate. The ratio between the diameter of gear 34 and the diameter of gear 33 is, for instance, 3:1, to provide sufficient rotation of the flywheel. A guard 37 encloses the flywheel, gears 33,34, and chain 36, to prevent contact with these items during use. Although the drive apparatus 30 is described as using gears 33,34 and a chain 36, it should be recognized that other driving connections could be used, such as drive pulleys connected by an endless belt.
Pedal means 40 are connected to opposite ends of the axle 35 for causing driving rotation of the gear 34. Each pedal means 40 comprises a crank arm 41 attached at one end to the axle, and a platform 42 attached to the other end of the crank arm. The platforms 42 are preferably oversized when compared to the pedals normally used on bicycles and stationary exercise bikes. For instance, the platforms are preferably about 7.5 inches from its inner end to its outer end, and about 6 inches from front to back. This size provides sufficient area for a person, especially children, to stand comfortably on each platform.
As illustrated in FIGS. 1-2, the platforms 42 are directly attached to the crank arms by means known in the art. The platforms 42 include a rigid guard flange 43 extending from a top surface of each platform, adjacent to the crank arms 41. The flanges 43 prevent the riders feet from contacting the crank arms 41 and the guard 37. The platforms also include a weight 44 attached to a bottom surface thereof having a weight sufficient to maintain the platforms in a substantially horizontal position. The top surface of each platform can also include a non-slip cover or pad attached thereto, such as a rubber pad, to prevent riders feet from slipping off of the platforms.
Instead of being directly connected to the crank arms, platforms can be used which are disposed over normal sized pedals (not shown). As illustrated in FIG. 5, such platforms take the form of an oversized, solid pedal cover 42a having a recess 45 (illustrated in dashed line) in a bottom surface of the cover 42a which is sized to receive a pedal of the size normally used on bicycles and exercise bikes. The recess 45 is preferably oversized relative to the average pedal, in order to accommodate different sized pedals. The top surface of the pedal cover 42a also includes a guard 43a.
In order to retain the cover 42a on the pedal, securement plate 46 is provided. The plate 46 is sized to cover the recess 45 with the pedal therein, and permit attachment of the plate to the bottom of the cover 42a. The plate 46 includes a plurality of holes 47 through which extend threaded fasteners 48. The bottom of the cover 42a includes appropriately located threaded holes (not shown) for receiving the fasteners 48. Thus, the fasteners 48 securely attach the plate 46 to the bottom surface of the cover. The plate 46 also includes threaded holes 49 which receive bolts 50. Threaded jam nuts 51 are placed between the plate 46 and the head of the bolts 50. The bolts 50 are screwed into the holes 49 until the bolt ends contact the bottom of the pedal which is in the recess. The jam nuts 51 are then tightened to lock the bolts in place. By screwing the bolts 50 until they contact the bottom of the pedal, the cover 42a and plate 46 are rigidly secured to the pedal, preventing shifting and other movements of the cover 42a and plate 46 on the pedal. In addition, the bolts 50 and nuts 51 acts as weights to maintain the cover 42a substantially horizontal. Rubber non-slip pad 52 is secured to the top of the cover 42a, such as by adhesives, in order to prevent slipping of riders feet on the cover 42a.
The handle bar 60 is secured to the distal ends of the front support bars 21,22. As illustrated in FIG. 2, the bar 60 is a single, elongated member having enlarged gripping surfaces 61,62 at each end of the bar. The surfaces 61,62 are sized such that two hands can comfortably grip each surface. The surfaces 61,62 can be covered with a non-slip covering, such as handle bar tape or a rubber-type cover.
Instead of a single bar, two unconnected bars 63,64 can be used, as is shown in FIG. 6. One bar 63 is connected to the end of the support bar 21 while the other bar 64 is connected to the support bar 22. Bar 63 includes two gripping surfaces 65, and bar 64 also includes two gripping surfaces 66. Therefore, a rider standing on one platform can grip the surfaces 65 of bar 63 with each hand, while the other rider grips the surfaces 66 of bar 64. Plate 67 preferably extends between the bars 21,22, in order to stiffen the bars at this end since the handle bars 63,64 are unconnected. The plate 67 also provides a handy location for placing logos, such as a manufacturers logo. In order to make it easier for a rider to grasp the handle bars, the bars 63a,64a can be angled such that the outer ends are angled backward towards the rider, as illustrated in FIG. 7.
In use, one rider stands on one of the platforms, while a second rider stands on the other platform. By cooperative effort, the riders cause the platforms, crank arms and sprocket to rotate, similar to a bicycle. This causes the flywheel to rotate, due to the chain and flywheel gear. Thus the riders move in a circular path, both up and down and front and back on the apparatus. Due to the size and mass of the flywheel, motion is easily maintained once it is started.
As to a further discussion of the manner of usage and operation of the present invention, the same should be apparent from the above description. Accordingly, no further discussion relating to the manner of usage and operation will be provided.
With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the invention, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present invention.
Therefore, the foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A new Two Person Rotating Amusement Apparatus for primarily entertaining children. The inventive device includes a support frame with handle bars attached thereto, a flywheel supported by the frame and driven by a drive sprocket, and large platforms secured to the drive sprocket. The platforms are large enough to support both feet of a person on each platform, and the handle bars are configured such that each person is able to grasp a portion thereof. One person stands on each platform and holds onto the handle bar, and by cooperative effort cause the drive sprocket to rotate, thus rotating the flywheel. The riders will therefore move up and down and in a circular path on the platforms, aided by the inertia of the flywheel. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an optical disc drive and its control method and in particular, to a servo control method and an optical disc drive appropriate for implementing the control method.
2. Description of the Related Art
A conventional optical disc drive usually uses a servo signal processor circuit (hereinafter, referred to as an SSP) as hardware for carrying out a servo processing. An error signal outputted from an optical unit is supplied to the SSP so as to be compared to a target value and a difference between the error signal and the target value is corrected for carrying out the servo processing. FIG. 8A is a block diagram showing configuration example of an optical disc drive for carrying out such a servo processing with hardware.
Referring to FIG. 8A, according to a reproduction signal read out from an optical disc 1 by an optical unit 2 , an RF circuit 4 creates a servo signal and an SSP 6 carries out a servo processing via a driver circuit 3 such as a focus servo, tracking servo, sled servo, and spindle servo. A microcomputer 5 carries out a system control such as a servo control sequence, disc information management, key-in information fetch, display control, and other system control.
The SSP 6 for the servo processing is constituted by hardware for carrying out the servo processing in parallel processing method. In this case, a filter calculation for determining a control amount for correcting the aforementioned difference between an error signal and a target value is carried out by combining an fs process with an 1/n fs process. The fs process is carried out for each sampling frequency (hereinafter, referred to as fs), and the 1/n fs process is carried out 1/n times of the sampling frequency. That is, a focus servo and a track servo need be controlled at a high speed, whereas a spindle servo need not be controlled at such a high speed as the focus and tracking servo. Accordingly, as shown in FIG. 9, the calculation amount varies depending on the sampling timing as follows: only an fs processing, or an fs processing in combination with a ¼ fs processing, or an fs processing in combination with a ¼ fs processing and ⅛ fs processing, and the like.
It should be noted that for carrying out a servo processing through hardware, there is also an optical disc drive using the SSP 6 and the microcomputer 5 which are made as a unitary block. In this case also, the system control of the servo control is carried out by the microcomputer portion and the servo processing is carried out by hardware.
In the optical disc drive shown in block diagrams of FIG. 8 A and FIG. 8B, the SSP 6 is hardware for carrying out a servo processing in a parallel processing method. However, it is desired to perform the servo processing with microcomputer software. If the servo processing is carried out by software, it becomes easy to modify the filter form such as the calculation order and calculation amount for general purpose. For example, a CD has been the main optical disc widely used, but recently new discs such as a PD (private disc, writable CD) and DVD (digital versatile disc) have been developed and are now in use. A servo processing through software would enable a single servo LSI to be used for various types of media.
However, if the servo processing which has been conventionally carried out by hardware is simply transferred to a microcomputer software, it is necessary to employ a microcomputer having a considerably high speed. This is because the processes carried out in parallel in the conventional hardware need be carried out in series in software, requiring a long calculation time at once. Moreover, as shown in FIG. 9, down sampling processes are concentrated in a particular sampling timing, and the time required for calculation greatly varies depending on the sampling timing.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a servo control method in which a servo processing load per one sampling is averaged to reduce the maximum calculation amount. This enables to obtain a servo control and a system control at a sufficiently practical speed even by using a microcomputer having a comparatively low speed, and an optical disc drive apparatus appropriate for implementing the servo control method.
The present invention provides an optical disc drive apparatus for carrying out a servo processing and system control by software using a microcomputer. Moreover, the present invention provides an optical disc drive control method characterized in that an interrupt is generated at a servo processing sampling period for carrying out a digital servo processing, and the remaining time is used for carrying out a system control.
In a servo processing of the optical disc drive according to the present invention, down sampling processes are not concentrated at a particular sampling timing. That is, the down sampling processes are classified according to the sampling frequency and the function (such as focus and tracking). Head addresses of the classified down sampling processes are stored in a servo table which will be detailed later with reference to FIG. 5 . Using this servo table and a counter value which is incremented by each sampling, a sampling process to be performed is selected from the servo table each sampling timing (step 22 in FIG. 6 ).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a block diagram showing a configuration of an optical disc drive apparatus according to a first embodiment of the present invention; and
FIG. 1B is a flowchart showing a servo processing according to the first embodiment of the present invention.
FIG. 2A shows servo processing processes distributed to respective sampling timings according to the first embodiment; and
FIG. 2B shows conventional hardware servo processes simply expressed for microcomputer software.
FIG. 3 shows calculation amounts required at respective sampling timings according to the first embodiment.
FIG. 4 shows creation of a servo table according to a second embodiment of the present invention.
FIG. 5 shows contents of the servo table.
FIG. 6 is a flowchart showing a servo processing according to the second embodiment.
FIG. 7 shows calculation amounts required at respective sampling timings in the servo processing according to the second embodiment.
FIG. 8A is a block diagram showing a configuration of a conventional optical disc drive apparatus in which a servo processing is performed by hardware; and
FIG. 8B shows a variation of the conventional optical disc drive apparatus.
FIG. 9 shows calculation amounts required at respective sampling timings when a servo processing conventionally performed by hardware is to be performed by microcomputer software.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Description will now be directed to embodiments of the present invention with reference to the attached drawings. Firstly, explanation will be given on a distribution of down sampling processes according to a first embodiment. FIG. 1A is a block diagram showing an optical disc drive apparatus according to the first embodiment, and FIG. 1B is a flowchart of a servo processing according to the first embodiment. Referring to FIG. 1, in the first embodiment, a timer 51 of a microcomputer 5 is used to generate an interrupt in one sampling timing so that a servo process is carried out within the interrupt processing. That is, as shown in FIG. 1B, down sampling processes are classified according to the sampling frequency in such a manner that one down sampling process is executed in each sampling timing. Thus, the calculation amounts of respective sampling timings are averaged, reducing the microcomputer load.
FIG. 2 shows a distribution of down sampling calculation amounts according to the first embodiment (FIG. 2A) in comparison to a case (FIG. 2B) in which the servo processing conventionally carried out by hardware is simply transferred to a microcomputer software. As can be seen from FIG. 2, in the present embodiment, down sampling processes are distributed evenly for each sampling timing, averaging the calculation amounts required in each sampling timing. On the contrary, in the case of simple transfer to a microcomputer software, a number of down sampling processes are concentrated in a particular sampling timing, greatly increasing the calculation amount.
Referring back to FIG. 1B, according to the present embodiment, a counter value of a counter incremented by each fs (step 10 ) is used to check whether to execute a down sampling process by referencing less significant bits (step 11 ). For example, when check is made whether to execute a ¼ fs down sampling process, i.e., a process which is executed once in four sampling timings, the least significant two bits are referenced. In a case of {fraction (1/512)} fs process, the least significant 9 bits are referenced (AND-ed).
In order to prevent overlap of more than one down sampling processes within one sampling timing, an appropriate correction value (a negative integer) is added to the aforementioned referenced value. If the referenced value is 0, the down sampling process is executed. Otherwise, control is passed to check whether to execute a following down sampling process (step 12 ). For example, for a ¼ fs process, the least significant 2 bits are referenced, and for a ⅛ fs process, the least significant 3 bits are referenced. In this case, if the counter value is 8 for example, both of the ¼ fs process and the ⅛ fs process are to be executed because the least significant 3 bits are 0. To prevent such an overlap, a correction value inherent to respective down sampling processes is added to the counter value. If 0 is the correction value for a ¼ fs process and −1 for a ⅛ fs process, then the ¼ fs process is executed when the least significant 2 bits are 0 and the ⅛ fs process is executed when the least significant 3 bits are 1. Thus, it is possible to prevent overlap of a plurality of processes.
In steps S 14 and after, the same down sampling process check is carried out as in the ¼ fs and ⅛ fs processes. That is, when a check is made for a down sampling process of ½ n fs, a counter value is used to reference the least significant n bits, to which a corresponding correction value (negative integer) is added. If the resultant value is 0, the down sampling process is carried out. Otherwise, control is passed to check a following down sampling process (½ n+1 fs process).
FIG. 3 shows the calculation amounts at respective sampling timings according to the present embodiment. As is clear from FIG. 3, the calculation amount varies depending on the sampling timing. This is because the execution check is carried out in the descending order of the sampling frequency. As the sampling frequency decreases, the number of checks is increased. That is, a branching 92 , i.e., a referencing of a sampling counter value at the head of each down sampling process to decide whether to perform the down sampling process is repeated an increased number of times as the sampling frequency is decreased. However, if FIG. 3 is compared to FIG. 9, it is clear that the calculation amount is more dispersed (less concentrated) in the present embodiment.
Next, description will be directed to a second embodiment of the present invention. In this embodiment, down sampling processes are distributed by using a servo table. In this embodiment also, the timer 51 of the microcomputer 5 in FIG. 1 is used to generate an interrupt at each sampling timing so that a servo process is carried out within the interrupt processing. FIG. 4 shows a table data creation procedure. Referring to FIG. 4, down sampling processes are arranged in the descending order of the sampling frequency (step 30 ).
Note that there are left timings when no down sampling processes are executed. This is because down sampling cycle is normally ½ n fs, and no down sampling processes are carried out at a timing such as 1/(2 n +1) fs for example. To utilize such sampling timings, the down sampling processes are further classified according to the functions such as focus and tracking, so that one of the functions is carried out in such a timing left. This classification according to the function is made into two groups (step 31 ). If the classification is carried out into three groups, there will arise a timing when a down sampling process of that frequency is concurrent with a down sampling of a lower frequency. For example, when carrying out ¼ fs, ⅛ fs, and {fraction (1/16)} fs down sampling processes, if the ¼ fs processes are divided into three groups, as shown in a left column of Table 1 below, there will arise a timing when a ⅛ fs process or {fraction (1/16)} process is overlapped with a ¼ fs process. That is, the ⅛ fs process or the {fraction (1/16)} process cannot be divided into two or more groups. Even if they are divided into two or more groups, a down sampling process having a frequency lower than {fraction (1/16)} fs cannot be divided at all.
TABLE 1
0
¼ fs (1)
¼ fs (1)
1
¼ fs (2)
¼ fs (2)
2
¼ fs (3)
⅛ fs (1)
3
⅛ fs
⅛ fs (2)
4
¼ fs (1)
¼ fs (1)
5
¼ fs (2)
¼ fs (2)
6
¼ fs (3)
{fraction (1/16)} fs (1)
7
{fraction (1/16)} fs
{fraction (1/16)} fs (2)
8
¼ fs (1)
¼ fs (1)
9
¼ fs (2)
¼ fs (2)
10
¼ fs (3)
⅛ fs (1)
11
⅛ fs (2)
12
¼ fs (1)
¼ fs (1)
13
¼ fs (2)
¼ fs (2)
14
¼ fs (3)
15
More specifically, a ¼ fs process is repeated at a periodicity of Execution-Nope-Nope-Nope. If ¼ fs processes are divided into two groups, i.e., ¼ fs (1) and ¼ fs (2), the servo table will repeat a sequence of four successive sampling timings assigned for ¼ fs (1), ¼ fs (2), other process, other process. If the ⅛ processes are also divided into two groups, the servo table will repeat a sequence of eight successive sampling timings assigned for ¼ (1), ¼ (2), ⅛ (1), ⅛ (2), ¼ (1), ¼ (2), other process, other process. Thus, the servo table has a periodicity in the contents (step S 32 ), leaving timings not assigned for any process. Such timings are utilized to check whether to execute a down sampling process of a lower sampling frequency (steps S 33 and S 34 ). This enables to create a servo table as shown in FIG. 5 .
FIG. 6 is a flowchart showing the second embodiment. In the second embodiment, a head address of a down sampling process contained in the servo table is used as a base address in combination with an offset address, i.e., a counter value incremented by each sampling (step 10 ). The base address is added to the offset address to determine a physical address containing a head address of a down sampling process to be executed (step S 21 ). After this, an unconditional branching is executed to the physical address determined (step S 22 ) for executing the down sampling process.
FIG. 7 shows calculation amounts for the respective sampling timings according to the second embodiment. In comparison to FIG. 3 where the branching time varies depending on the sampling timing, FIG. 7 shows that the branching using the servo table can be performed with an almost identical calculation amount regardless of the sampling timing. Moreover, by distributing the down sampling processes for the respective sampling timings, it is possible to average the calculation amount per one sampling as well as to reduce the number of sampling timings not assigned for any down sampling process.
As has been described above, according to the present invention, down sampling processes are distributed for respective sampling timings so as to average the calculation amount at each sampling timing and reduce the maximum calculation amount at one timing. Thus, the present invention enables to perform a servo processing using microcomputer software while preventing an increase of the calculation time per sampling. This enables to assure a practical processing speed even with a microcomputer not having a high speed.
The invention may be embodied in other specific forms without departing from the spirit or essential characteristic thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.
The entire disclosure of Japanese Patent Application No. 09-307211 (Filed on Nov. 10, 1997) including specification, claims, drawings and summary are incorporated herein by reference in its entirety. | The present invention provides an optical disc drive apparatus comprising: an optical unit ( 2 ) for reading out a data recorded on an optical disc ( 1 ) from a position specified by a servo signal; a signal processor ( 4 ) for calculating and amplifying the data which has been read out by said optical unit ( 2 ); a microcomputer ( 5 ) provided with software for performing a calculation for a servo processing and a system control according to an output signal from said signal processor ( 4 ); and a servo driver ( 3 ) for performing a servo processing via said optical unit according to an output signal from said microcomputer. | 6 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 09/867,263, filed May 30, 2001 now U.S. Pat. No. 6,553,563, which is a continuation of PCT Application No. PCT/US99/28427, filed Nov. 30, 1999, which claims the benefit of U.S. Provisional Application No. 60/110,416, filed Nov. 30, 1998, which are hereby incorporated in their entirety by reference.
FIELD OF THE INVENTION
The method, and system of our invention relate to client server systems, and especially to development tools, methods and systems that build upon functions, routines, subroutines, subroutine calls, or object oriented programming.
BACKGROUND OF THE INVENTION
Programming paradigms built upon such concepts as functions and function calls, subroutines and subroutines and subroutine calls, global variables and local variables, and object orientation are characterized by such features as “reusable code”, and “inheritance.”
In older languages, such as FORTRAN and BASIC, reusability and inheritance were obtained through crafting of functions, routines, and subroutines that were called through global variables in a main program. Subsequently, this has evolved into object oriented programming in such languages as C++ and Java and is built upon a programming paradigm foundation of objects, functions, and class data types. An “object” is a variable that has “functions” associated with it. These functions are called “member functions.” A “class” is a data type whose variable are “objects.” The object's class, that is, the type of the object, determines which member functions the object has.
In a modern, object oriented programming language, such as C++ or Java, the mechanism to create objects and member functions is a “class.” Classes can support “information hiding” which is a critical part of modern program design. In “information hiding”, one programming team may design, develop, and implement a class, function, routine, or subroutine while another programming team may use the new class, function, routine, or subroutine. It is not necessary for the programmers who use the class, function, routine, or subroutine to know how it is implemented.
To be noted is that “object oriented programming” uses the terms “public” and “private” while the older techniques use the terms “global” and “local” for the domain of variables.
One aspect of both paradigms is “code reusability,” whether implicitly by the subroutine or function calls of FORTRAN and the like or explicitly by declaring variables in C++ or JAVA.
There is an especially strong need for a development environment, including development tools, and either functions, routines, and subroutines with global and local variables, or base classes, to allow end users to develop business applications customized to their needs and derived from the supplied functions, routines, and subroutines with global and local variables, or base classes.
SUMMARY OF THE INVENTION
The method and system of our invention is an application development environment. It is designed to meet the customization needs of demanding sales, marketing, and customer service information system deployments.
One embodiment of our invention is a system for customizing an application program. The system includes a plurality of reusable modules (characterized as “base” modules in object oriented programming literature and as functions, routines and subroutines in other programming paradigms) for incorporation into end-user derived modules (characterized as “derived” in object oriented programming literature). At least one of the reusable modules has a set of variables accessible by an end-user (“public” in object oriented programming and “global” in conventional programming) and a set of variables not accessible by the end-user (“private” in object oriented programming and “local” in conventional programming). When a derived module incorporates a reusable module, the derived module inherits attributes of the reusable module.
A further aspect of our invention is the provision of a graphical editor for modifying and managing software modules, and an object visualization editor for graphically representing relationships between modules and variables within modules. A further aspect of our invention is the provision of one or more applet designer modules for doing one or more of modifying and extending lists, forms, dialogs, and chart user interfaces. The system can also include one or more view designer modules for visually modifying existing views, as well as wizard modules for creating end user created modules. In one embodiment of our invention at least one of the wizard modules provides an enumeration of required end-user entries for an end user module, this being in response to an end-user entry of the type of end-user created module to be created.
A directory or module repository manager may be provided to allow only one end-user to modify a module at one time.
Depending on the underlying source code, the system of the invention may include a compiler or translator for incremental compilation or translation of end user created modules.
In a preferred embodiment the system of our invention includes one or more interfaces for accessing data and rules from external applications.
In still another embodiment, especially useful for spreadsheet or database applications, the system includes database extension modules for extending a database and to capture data from new fields in one or more of application screens, and external sources. In a particularly preferred embodiment, the database extension modules may contain modules for triggering updates to client applications that reflect and incorporate new database extensions, and for reflecting new columns in existing end user created modules.
A further aspect of the system of our invention is the provision of modules for notification of conflicts between new end user created modules and existing modules. These modules may be incorporated in the translator or compiler, or in an index to the repository.
A further aspect of our invention is a method having for customizing an application program. This method works with the system of the invention, summarized above, and includes the steps of modifying and managing the end user created modules through a graphical editor; and graphically representing relationships between modules and variables within modules.
A further aspect of the method of our invention is doing one or more of modifying and extending lists, forms, dialogs, and chart user interfaces. Another aspect of our invention is visually modifying existing views.
Another aspect of the method of our invention is creating end user created modules using wizard modules. This may include the additional step of providing an enumeration of required end-user entries for an end user created module in response to an end-user entry of the type of end-user derived module to be created.
Yet another aspect of our invention is storing derived (that is, end user created) modules in a derived module repository manager. This is to allow only one end-user to modify a software module at one time.
A still further aspect of our invention is incrementally compiling a derived module.
Another aspect of our invention is accessing data and rules from external software applications through interfaces.
Another aspect of our invention is extending or scaling a database, that is, modifying its metadata and/or schema, to include new fields and capturing data from new fields in one or more of application screens, and external sources. A further aspect of this is triggering updates to client applications that reflect and incorporate new database extension, as well as reflecting new columns in existing end user created modules.
A further aspect of our invention is providing notification of conflicts between end user created modules and existing modules.
The software development method and system of our invention utilizes a suite of tools that serve as the bases for “reusability”, whether implicitly or explicitly. This enables developers to rapidly configure all aspects of the underlying application software, including the look-and-feel, behavior, and workflow, without modifying application source code, SQL, or base classes. The sophisticated repository management capabilities of the method and system of our invention allows teams of developers work efficiently on configuring applications.
The suite of conventional and object oriented development tools includes a business object designer; a Microsoft Visual Basic-like scripting language, a set of business object interfaces, a Database Extension Designer, and an Application Upgrader.
The application upgrader provides an automated process to upgrade the customizations to future product releases thus protecting the investment in customization. The ease, comprehensiveness, scalability, and upgradeability of the customization process help reduce the total lifecycle cost of customizing enterprise applications.
To be noted is the difference between declarative programming and procedural programming. Declarative programming allows developers to control the behavior of a class by merely setting attribute values, that is, set the property color=black, instead of writing a line of code to set the color the color to black. This may be accomplished under either paradigm.
Also to be noted is that the meta-data repository that contains configuration and customization information can serve to separate this configuration and customization data from the application source code. By this expedient, developers and end-users can configure these objects in an intuitive and easy manner that is less prone to error.
THE FIGURES
The method and system of our invention may be understood by reference to the Figures appended hereto.
FIG. 1 illustrates a screen shot of a Business Component definition.
FIG. 2 illustrates a screen shot of details of a Business Component definition.
FIG. 3 illustrates a screen shot of features of the Applet Designer.
FIG. 4 illustrates a screen shot of features of the view.
FIG. 5 illustrates a screen shot of aspects of the editor and debugger.
FIG. 6 illustrates a screen shot of the components of the application upgrader.
DETAILED DESCRIPTION OF THE INVENTION
Using the method and system of our invention, teams of developers can work together cooperatively, to rapidly customize all aspects of software applications without modifying application source code, SQL, or vendor supplied base classes (referred to herein as “business objects”). This approach to customization results in dramatically lower development and maintenance costs, and provides seamless upward compatibility with future product releases.
The components of the development tool include:
1. A business object designer 2. A language, such as Microsoft Visual Basic, Microsoft Visual C++, Microsoft Visual J++ or the like. 3. Business object interfaces 4. A Database Extension Designer 5. An Application Upgrader
Business Object Designer
The business object designer gives developers the ability to quickly and easily customize software applications. It includes a business object explorer. This is a graphical editing tool for modifying and managing object definitions. It includes a hierarchical object explorer that allows developers to browse the various object types, an object list editor viewing and editing object definitions, and a properties window for editing object property values. The business object explorer also includes a Windows-style “Find” capability that allows developers to quickly locate objects in the repository.
Object Visualization Views
The Object Visualization Views are a set of graphical representations of the relationships between the various object definitions in the business object repository that help simplify the configuration process. A typical application configuration contains thousands of objects. Developers can use these views to understand and navigate through the object hierarchies. Then, using the editing tools, they can modify the properties of these objects. These views help assess the impact of these modifications, and track down configuration errors. The visualization views can be printed and used as a valuable reference during configuration. FIG. 1 illustrates a screen shot of a Business Component definition, 1 , with an objects field, 11 , a field indicating the source and type of components, 12 , and a field indicating the actions to be taken with respect to a component, 13 , while FIG. 2 illustrates a screen shot of the details of a Business Component definition 2 with the account object explorer, 21 , the account external products, 22 , and the object attributes, 23 . It depicts the various Fields in the Business Component, their types, and points to their respective sources—either Columns in underlying database tables, or Fields in other Business Components. A developer can further introspect the properties of an object in this view, by using the Properties window. The other Visualization Views work similarly. The Hierarchy View describes the object hierarchy as it relates to the selected object, i.e., the Objects used by the selected Object and the Objects that use it. For example, the Hierarchy View for a View Object will show the Applets contained in that View, the Business Components on which each of these Applets are based, the Screens and Applications in which this View appears.
Applet Designer
The Applet Designer module is an intuitive drag-and-drop visual programming interface for modifying and extending list, form, dialog, and chart user interface objects (Applets). These objects can be populated with standard Windows controls, including buttons, combo boxes, check boxes, labels, and text fields, as well as ActiveX controls. The Applet Designer of the method and system of our invention leverages the familiarity of developers with popular graphical application development tools such as Microsoft Visual Basic. Features of the Applet Designer 3 are illustrated in FIG. 3 . These include the object explorer, 31 , and the applet being designed or modified, 32 . An account information form is being designed in block 32 .
The developer can add, delete, and modify the properties of the controls. The controls can be configured using the Properties Window. For example, a control can be associated with a Field in the underlying Business Component. This is accomplished by setting the Field attribute of the Control to one of the Fields in the Business Component. The choice of Fields is limited to those that belong to the Business Component that the Applet is based on. The behavior of controls can be scripted using the Visual Basic or other script editor. The Applet Designer also helps ensure visually accurate and correctly translated configurations by providing a design-time preview of the Applet on various screen resolutions, and under different language settings. In this mode, the Applet designer simulates the Applet being viewed under the specified settings and allows the developer to quickly detect any presentation errors such as truncation or overlapping controls. Features of the Applet Designer are illustrated in FIG. 3 .
View Designer
The view designer module of the development tool method and system of our invention allows developers to visually modify existing views and construct new views by simply dragging and dropping the desired Applets onto the view canvas. There is no additional specification or code required to define the relationships between the Applets. Most other application customization tools require developers to write significant amounts of code to achieve this same functionality. In the prior art, this code had to be replicated for each and every screen in the application. This was inefficient and error-prone. Features of the view designer 4 are illustrated in FIG. 4 . To create a View based on a specific Business Object, the developer is presented with a blank canvas with eight sectors and a window 41 containing the list of Applets that can be included in the View (based on the Business Object of the View). The desired Applets can then be simply dragged from the Applets window and dropped on the View canvas in the desired sector. The Applets may be resized at this point, if necessary. The underlying Business Components, and their context within the Business Object determine the relationships between the Applets in the View. Hence, these relationships do not need to be specified again in the definition of the View. They are simply re-used.
Menu Designer
The menu designer module of the development tool method and system of our invention allows developers to customize and extend Siebel menu structures using a visual metaphor. A menu can be created by adding menu items, defining the command to be executed when the menu is clicked, and specifying an accelerator key for easy navigation.
Object Wizards
The development tool method and system of our invention provides a set of Wizards to assist developers in the creation of new objects in the underlying repository. Examples of Wizards include a Form Applet Wizard, Chart Applet Wizard, List Applet Wizard, and Business Component Wizard. The user clicks on the type of the new object he or she wants to create, and the Wizard guides them through the entry of the properties needed for that type of object.
Typically, the graphical user interface guides the user through the various steps of creating an applet, such as selecting the business component that it is based on, the dimensions of the applet, the fields to be included, the buttons that appear in the applet, and the like. Wherever possible, the list of choices are restricted to only those that are applicable—Fields in the underlying Business Component, Projects that have been locked by the developer, etc. Once the developer has gone through the various screens in a wizard, a new Object is created based on the attributes specified. A default layout is generated for the type of Object being created. For example, for a Form Applet, Text box and Check box controls are created for each Business Component Field that is to be included in the Applet, depending on the data type of Field. Labels are also created right next to the Text boxes and Check boxes. All these controls are laid out in an aesthetically pleasing columnar layout.
Business Object Repository Manager
The business object repository manager of our invention provides application developers with an efficient multi-user development environment that includes access to check-in/check-out functionality and version control. In a typical development environment, there is a server repository that contains the master application definition. Each developer on the team has a local repository that the development tools method and system of our invention connects to. The various object definitions in the business object repository are grouped into Projects. Developers lock and check out projects from the server repository onto their local repositories in order to make changes to the object definitions. If another developer tries to check out the same Project, he/she is unable to do so, and is informed that the Project is locked. This prevents other developers on the team from modifying the same project. Once the developer has made the changes and tested them, the project can be checked into the server repository. Before checking in a project, the developer can review the changes that have been made thereby minimizing check-in errors. The check-in/check-out process can be integrated with an external version control system such as Microsoft Visual SourceSafe, PVCS, or ClearCase. This allows the development team to maintain a version history of all changes to the repository.
Business Object Compiler
This tool that is part of the development tool method and system of our invention allows developers to compile the repository or projects either completely or incrementally. Incremental compilation involves a compilation of only a subset of the Projects (typically those that have been modified). The definitions of objects in these Projects are the only ones that are updated. The remainder of the repository file is left untouched. This significantly speeds the development cycle of any project. The compiler generates a repository file that is used to run the underlying application. The storage of the application definition in the repository file is optimized for high-speed access and performance. This repository file is then deployed to the end-users of the application. The application executable reads the application definition from the repository file and instantiated objects based on their definitions stored in the repository file.
Programming Platform
The development tool method and system of our invention includes a development platform. For example, a Microsoft Visual Basic or Microsoft Visual C++ programming platform for integrating enterprise applications with third-party cooperative applications and extending the base functionality of the application screens and business components. In a preferred embodiment of our invention, the Visual Basic provides a Visual Basic-compliant environment that includes an editor, debugger, and interpreter/compiler. This allows application developers to extend and further configure applications. This capability may be integrated with the Applet Designer so developers can attach scripts to user interface element controls such as buttons, fields, and ActiveX controls. Business component behavior can also be further configured using the programming platform. FIG. 5 illustrates some aspects of the editor and debugger screen 5 . It includes the object explorer 51 and the object code view, 52 .
Business Object Interfaces
Not only can application developers extend applications with the development platform, e.g., Visual Basic, they can also use COM interfaces to access data from third-party applications, provide integration with legacy systems, and automate applications from other external applications. This allows developers to extend application behavior, provide client-side integration to other applications, and enable access to data and business rules from other programs that use Microsoft Visual Basic, Powerbuilder, Java, or ActiveX. COM interfaces expose selected objects to custom routines external from the applications. Developers can access these COM interfaces using a wide variety of programming languages.
Database Extension Designer
When developers require extensions beyond built-in database extensions, the database extension designer module of the method provides a point-and-click interface to extend application tables. Developers can use these database extensions to capture data from new fields in application screens, or from external sources using enterprise integration managers.
The database extension designer is integrated with the business object repository. The developer first defines the extensions in the repository and makes use of these extensions in Business Components and Applets. These changes are then applied to the local database by clicking on the Apply button. This causes the database schema of the local database to be updated. The developer then tests these extensions in the local environment. Once the testing is complete, the changes are checked into the server repository and made available to the rest of the team.
This process allows developers to make one set of changes that automatically triggers updates to client applications that reflect and incorporate the new database extension into mobile users' databases. These changes reflect the appropriate visibility rules for database extensions. New columns are automatically reflected in the business object repository and named appropriately to ensure easy migration to, for example, future releases of applications.
The database extension designer works with client-server applications to provide seamless integration of database extensions for mobile user databases. The database extension designer automatically applies database extension instructions to the server database and these extensions are automatically routed to mobile user databases via remote software distribution applications such as Siebel Remote. Changes take effect automatically the next time mobile users synchronize. The changes are “in-place.” so mobile users do not need to refresh or reinitialize their local database.
Application Upgrader
The application upgrader module of the method and system of our invention dramatically reduces the time and cost of version upgrades by allowing customers to better determine what changes are available with each release and compare unique object customizations from the prior release with changes in the new release. The application upgrader provides systems administrators with notification of conflicts between object customizations and new releases, automatically merges differences between object definitions, and allows administrators to manually override and apply any changes. This tool obviates the need to manually migrate changes from release to release and significantly reduces the total lifecycle cost of ownership of typical business applications as compared to traditional client/server applications. FIG. 6 illustrates the components of the application upgrader 6 of the method and system of our invention. The Application Upgrader screen has two views, an “Application Upgrades” view, 61 , and an “Object Differences” view, 62 , as well as a “Merge Repositories” choice box 63 .
The Application Upgrader identifies customizations made to an Application, and applies these customizations to the newer release of that Application. Application definitions are contained in a repository. The Application upgrader compares three repositories—the Prior Standard Repository, the Customized Repository, and New Standard Repository—and generates a fourth repository (New Customized Repository) based on the new repository but containing the customizations made by the customer. Any object definitions that have been added to the Customized Repository, but not in the New Standard Repository are added to the New Customized Repository. If an object definition has been modified in the Customized Repository and also in the New Standard Repository, the upgrader compares each attribute of the two versions of object definition, and for each conflict encountered (i.e. differing attribute values), selects the value from one of the versions based on a set of predetermined rules. All conflicts and their resolutions are presented to the user who then has the option of reviewing these and overriding the default resolution adopted by the Application Upgrader.
The result of the upgrade process is an upgraded version of the Application that incorporates the features of the new release with the customizations made to the prior release.
While the invention has been described with respect to certain preferred embodiments and exemplifications, it is not intended to limit the scope of the invention thereby, but solely by the claims appended hereto. | A software development method and system having a suite of graphical customization tools that enables developers to rapidly configure all aspects of the underlying application software, including the look-and-feel, behavior, and workflow. This is accomplished without modifying application source code, base objects, or SQL. The sophisticated repository management capabilities of the method and system of our invention allows teams of developers to work efficiently on configuring applications. The application upgrader provides an automated process to upgrade the customizations to future product releases thus protecting the investment in customization. The ease, comprehensiveness, scalability, and upgradeability of the customization process help reduce the total lifecycle cost of customizing enterprise applications. | 8 |
CROSS REFERENCE APPLICATIONS
[0001] This application is a continuation of application No. 09/923,027 filed Aug. 6, 2001 which is a divisional of application No. 09/410,849 filed Oct. 1, 1999 and issued as U.S. Pat. No 6,272,025 on Aug. 7, 2001.
FIELD OF INVENTION
[0002] The present invention relates to converters, power supplies, more particularly, to single, or multi stage, AC/DC or DC/DC isolated and non-isolated push-pull converters including but not limited to, forward, flyback, buck, boost, push pull, and resonant mode converters, and power supplies, having individual or distributed NSME with high speed FET switching and efficient flyback management and or having input PFC (power factor correction) and input protection from lightning transients. The invention also allows the magnetic element(s) be distributed to accommodate packaging restrictions, multiple secondary windings, or operation at very high winding voltages.
BACKGROUND OF THE INVENTION
[0003] There are several basic topologies commonly used to implement switching converters.
[0004] A DC-DC converter is a device that converts a DC voltage at one level to a DC voltage at another level. The converter typically includes a magnetic element having primary and secondary windings wound around it to form a transformer. By opening and closing the primary circuit at appropriate intervals control over the energy transfer between the windings occurs. The magnetic element provides an alternating voltage and current whose amplitude can be adjusted by changing the number and ratio of turns in each set of the windings. The magnetic element provides galvanic isolation between the input and the output of the converter.
[0005] One of the topologies is the push-pull converter. The output signal is the output of an IC network that switches the transistors alternately “on” and “off”. High frequency square waves on the transistor output drive the magnetic element into AC (alternating current) bias. The isolated secondary outputs a wave that is rectified to produce DC (direct current). The push-pull converters generally have more components as compared to other topologies. The push-pull approach makes efficient use of the magnetic element by producing AC bias, but suffers from high parts count, thermal derating, oversized magnetics, and elaborate core reset schemes. The destructive fly-back voltages occurring across the switches are controlled through the use of dissipative snubber networks positioned across the primary switches. Another of the topologies is the forward converter. When the primary of the forward converter is energized, energy is immediately transferred to the secondary winding. In addition to the aforementioned issues the forward converter suffers from inefficient (dc bias) use of the magnetic element. The prior art power supplies use high permeability gapped ferrite magnetic elements. These are well known in the art and are widely used. The magnetics of the prior art power supplies are generally designed for twice the required power rating and require complex methods to reset and cool the magnetic elements resulting in increased costs and limited operating temperatures. This is because high permeability magnetic elements saturate during operation producing heat in the core, which increases permeability and lowers the saturation threshold. This produces runaway heating, current spikes and/or large leakage currents in the air gap, reduced efficiency, and ultimately less power at higher temperatures and/or high load. The overall effects are, lower efficiency, lower power density, and forced air/heatsink dependant supplies that require over-rated ferrite magnetic elements for a given output over time, temperature, and loading.
Improvements
[0006] The combined improvements of the invention translate to higher system efficiencies, higher power densities, lower operating temperatures, and, improved thermal tolerance thereby reducing or eliminating the need for forced air cooling per unit output. The non-saturating magnetic properties are relatively insensitive to temperature (see FIG. 17), thus allowing the converter to operate over a greater temperature range. In practice, the operating temperature for the NSME is limited to 200C by wire/core insulation; the non-saturating magnetic material remains operable to near its Curie temperature of 500C.
[0007] What are needed are converters having circuit strategies that make advantageous use of individual and distributed NSME.
[0008] What are needed are converters having buffer circuits that provide fast, low impedance critically damped switching of the main FET's.
[0009] What are needed are converters that incorporate efficient multiple “stress-less” flyback management techniques to rectify and critically damp excessive node voltages across converter switches.
[0010] What are needed are converters having flux feedback frequency modulation.
[0011] What are needed are converters that correct AC power factor.
[0012] What is needed are converters that meet or exceed class B conducted EMI requirements.
[0013] What are needed are converters tolerant of lightning and harsh thermal environments. The present invention addresses these and more.
SUMMARY OF THE INVENTION
[0014] The main aspect of the present invention is to implement converters having circuit strategies that make advantageous use of individual and distributed NSME for the achievement of the key performance enhancements disclosed herein.
[0015] Another aspect of the present invention is to provide unique resonant tank circuit converter strategies with individual and distributed NSME that make use of higher primary circuit voltage excursions in the production of high frequency/high density magnetic flux.
[0016] Another aspect of the present invention is a high energy density single stage frequency controlled resonant tank converter topology enabled by the use of individual and distributed NSME. Another aspect of the present invention is to provide a converter design that utilizes a FET drive technique consisting of an ultra fast, low RDS on N-channel FET for charging the main FET gate and an ultra fast P-channel transistor for discharging the main FET gate.
[0017] Another aspect of the present invention is to provide converters that incorporate efficient multiple “stress-less” flyback management techniques to rectify and critically damp excessive node voltages across converter switches.
[0018] Another aspect of the present invention is to provide a converter having core (flux) synchronized zero crossing frequency modulation.
[0019] Another aspect of the present invention is to present a high power factor to the AC line.
[0020] Another aspect of the present invention is to provide protection from high voltage (input line) transients.
[0021] Another aspect of the present invention is to combine distributed magnetics advantageously with the other converter aspects.
[0022] Another aspect of the present invention is active ripple rejection provided by several high-gain high-speed isolated control and feedback systems.
[0023] Other aspects of this invention will appear from the following description and appended claims, reference being made to the accompanying drawings forming a part of this specification wherein like reference characters designate corresponding parts in the several views.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] [0024]FIGS. 1 and 1A is a schematic diagram of a two-stage power factor corrected AC to DC isolated output converter embodiment of the invention.
[0025] [0025]FIG. 2 is a schematic diagram of a single stage DC to AC converter embodiment with isolated output sub-circuit DCAC 1 .
[0026] [0026]FIGS. 3 and 3A is a schematic diagram of a three stage AC to DC isolated output converter embodiment of the invention.
[0027] [0027]FIG. 4 is a schematic diagram of a power factor corrected single stage AC to DC converter sub-circuit ACDFPF.
[0028] [0028]FIG. 5 is a graph comparing typical winding currents in saturating and non-saturating magnetics of equal inductance.
[0029] [0029]FIG. 6 is a schematic for a non-isolated low side switch buck converter sub-circuit NILBK.
[0030] [0030]FIG. 7 is the preferred embodiment schematic for a tank coupled single stage converter sub-circuit TCSSC.
[0031] [0031]FIG. 8 is a schematic for a tank coupled totem pole converter sub-circuit TCTP.
[0032] [0032]FIG. 9 is a block diagram for a single stage non-isolated DC to DC boost converter NILSBST.
[0033] [0033]FIG. 10 is a schematic for a two stage isolated DC to DC boost controlled push-pull converter BSTPP.
[0034] [0034]FIG. 11 is a graph of permeability as a function of temperature for typical prior art magnetic element material.
[0035] [0035]FIG. 12 is a graph of flux density as a function of temperature for typical prior art magnetic element material.
[0036] [0036]FIG. 12A is a graph of magnetic element losses for various flux densities and operating frequencies typical of prior art magnetic element material.
[0037] [0037]FIG. 13 is a graph showing standard switching losses.
[0038] [0038]FIG. 14 is a graph showing lower switching losses of the invention.
[0039] [0039]FIG. 15 is a graph showing the magnetizing curve (BH) for the NSME material.
[0040] [0040]FIG. 16 is a graph of magnetic element losses for various flux densities and operating frequencies of the NSME material.
[0041] [0041]FIG. 17 is a graph of permeability as a function of temperature for the NSME.
[0042] [0042]FIG. 18 is a schematic representation of the boost NSME sub-circuit PFT 1 .
[0043] [0043]FIG. 18A is a schematic representation of the NSME sub-circuit PFT 1 A.
[0044] [0044]FIG. 18B is a schematic representation of the non-saturating two terminal NSME sub-circuit BL 1 .
[0045] [0045]FIG. 18C is a schematic diagram of the NSME implemented as distributed magnetic assembly PFT 1 D.
[0046] [0046]FIG. 19 is a schematic representation of the push-pull NSME sub-circuit PPT 1 .
[0047] [0047]FIG. 19A is a schematic representation of the alternate push-pull NSME sub-circuit PPT 1 A.
[0048] [0048]FIG. 20 is a schematic diagram of the NSME input transient protection and line filter sub-circuit LL.
[0049] [0049]FIG. 21 is a schematic diagram of the alternate NSME input transient protection and line filter sub-circuit LLA.
[0050] [0050]FIG. 22 is a schematic diagram of the AC line rectifier sub-circuit BR.
[0051] [0051]FIG. 23 is a schematic diagram of the power factor controller sub-circuit PFA.
[0052] [0052]FIG. 24 is a schematic diagram of the alternate power factor correcting boost control element sub-circuit PFB.
[0053] [0053]FIG. 25 is a schematic diagram of the output rectifier and filter sub-circuit OUTA.
[0054] [0054]FIG. 25A is a schematic diagram of an alternate rectifier sub-circuit OUTB.
[0055] [0055]FIG. 25B is a schematic diagram of an alternate final output rectifier and filter sub-circuit OUTBB.
[0056] [0056]FIG. 26 is a schematic diagram of the floating 18_Volt DC control power sub-circuit CP.
[0057] [0057]FIG. 27 is a schematic diagram of the alternate floating 18_Volt DC push-pull control power sub-circuit CPA.
[0058] [0058]FIG. 28 is a schematic diagram of the over temperature protection sub-circuit OTP.
[0059] [0059]FIG. 29 is a schematic diagram of the high-speed low impedance buffer sub-circuit AMP, AMP 1 , AMP 2 and AMP 3 .
[0060] [0060]FIG. 30 is a schematic diagram of the main switch snubber sub-circuit SN.
[0061] [0061]FIG. 30A is a schematic diagram of the main switch rectifying diode snubber sub-circuit DSN.
[0062] [0062]FIG. 31 is a schematic diagram of the alternate snubber sub-circuit SNA.
[0063] [0063]FIG. 32 is a schematic diagram of the mirror snubber sub-circuit SNB.
[0064] [0064]FIG. 33 is a schematic diagram of the pulse-width/Frequency modulator sub-circuit PWFM.
[0065] [0065]FIG. 34 is an oscillograph of node voltages measured during operation of sub-circuit PWFM (FIG. 33).
[0066] [0066]FIG. 35 is an oscillograph of the primary tank voltage measured during operation of sub-circuit TCTP (FIG. 8).
[0067] [0067]FIG. 36 is a schematic diagram of the non-isolated 18-Volt DC control power sub-circuit REG.
[0068] [0068]FIG. 37 is a schematic for a non-isolated high-side switch buck converter sub-circuit HSBK.
[0069] [0069]FIG. 38 is a schematic for the low-side buck regulated two-stage converter embodiment with isolated push-pull output sub-circuit LSBKPP.
[0070] [0070]FIG. 39 is a schematic for an alternate isolated two-stage low-side switch buck converter sub-circuit LSBKPPBR.
[0071] [0071]FIG. 40 is a schematic diagram of the over voltage feed back sub-circuit IPFFB.
[0072] [0072]FIG. 40A is a schematic diagram of the non-isolated boost output voltage feedback sub-circuit FBA.
[0073] [0073]FIG. 40B is a schematic diagram of the isolated output voltage feedback sub-circuit IFB.
[0074] [0074]FIG. 40C is a schematic diagram of the alternate isolated over voltage feedback sub-circuit IOVFB.
[0075] [0075]FIG. 41 is a schematic diagram of the non-isolated output voltage feedback sub-circuit FBI.
[0076] [0076]FIG. 42 is a schematic diagram of an over voltage protection sub-circuit OVP.
[0077] [0077]FIG. 42A is a schematic diagram of the isolated over voltage feedback sub-circuit OVP 1 .
[0078] [0078]FIG. 42B is a schematic diagram of the over voltage protection sub-circuit OVP 2 .
[0079] [0079]FIG. 42C is a schematic diagram of the isolated over voltage feedback sub-circuit OVP 3 .
[0080] [0080]FIG. 43 is a schematic diagram of the Push-pull oscillator sub-circuit PPG.
[0081] Before explaining the disclosed embodiments of the present invention in detail, it is to be understood that:
[0082] The invention is not limited in its application to the details of the particular arrangements shown or described, since the invention is capable of other embodiments.
[0083] The expression “distributed magnetic(s)” refers to the configuration of multiple magnetic elements that share a single series coupled primary winding to induce isolated output currents from multiple series or parallel secondary windings.
[0084] Also, the terminology used herein is for the purpose of description not limitation.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0085] In this and other descriptions contained herein, the following symbols shall have the meanings attributed to them: “+” shall indicate a series connection, such as resistor A in series with resistor B shown as “A+B”. “||” Shall indicate a parallel connection, such as resistor A in parallel with resistor B shown as “A||B”.
[0086] Referring first to FIG. 7, a schematic diagram of the preferred embodiment of the invention.
[0087] [0087]FIG. 7 is a schematic of the preferred embodiment of a tank coupled single stage converter sub-circuit TCSSC. Sub-circuit TCSSC consists of resistor R20 and RLOAD, capacitor C10, transistors Q21 and Q11, sub-circuit CP (FIG. 26), sub-circuit PFT 1 (FIG. 18), sub-circuit OUTA (FIG. 25), sub-circuit AMP (FIG. 29), sub-circuit IFB (FIG. 40B) and sub-circuit PWFM (FIG. 33).
Table Element Value/part number R20 1 k ohms R61 2 k ohms Q21 TST541 U12 4N29 Q11 IRFP460 C10 1.8 uf
[0088] TCSSC can be configured to operate as an AC-DC converter, a DC-DC converter, a DC-AC converter, and an AC-AC converter. Sub-circuit TCSSC consists of resistor R20 and RLOAD, capacitor C10, switches Q11 and Q21, opto-isolator U12, sub-circuit PFT 1 (FIG. 18), sub-circuit OUTA (FIG. 25), sub-circuit CP (FIG. 26), sub-circuit AMP (FIG. 29), sub-circuit IFB (FIG. 40B) and sub-circuit PWFM (FIG. 33). External power source VBAT connects to pins DCIN+ and DCIN−. Source power may also be derived from rectified AC line voltage such as FIG. 20 or FIG. 21 to form a single stage power factor corrected AC to DC converter with isolated output. From DCIN+resistor R20 connects to sub-circuit CP pin CP+, sub-circuit AMP pin GA+, U12 LED anode and to sub-circuit PWFM pin PWFM+. Resistor R20 provides startup power to the converter until the control supply regulator sub-circuit CP reaches the desired 18-volt output. VBAT negative is the ground return node connects to sub-circuit PWFM pin PWFM 0 , Q11 source, sub-circuit AMP pin GA 0 , sub-circuit CP pin CT 0 , pin DCIN- and sub-circuit PFT 1 pin S 1 CT. Magnetic element winding node S 1 H of sub-circuit PFT 1 is connected to CP pin CT 1 A. Magnetic element winding node S 1 L of sub-circuit PFT 1 is connected to CP pin CT 2 A. Sub-circuit PWFM is designed as a constant 50% duty-cycle variable frequency generator. Sub-circuit PWFM Clock output pin CLK is connected to input of buffer sub-circuit AMP pin GA 1 . The output of buffer sub-circuit AMP pin GA 2 is connected to the gate of Q11 and R21. Resistor R21 is connected to the cathode of U12 LED. The emitter of Q21 and drain of Q11 is connected to sub-circuit PFT 1 pin P 1 A. Pin P 1 B of sub-circuit PFT 1 is connected through tank capacitor C10 to node DCIN+, Q21 collector and through resistor R61 to U12 phototransistor collector. The emitter of U12 phototransistor is connected to the base of Q21. With PWFM pin CLK high transistor Q11 conducts charging capacitor C10 through NSME PFT 1 from VBAT storing energy in PFT 1 . Sub-circuit PWFM switches CLK low, Q11 turns “off”. With CLK low LED of U12 is turned “on” injecting base current into Q21. With transistor Q21 “on” the tank circuit is completed, allowing capacitor C10 to discharge into NSME PFT 1 winding 100 (FIG. 18). Now the energy not transferred into the load is released from NSME PFT 1 into the now forward biased NPN switch Q21 back into capacitor C10. Thus any energy not used by the secondary load remains in the tank coupled primary circuit (winding 100 ). When the switching occurs at the resonant frequency, high voltages oscillate between C10 and winding 100 creating high flux density AC excursions in PFT 1 . C10 and PFT 1 exchange variable AC currents whose magnitude is controlled by frequency modulation scheme IFB and PWFM. The large primary voltage generates large, high frequency biases in the NSME PFT 1 thereby producing high flux density AC excursions to be harvested by secondary windings 102 and 103 (FIG. 18) to support a load or rectifier sub-circuit OUTA. Magnetic element winding node S 2 H of sub-circuit PFT 1 is connected to OUTA pin C 7 B. Magnetic element winding node S 2 L of sub-circuit PFT 1 is connected to OUTA C 8 B. Magnetic element winding node S 2 CT of sub-circuit PFT 1 is connected to OUTA pin OUT−. Node OUT− is connected to RLOAD, pin B− and to sub-circuit IFB pin OUT−. Rectified power is delivered to pin OUT+ of OUTA and is connected to RLOAD, pin B+ and to sub-circuit IFB pin OUT+. Sub-circuit IFB provides the isolated feedback signal to the sub-circuit PWFM. Frequency control pin FM 1 of sub-circuit PWFM is connected to sub-circuit IFB pin FBE. Internal reference pin REF of sub-circuit PWFM is connected to sub-circuit IFB pin FBC. PWFM is designed to operate at the resonate frequency of the tank (2*pi*(square root (C10 * inductance of 100 (FIG. 18)). When sub-circuit IFB senses the converter output is at the target voltage, current from PWFM pin REF is injected into FM 1 . Injecting current into FM 1 commands the PWFM to a lower clock frequency pin CLK. Driving the tank out of resonance reduces the amount of energy added to the tank thus reducing the converter output voltage. In the event the feedback signal from IFB commands the PWFM off or OHz, i.e.: at no load, all primary activity stops. The input current from VBAT may be steady state or variable DC. When TCSSC is operated from rectified AC (sub-circuit LL FIG. 20), high input (line) power factor and input transient protection is achieved. The primary and secondary currents of PFT 1 are sinusoidal and free of edge transitions making the converter very quiet. In addition the switches Q11 and Q21 are never exposed to the large circulating voltage induced in the tank (See FIG. 35). This allows the use of lower voltage switches in the design thereby reducing losses and increasing the MTBF. Sub-circuit TCSSC takes advantage of the desirable properties of the NSME in this converter topology. TCSSC is well suited for implementation with distributed NSME PFT 1 D (FIG. 18C). This combination exemplifies how distributed magnetics enable advantageous high voltage converter design variations that support form factor flexibility and multiple parallel secondary outputs from series coupled voltage divided primary windings across multiple NSME. This magnetic strategy is useful in addressing wire/core insulation, form factor and packaging limitations, circuit complexity and manufacturability. These converter strategies are very useful for obtaining isolated high current density output from a high voltage low current series coupled primary. Adjusting the secondary turn's ratio allows TCSSC to generate very large AC or DC output voltages as well as low-voltage high current outputs.
Additional Embodiments
[0089] [0089]FIGS. 1 and 1A is a schematic diagram of a two stage power factor corrected AC to DC converter. The invention is comprised of line protection filter sub-circuit LL (FIG. 20) and full-wave rectifier sub-circuit BR (FIG. 22). A power factor corrected regulated boost stage with sub-circuits PFA 2 (FIG. 23), snubber sub-circuit SN (FIG. 30), magnetic element sub-circuit PFT 1 (FIG. 18), sub-circuit CP (FIG. 26), buffer sub-circuit AMP (FIG. 29), over temperature sub-circuit OTP (FIG. 28), over voltage feedback sub-circuit IPFFB (FIG. 40) and voltage feedback sub-circuit IFB (FIG. 40B). Start up resistor R2, filter capacitor C1, PFC capacitor C2, flyback diode D4, switch transistor Q1, hold up capacitors C17 and C16, and resistor R17. An efficient push-pull isolation stage with sub-circuits CPA (FIG. 27), PPG (FIG. 43), AMP 1 (FIG. 29), AMP 2 (FIG. 29), snubber sub-circuits SNB (FIG. 32) and SNA (FIG. 31), resistor Rload, transistors Q6 and Q9, magnetic element PPT 1 (FIG. 19), and OUTA (FIG. 25).
Table Element Value/part number C1 0.01 uf C2 1.8 uf R2 100 k ohms D4 8A,600V Q1 IRFP 460 C17 100 uf C16 100 uf R17 375 k ohms Q6 FS 14SM-18A Q9 FS 14SM-18A
[0090] In the two-stage converter the primary side voltage to the second push-pull output stage is modulated by the power factor corrected input (boost) stage. Each stage can comprise of individual and distributed NSME. A graph of B-H hysteresis for the non-saturating magnetics is set forth in FIG. 15. Although the following description is in terms of particular converter topologies, i.e., flyback controlled primary and constant duty cycle push pull secondary, number of outputs, the style, and arrangement of the several topologies are offered by way of example, not limitation. In addition non-saturating magnetics BL 1 , PFT 1 , and PPT 1 may be implemented as distributed NSME. As an example PFT 1 is shown as a distributed magnetic PFT 1 A (FIG. 18C). Distributed magnetics enable advantageous high voltage converter design variations that support form factor flexibility and multiple parallel secondary outputs from series coupled voltage divided primary windings across multiple NSME. The negative of the hold-up capacitor(s) [C17||C16] is connected to bridge positive. This allows the rectified line voltage to be excluded from the boost voltage in the hold-up capacitor(s). This, in turn, allows direct regulation of the push-pull stage from the boost (PFC) stage. This eliminates the typical PWM control of the oversized thermally derated transformer and many sub-circuit components from the known art. AC line is connected to sub-circuit LL (FIG. 20) between pins LL 1 and LL 2 . AC/earth ground is connected to node LL 0 . The filtered and voltage limited AC line appears on node/pin LL 5 of sub-circuit LL and connected to node BR 1 of bridge rectifier sub-circuit BR (FIG. 22). The neutral/AC return leg of the filtered and voltage limited AC appears on pin LL 6 of sub-circuit LL is connected to input pin BR 2 of BR. The line voltage is full-wave rectified and is converted to a positive haversine appearing on node BR+ of sub-circuit BR (FIG. 22). Start up resistor R2 connects BR+ to sub-circuit CP pin CP+. Node CP+ connects to pins PFA+ of control element sub-circuit PFA (FIG. 23) and over temperature switch sub-circuit OTP (FIG. 28) pin GAP. Resistor R2 provides start up power to the control element until the rectifier/regulator CP is at full output. Node S 1 H from PFT 1 is connected to node PFVC of sub-circuit PFA. The zero crossings of the core are sensed when the voltage at S 1 H is at zero. The core zero crossings are used to reset the PFC and start a new cycle. The positive node of the DC side of bridge BR+ is connected through capacitor C2 to BR−. C2 is selected for various line and load conditions to de-couple switching current from the line improving power factor while reducing line harmonics and EMI. Primary of NSME sub-circuit PFT 1 (FIG. 18) pins P 1 B and S 2 CT connects to pin SNL 1 of snubber sub-circuit SN (FIG. 30), to sub-circuit BR pin BR+ and connects to pin BR+ (FIG. 1A). The return line for the rectified AC power BR− is connected to the following pins: BR− of sub-circuit BR, PFA pin BR−, sub-circuit AMP pin GA 0 , output switch Q1 source, capacitor C2, sub-circuit CP pin CT 0 sub-circuit PFT 1 pin S 1 CT and CT 20 through EMI filter capacitor C1 to earth ground node LL 0 . Pin BR+ from FIG. 1 is connected to FIG. 1A sub-circuits CPA pin SN pin SNL 1 , sub-circuit PFT 1 pin P 1 B, and sub-circuit PFT 1 pin S 2 CT. Pin BR+ continues to FIG. 1A connecting to sub-circuit CPA pin CT 20 , PPG (FIG. 43) pin PPG 0 , sub-circuit AMP 1 pin GA 0 , sub-circuit AMP 2 pin GA 0 , sub-circuit IPFFB pin PF−, Capacitor [C16||C17|| resistor R17], transistor Q6 source, transistor Q9 source, sub-circuit SNA pin SNA 2 and sub-circuit SNB pin SNB 2 . The drain of output switch Q1 is connected to diode D4 anode, sub-circuit SNB pin SNL 2 , and sub-circuit PFT 1 pin P 1 A and sub-circuit SN pin SNL 2 . Snubber network SN reduces the high voltage stress to Q1 until flyback diode D4 begins conduction. Line coupled, power factor corrected boost regulated output voltage of the AC to DC converter stage (FIG. 1) appears on node PF+. Addition efficiency may be realized by connecting sub-circuit DSN (FIG. 30A) in parallel with D4. The regulated boost output PF+ connects to the following: sub-circuit SN pin SNOUT, sub-circuit DSN pin SNOUT and diode D4 cathode. Node PF+ also connects on FIG. 1A to capacitors [C16||C17||R17], sub-circuit IPFFB (FIG. 40) pin PF+, sub-circuit PPT 1 (FIG. 19) pin P 2 CT, snubber sub-circuit SNA (FIG. 31) pin SNA 3 , and snubber SNB (FIG. 32) pin SNB 3 . Magnetic element winding pin S 1 H of sub-circuit PFT 1 is connected to CP pin CT 1 A and pin PFVC of sub-circuit PFA. Magnetic element winding node S 1 L of sub-circuit PFT 1 is connected to CP pin CT 2 A. Magnetic element winding node S 2 H of sub-circuit PFT 1 is connected to pin 10 FIG. 1A then to CPA pin CT 1 B. Magnetic element winding node S 2 L of sub-circuit PFT 1 is connected to pin 12 FIG. 1A then to CPA pin CT 2 B. Sub-circuit PFA using the AC line phase, load voltage, and magnetic element feedback, generates a command pulse PFCLK. Pin PFCLK of sub-circuit PFA (FIG. 23) is connected to the input of buffer amplifier pin GA 1 of sub-circuit AMP 1 (FIG. 29). Buffered high-speed gate drive output pin GA 2 of sub-circuit AMP is connected to gate of switch FET Q1. The buffering provided by AMP shortens switch Q1 ON and OFF times greatly reducing switch losses (see FIGS. 13 & 14). The source of Q1 with pin GA 0 is connected to return node BR−. Power to sub-circuit AMP is connected to pin GA+ from sub-circuit OTP pin TS+. Thermal switch THS 1 is connected to Q1. In the event the case of Q1 reaches approximately 105C THS 1 opens removing power to sub-circuit AMP, safely shutting down the first (input) stage. Normal operation resumes after the switch temperature drops 20-30 deg. C. closing THS 1 . Drain of output switch Q 1 is connected to primary winding pin P 1 A of non-saturating magnetic sub-circuit PFT 1 (FIG. 18) and to pin SNL 2 of snubber sub-circuit SN (FIG. 30). Reference voltage from PFC sub-circuit PFA pin PFA 2 is connected to feedback networks sub-circuit IPFFB pin FBC and to sub-circuit IFB pin FBC. Control current feedback networks is summed at node PF 1 of sub-circuit PFA. Pin PF 1 is connected to feed back networks sub-circuit IPFFB pin FBE and to sub-circuit IFB pin FBE. Constant frequency/duty-cycle non-overlapping two-phase generator sub-circuit PPG (FIG. 43 1 A) generates the drive for the push-pull output stage. Phase one output pin PH 1 is connected to sub-circuit AMP 1 pin GA 1 , second phase output pin PH 2 is connected to sub-circuit AMP 2 pin GA 1 . Output of amplifier buffer sub-circuit AMP 1 pin GAP 2 connects to gate of push-pull output switch Q 6 . Output of amplifier buffer sub-circuit AMP 2 pin GAP 2 connects to gate of push-pull output switch Q9. The buffering currents from AMP 1 and AMP 2 provide fast, low impedance critically damped switching to Q6 and Q9 greatly reducing ON-OFF transition time and switching losses. Regulated 18-volt power from sub-circuit CPA (FIG. 1A) pin CP 2 + is connected to amplifier buffer sub-circuit AMP 1 pin GA+, amplifier buffer sub-circuit AMP 2 pin GA+ and sub-circuit PPG pin PPG+. Drain of transistor Q6 is connected to snubber network sub-circuit SNB pin SNB 1 and to non-saturating center tapped primary magnetic element sub-circuit PPT 1 pin P 2 H. Drain of transistor Q9 is connected to snubber network sub-circuit SNA (FIG. 31) pin SNA 1 and sub-circuit PPT 1 pin P 2 L. Source of transistor Q6 is connected to snubber network sub-circuit SNB pin SNB 2 , transistor Q9 source, sub-circuit SNA pin SNA 2 and to return node BR+. Isolated output of NSME sub-circuit PPT 1 pin SH connects to Pin C 7 B of rectifier sub-circuit OUTA (FIG. 25A), pin SL connects to sub-circuit OUTA C 8 B. Center tap of PPT 1 pin SCT is the output return or negative node OUT− it connects to sub-circuit OUTA pin OUT− and sub-circuit IFB (FIG. 40B) pin OUT− and RLOAD. Converter positive output from sub-circuit OUTA pin OUT+ is connected to RLOAD and sub-circuit IFB pin OUT+. FIG. 1 elements LL 1 , BR, PFA, AMP, Q1, IPFFB, IFB and PFT 1 (input stage) perform power factor corrected AC to DC conversion. The regulated high voltage output of this converter supplies the efficient fixed frequency/duty-cycle push-pull stage comprising PPG, AMP 1 , AMP 2 , Q6, Q9, PPT 1 and OUTA (FIG. 1A). Magnetic element sub-circuit PPT 1 provides galvanic isolation and minimal voltage overshoot and ripple in the secondary thus minimizing filtering requirements of the rectifier sub-circuit OUTA. Five volt reference output from sub-circuit PFA pin PFA 2 connects to pin 15 then to FIG. 1A sub-circuit IPFFB pin FBC and to sub-circuit IFB pin FBC. Pulse width control input from sub-circuit PFA pin PF 1 connects to pin 14 then to FIG. 1A sub-circuit IPFFB pin FBE and to sub-circuit IFB pin FBE. Sub-circuit IFB provides high-speed feedback to the AC DC converter, the speed of the boost stage provides precise output voltage regulation and active ripple rejection. In the event of sudden line or load changes, sub-circuit IPFFB corrects the internal boost to maintain regulation at the isolated output. Remote load sensing and other feedback schemes known in the art may be implemented with sub-circuit IPFFB. This configuration provides power factor corrected input transient protection, rapid line-load response, excellent regulation, isolated output and quiet efficient operation at high temperatures.
[0091] [0091]FIG. 2 is a schematic diagram of an embodiment of a DC to AC converter. The invention DCAC 1 is an efficient push-pull converter. Comprised of sub-circuits PPG (FIG. 43), AMP 1 (FIG. 29), AMP 2 (FIG. 29), SNB (FIG. 32), SNA (FIG. 31), PPT 1 (FIG. 19) and OUTA (FIG. 25), switches Q6 and Q9.
Table Element Value/part number Q6 FS 14SM-18A Q9 FS 14SM-18A
[0092] Converter ACDC 1 accepts variable DC voltage and efficiently converts it to a variable AC voltage output at a fixed frequency. Variable frequency operation may be achieved by simple changes to PPG. In this embodiment fixed frequency operation is required. The magnetic element comprises non-saturating magnetics. A graph of B-H hysteresis for the non-saturating magnetics is set forth in FIG. 15. Variable DC voltage is applied to pin DC+. The pin DC+ connects to the following, sub-circuit PPT 1 (FIG. 19) pin P 2 CT, snubber sub-circuit SNA (FIG. 31) pin SNA 3 , and snubber SNB (FIG. 32) pin SNB 3 . Constant frequency non-overlapping two-phase generator sub-circuit PPG (FIG. 43) generates the drive for the push-pull output switches. Phase one output pin PH 1 is connected to sub-circuit AMP 1 pin GA 1 , the second phase output pin PH 2 is connected to sub-circuit AMP 2 pin GA 1 . Output of amplifier buffer sub-circuit AMP 1 pin GAP 2 connects to gate of push-pull output switch Q6. Output of amplifier buffer sub-circuit AMP 2 pin GAP 2 connects to gate of push-pull output switch Q9. The buffering provided by AMP 1 and AMP 2 shortens switch Q1 ON and OFF times greatly reducing switching losses (See FIGS. 13 and 14). External regulated 18-volt power from pin P18V connected to amplifier buffer sub-circuit AMP 1 pin GA+, amplifier buffer sub-circuit AMP 2 pin GA+ and sub-circuit PPG pin PPG+. Drain of transistor Q6 is connected to snubber network sub-circuit SNB pin SNB 1 and to non-saturating center tapped primary magnetic element sub-circuit PPT 1 pin P 2 H. Drain of transistor Q9 is connected to snubber network sub-circuit SNA (FIG. 31) pin SNA 1 and sub-circuit PPT 1 pin P 2 L. Source of transistor Q6 is connected to snubber network sub-circuit SNB pin SNB 2 , transistor Q9 source, sub-circuit SNA pin SNA 2 , sub-circuit AMP 1 pin GA 0 , sub-circuit AMP 2 pin GA 0 , sub-circuit PPG pin PPG 0 , and to return pin DC−. AC output of NSME sub-circuit PPT 1 pin SH connects to Pin ACH, pin SL connects to pin ACL. Center tap of PPT 1 pin SCT is connected to pin AC 0 . Magnetic element sub-circuit PPT 1 provides galvanic isolation and minimal voltage overshoot in the secondary thus minimizing filtering requirements if a rectifier assembly is attached. Sub-circuit DCAC 1 may be used as a stand-alone converter or as a fast quiet efficient stage in a multi stage converter system. Sub-circuit DCAC 1 achieves isolated output, quiet operation, efficient conversion, and operation at high and low temperatures.
[0093] [0093]FIGS. 3 and 3A is a three-stage version of the present invention. The arrangement is comprised of an AC-DC or DC-DC boost converter stage, DC-DC forward converter stage, and a push-pull stage. This system reduces losses by combining low current buck regulation, buffered switching, rectified snubbering, and NSME in each stage. A power factor corrected boost stage is used to assure that any load connected to the converter looks like a resistive load to the AC line, eliminating undesirable harmonic and displacement currents in the AC power line. NSME having a lower permeability compared to the prior art are used to minimize magnetizing losses, improve coupling efficiency, minimize magnetic element heating, eliminate saturated core current spikes/gap leakage, reduce parts count, reduce thermal deterioration, and increase MTBF (mean time before failure). The invention also uses an emitter follower circuit with a high speed switching FET to slew the main FET gate rapidly. The use of non-saturating magnetics allows operation at higher voltages, which proportionally lowers current further reducing switch, magnetic element, and conductor losses due to I 2 R heating. High voltage FET switches have the added benefit of lower gate capacitance, which translates to faster switching. At turn on, the n-channel gate drive FET quickly charges the main FET gate. At turn off, a PNP Darlington transistor switch quickly discharges the main FET gate. The flyback effect in the PFC stage is managed by use of rectifying RC networks positioned across the output diode with an additional capacitor coupled diode across the switched magnetic element to decouple and further dampen the inductive flyback.
[0094] [0094]FIG. 3 and FIG. 3A is a schematic diagram of a three stage AC to DC converter. FIGS. 3 and 3A is a three-stage version of the present invention. The arrangement is comprised of an AC-DC or DC-DC boost converter stage, DC-DC forward converter stage, and a push-pull stage. This system reduces losses by combining low current buck regulation, buffered switching, rectified snubbering, and NSME in each stage. A power factor corrected boost stage is used to assure that any load connected to the converter looks like a resistive load to the AC line, eliminating undesirable harmonic and displacement currents in the AC power line. NSME having a lower permeability compared to the prior art are used to minimize magnetizing losses, improve coupling efficiency, minimize magnetic element heating, eliminate saturated core current spikes/gap leakage, reduce parts count, reduce thermal deterioration, and increase MTBF (mean time before failure). The invention also uses an emitter follower circuit with a high speed switching FET to slew the main FET gate rapidly. The use of non-saturating magnetics allows operation at higher voltages, which proportionally lowers current further reducing switch, magnetic element, and conductor losses due to I 2 R heating. High voltage FET switches have the added benefit of lower gate capacitance, which translates to faster switching. At turn on, the n-channel gate drive FET quickly charges the main FET gate. At turn off, a PNP Darlington transistor switch quickly discharges the main FET gate. The flyback effect in the PFC stage is managed by use of rectifying RC networks positioned across the output diode with an additional capacitor coupled diode across the switched magnetic element to decouple and further dampen the inductive flyback. The invention is comprised of a power factor corrected regulating boost stage with line protection filter sub-circuit LL 1 (FIG. 21) and full-wave rectifier sub-circuit BR (FIG. 22) and capacitors C1 and C2. Sub-circuits PFB (FIG. 24), resistor R2, rectifier CP (FIG. 26), magnetic element PFT 1 (FIG. 18), over temperature protection OTP (FIG. 28) snubber SN (FIG. 30) gate buffer AMP (FIG. 29), switch transistors Q1, flyback diode D4, holdup capacitors C17 and C16, bleed resistor R17, and voltage feedback sub-circuit FBA (FIG. 40A). An efficient second pre-regulating buck stage with sub-circuits PWFM (FIG. 33), current sense resistor R26, rectifier CPA (FIG. 27), magnetic element BL 1 (FIG. 18B), over voltage protection OVP (FIG. 42), IPFFB (FIG. 40) gate buffer AMP 3 (FIG. 29), switch transistor Q2, flyback diode D70, storage capacitor C4, and voltage feedback sub-circuit IFB (FIG. 40B).
[0095] An efficient third push-pull isolation stage with sub-circuits CPA (FIG. 27), two-phase generator PPG (FIG. 43), gate buffers AMP 1 (FIG. 29) and AMP 2 (FIG. 29), switch transistors Q6, and Q9, snubbers SNA (FIG. 31) and SNB (FIG. 32), magnetic element PPT 1 (FIG. 19) and rectifier OUTA (FIG. 25).
Table Element Value/part number C1 .01 uf C2 1.8 uf R2 100 k ohms D4 STA1206 DI R17 375 k ohms Q1 IRFP460 C16 100 uf C17 100 uf R26 .05 ohms D70 STA1206 DI Q2 IRFP460 C4 10 uf Q6 FS14Sm-18A Q9 FS14Sm-18A
[0096] AC line is connected to sub-circuit LLA (FIG. 21) between pins LL 1 and LL 2 . AC/earth ground is connected to node LL 0 . The filtered and voltage limited AC line appears on node/pin LL 5 of sub-circuit LLA and connected to node BR 1 of bridge rectifier sub-circuit BR. The neutral/AC return leg of the filtered and voltage limited AC appears on pin LL 6 of sub-circuit LL is connected to input pin BR 2 of BR. The line voltage is full-wave rectified and is converted to a positive haversine appearing on node BR+ of sub-circuit BR. Start up resistor R2 connects BR+ to sub-circuit CP pin CP+. Node CP+ connects to pins PFA+ of control element sub-circuit PFB and over temperature switch sub-circuit OTP pin GAP. Resistor R2 provides start up power to the control element until the regulator CP is at full output. Node S 1 H from PFT 1 is connected to pin 31 (FIG. 3) then to pin CT 1 A of sub-circuit CP and pin PFVC of sub-circuit PFB. The zero crossing of the core bias are sensed when the voltage at S 1 H is at zero relative to BR−. The core zero crossings are used to reset the PFC and start a new cycle. The positive node of the DC side of bridge BR+ is connected through capacitor C2 to BR−. Capacitor C2 is selected for various line and load conditions to de-couple switching current from the line improving power factor. Sub-circuit BR pin BR+ connects to pin SNL 1 of snubber sub-circuit SN, sub-circuit PFB pin BR+ and pin BR+ (FIG. 3A) then to primary of NSME sub-circuit PFT 1 pin P 1 B and to sub-circuit OVP pin BR+. The return line for the rectified AC power is connected to the following pins; BR− of sub-circuit BR, sub-circuit PFT 1 pin S 1 CT, PFC sub-circuit PFB pin BR−, sub-circuit FBA pin BR−, capacitor C2, sub-circuit CP pin CT 0 , sub-circuit IPFFB pin FBE, and through EMI filter capacitor C1 to earth ground node LL 0 . Node BR− continues to FIG. 3A connecting to R26, capacitors [C16||C17||R17], sub-circuit OVP pin BR−, sub-circuit PWFM pin PWFM 0 , sub-circuit AMP 3 pin GA 0 , switch Q 2 source. Floating ground node PF− is connected to magnetic element sub-circuit PFT 1 pin S 2 CT, rectifier sub-circuit CPA pin CT 20 , generator sub-circuit PPG (FIG. 43) pin PPG 0 , sub-circuit AMP 1 pin GA 0 , sub-circuit AMP 2 pin GA 0 , capacitor C4, magnetic element BL 1 pin, transistor Q6 source, transistor Q9 source, sub-circuit SNA pin SNA 2 sub-circuit SNB pin SNB 2 , pin PF−FIG. 3 then to sub-circuit IPFFB pin PF−. Drain of output switch Q 1 is connected to diode D4 anode, sub-circuit SN pin SNL 2 , then to pin 34 of FIG. 3A then to sub-circuit PFT 1 pin P 1 A. Snubber SN reduces the high voltage stress to Q1 until flyback diode D4 begins conduction. Additional rectification efficiency and protection is achieved by adding sub-circuit DSN (FIG. 30A) across flyback diode D4. Feedback corrected boost output voltage of the power factor corrected AC to DC converter stage appears across nodes PF+ and PF+. The regulated 385-volt boost output node PF+ connects to the following; sub-circuit SN pin SNOUT, diode D4 cathode, sub-circuit IPFFB (FIG. 40) pin PF+, sub-circuit FBA pin PF+, then to pin PF+ of FIG. 3A, capacitors [C16||C17||R17], magnetic element sub-circuit PTT 1 (FIG. 19) pin P 2 CT, snubber sub-circuit SNA (FIG. 31) pin SNA 3 , and snubber SNB (FIG. 32) pin SNB 3 , sub-circuit OVP pin PF+, capacitor C4 and diode D70 cathode. Magnetic element winding node S 1 H of sub-circuit PFT 1 is connected to pin 31 FIG. 3 then to sub-circuit CP pin CT 1 A and pin PFVC of sub-circuit PFB. Magnetic element winding node S 1 L of sub-circuit PFT 1 is connected to pin 33 FIG. 3 then to sub-circuit CP pin CT 2 A. Magnetic element winding node S 2 H of sub-circuit PFT 1 is connected to CPA pin CT 1 B. Magnetic element winding node S 2 L of sub-circuit PFT 1 is connected to CP pin CT 2 B. Sub-circuit PFB using feedback from the phase of the AC line, Q1 switch current, magnetic bias first stage and output voltage feedback generates a command pulse on pin PFCLK. Pin PFCLK of sub-circuit PFB (FIG. 24) is connected to the input of buffer AMP amplifier pin GA 1 of sub-circuit AMP 1 . Buffered high-speed low impedance gate drive output pin GA 2 of sub-circuit AMP is connected to gate of switch FET Q1. The buffering provided by AMP shortens switch Q1 “ON” and “OFF” times greatly reducing switch losses (See FIGS. 13 and 14). The source of Q1 is connected to sub-circuit AMP pin GA 0 , pin 35 of FIG. 3A then to current sense resistor R26 connected to return node BR−. The voltage developed across R26 is fed back to PFB pin PFSC. This signal is used to protect the switch by reducing the pulse width in response to a low line or high load induced over current fault. The return line of sub-circuit FBA pin BR− is connected to node BR− and to pin BR− of sub-circuit PFB. This feedback is non-isolated; network values are selected for the first stage to develop a 385-Volt output at PF+. Sub-circuit feedback network FBA (FIG. 40A) pin PF 1 is connected to sub-circuit PFB pin PF 1 . Controller PFB modulates PFCLK signal to maintain a substantially constant 385-voltage at PF+ independent of line and load conditions. In the event of a component failure in sub-circuit FBA the PBF may command the converter to very high voltages. Sub-circuit OVP monitors the first stage boost in the event it exceeds 405-volts OVP will clamp the output of sub-circuit BR causing fuse F 1 in sub-circuit LLA to open. An alternate over voltage network OVP 1 (FIG. 42A) may replace OVP clamping the 18-volt control power stopping the boost action of the converter without opening the fuse. Sampled converter output at node from sub-circuit FBA pin PF 1 is connected to sub-circuit PFB pin PF 1 . The haversine on BR+ is used with an internal multiplier by PFB to generate variable width control pulses on pin PFCLK. The high frequency modulation of switch Q1 makes the load/converter appear resistive to the AC line. Over temperature protection sub-circuit OTP pin TS+ is connected to sub-circuit AMP pin GA+. Thermal switch THS 1 is connected to Q1. In the event Q1 reaches approximately 105C THS 1 opens removing power to sub-circuit AMP, safely shutting down the first stage. Normal operation resumes after the temperature decreases 20-30C closing THS 1 . The second stage is configured as a buck stage. It accepts the 385-Volt output of the first stage. By employing a second floating reference node PF− energy storage element capacitor C4 the voltage to the final push-pull stage may be regulated with minimal loss. Power from sub-circuit CP pin CP18V+ is connected to pin 30 of FIG. 3A then to sub-circuit PWFM (FIG. 33) pin PWM+ and AMP 3 pin GA+. Feedback current from sub-circuit IPFFB pin FBC is connected to pin 36 FIG. 3A then to sub-circuit IFB pin FBC and sub-circuit PWFM pin PF 1 . Sub-circuit IPFFB only shunts current from this node if the output of the second stage is greater than 200-volts. When the converter reaches its designed output voltage, IFB shunts current from PWFM pin PF 1 signaling PWFM to reduce the pulse width on pin PWMCLK. Sub-circuit AMP 3 input pin is connected to sub-circuit PWFM pin PWMCLK. Output of AMP 3 buffer pin GA 2 is connected to gate of switch Q2. Drain of Q2 is connected to anode of D70 and non-saturating magnetic sub-circuit BL 1 pin P 2 B (FIG. 18B). Turning on switch Q2 charges C4 also storing energy in magnetic element BL 1 . Releasing switch Q2 allows energy stored in magnetic element BL 1 to charge C4 through flyback diode D70. Larger pulse widths charge C4 to larger voltages thus efficiently blocking part of the first stage voltage to the final push-pull stage. This action provides regulated voltage to the final converter stage. The third and final push-pull (transformer) converter stage provides the galvanic isolation, filtering and typically converts the internal high voltage bus to a lower regulated output voltage. The efficient push-pull stage produces alternating magnetizing currents in the NSME for maximum load over core mass. Constant frequency non-overlapping two-phase generator sub-circuit PPG (FIG. 43) generates the drive for the push-pull output stage. Phase one output pin PH 1 is connected to sub-circuit AMP 1 pin GA 1 , output pin PH 2 is connected to sub-circuit AMP 2 pin GA 1 . Output of amplifier buffer sub-circuit AMP 1 pin GAP 2 connects to gate of push-pull output switch Q6. Output of amplifier buffer sub-circuit AMP 2 pin GAP 2 connects to gate of push-pull output switch Q9. The buffering provided by AMP 1 and AMP 2 shortens switch Q1 ON and OFF times greatly reducing switching losses. (See FIGS. 13 and 14) Regulated 18-volt power from sub-circuit CPA pin CP 18 + is connected to amplifier buffer sub-circuit AMP 1 pin GA+, amplifier buffer sub-circuit AMP 2 pin GA+ and sub-circuit PPG pin PPG+. Drain of transistor Q6 is connected to snubber network sub-circuit SNB pin SNB 1 and to non-saturating center tapped primary magnetic element sub-circuit PPT 1 pin P 2 H. Drain of transistor Q9 is connected to snubber network sub-circuit SNA (FIG. 31) pin SNA 1 and sub-circuit PPT 1 pin P 2 L. Return node PF− connects source of transistor Q6 to snubber network sub-circuit SNB pin SNB 3 , transistor Q9 source, sub-circuit SNA pin SNA 3 and to return node GND 2 . Output of NSME sub-circuit PPT 1 pin SH connects to pin C 7 B of rectifier sub-circuit OUTA (FIG. 25), pin SL connects to C 8 B. Center tap of PPT 1 pin SCT is the output return or negative node OUT− it connects to sub-circuit pin OUT− and sub-circuit IFB pin OUT− and RLOAD. Supply positive output from sub-circuit OUTA pin OUT+ is connected to RLOAD and sub-circuit IFB pin OUT+. Elements LL 1 , BR, PFA, AMP, Q1, IPFFB, IFB and PFT 1 provide power factor corrected AC to DC conversion and DC output regulation. The regulated high voltage output of this converter is used to power the efficient fixed frequency push-pull stages PPG, AMP 1 , AMP 2 , Q6, Q9, PPT 1 and OUTA. Magnetic element sub-circuit PPT 1 provides galvanic isolation and minimal voltage overshoot in the secondary thus minimizing filtering requirements of the rectifier sub-circuit OUTA. Sub-circuit IFB provides high-speed feedback to the AC DC converter, the speed of the boost stage provides precise output voltage regulation and active ripple rejection. In the event of a sudden line or load changes sub-circuit IPFFB compensates the internal boost. This system reduces losses by focusing output control in the middle (low current) stage of the converter and by using non-saturating magnetics, buffered switching, and rectifying snubbers throughout each stage. The combined improvements translate to higher system efficiencies, higher power densities, lower operating temperatures, and, improved thermal tolerance thereby reducing or eliminating the need for forced air-cooling per unit output. The non-saturating magnetic properties are relatively insensitive to temperature (see FIG. 17), thus allowing the converter to operate over a greater temperature range. In practice, the operating temperature for the Kool Mu NSME is limited to 200C by wire/core insulation; the non-saturating magnetic material remains operable to near its Curie temperature of 500C. This configuration provides power factor corrected input transient protection, rapid line-load and ripple compensation, excellent output regulation, output isolation and quiet efficient operation at high temperatures.
[0097] [0097]FIG. 4 is a schematic diagram sub-circuit ACDCPF.
[0098] [0098]FIG. 4 is a schematic diagram of a power factor corrected single stage AC to DC converter sub-circuit ACDCPF. The invention is comprised of line protection filter sub-circuit LL (FIG. 20) and full-wave rectifier sub-circuit BR (FIG. 22). A power factor corrected regulated boost stage with sub-circuits PFB (FIG. 24), snubber sub-circuit SN (FIG. 30), magnetic element sub-circuit PFT 1 A (FIG. 18A), sub-circuit CP (FIG. 26), buffer sub-circuit AMP (FIG. 29), over temperature sub-circuit OTP (FIG. 28), and voltage feedback sub-circuit FBA (FIG. 40A). Start up resistor R2, filter capacitor C1, PFC capacitor C2, flyback diode D4, switch transistor Q1, hold up capacitors C17 and C16, and resistor R17.
Table Element Value/part number C1 .01 uf C2 1.8 uf R2 100 k ohms R26 0.05 ohms Q1 IRFP 460 D4 STA1206 DI C17 100 uf C16 100 uf R17 375 k ohms
[0099] AC line is connected to sub-circuit LL (FIG. 20) between pins LL 1 and LL 2 . AC/earth ground is connected to node LL 0 . The filtered and voltage limited AC line appears on node/pin LL 5 of sub-circuit LL 1 and connected to node BR 1 of bridge rectifier sub-circuit BR (FIG. 22). The neutral/AC return leg of the filtered and voltage limited AC appears on pin LL 6 of sub-circuit LL is connected to input pin BR 2 of BR. The line voltage is full-wave rectified and is converted to a positive haversine appearing on node BR+ of sub-circuit BR (FIG. 22). Start up resistor R2 connects BR+ to sub-circuit CP pin CP+. Node CP+ connects to pins PFA+ of power factor controller sub-circuit PFA (FIG. 24) and over temperature switch sub-circuit OTP (FIG. 28) pin GAP. Resistor R2 provides start up power to the control element until the rectifier and regulator CP is at full output. Node S 1 H from PFT 1 A is connected to node PFVC sub-circuit PFB. The zero crossing of the core bias are sensed when the voltage at S 1 H is at zero. The core zero crossings are used to reset the PFC and start a new cycle. The positive node of the DC side of bridge BR+ is connected through capacitor C2 to BR−. C2 is selected for various line and load conditions to de-couple switching current from the line improving power factor. Primary of NSME sub-circuit PFT 1 A (FIG. 18A) pin P 1 B connects to pin SNL 1 of snubber sub-circuit SN (FIG. 30), sub-circuit PFB pin BR+ and connects to node BR+. The return line for the rectified AC power BR− is connected to the following pins; BR− of sub-circuit BR, sub-circuit PFB pin BR−, sub-circuit AMP pin GA 0 , sense resistor R26, capacitor [C16||C17 ||resistor R17], capacitor C2, sub-circuit CP pin CT 0 , sub-circuit PFT 1 A pin S 1 CT and through EMI filter capacitor C1 to earth ground node LL 0 . Drain of output switch Q1 is connected to diode D4 anode, sub-circuit PFT 1 A pin P 1 A and snubber sub-circuit SN pin SNL 2 . Additional rectification efficiency and protection is achieved by adding sub-circuit DSN (FIG. 30A) in parallel flyback diode D4. Sub-circuit provides reduces the high voltage stress to Q1 until flyback diode D4 begins conduction. Line coupled, power factor corrected boost regulated output voltage of the AC to DC converter stage (FIG. 1) appears on node PF+. The regulated boost output PF+ connects to the following; sub-circuit SN pin SNOUT, diode D4 cathode, capacitor [C16||C17||R17], and snubber DSN (FIG. 30A) pin SNOUT. Magnetic element winding node S 1 H of sub-circuit PFT 1 A is connected to CP pin CT 1 A and pin PFVC of sub-circuit PFB. Magnetic element winding node S 1 L of sub-circuit PFT 1 A is connected to CP pin CT 2 A. Sub-circuit PFB using the phase of the AC line, and load voltage generates a command pulse PFCLK. Pin PFCLK of sub-circuit PFB (FIG. 24) is connected to the input of buffer amplifier pin GA 1 of sub-circuit AMP 1 (FIG. 29). Buffered high-speed gate drive output pin GA 2 of sub-circuit AMP is connected to gate of switch FET Q1. The buffering provided by AMP shortens switch Q1 ON and OFF times greatly reducing switch losses. The source of Q1 is connected to current sense resistor R26, pin PFSC of sub-circuit PFB, connected then to return node BR−. The voltage developed across R26 is feedback to PFB pin PFSC. This signal is used to protect the switch in the event of an over current fault. Thermal switch THS 1 is connected to Q1. In the event Q1 reaches approximately 105C THS 1 opens removing power to sub-circuit AMP, safely shutting down the first stage. Normal operation resumes after the switch temperature drops 20-30 C. closing THS 1 . Sub-circuit feedback network FBA (FIG. 40A) pin PF 1 is connected to sub-circuit PFB pin PF 1 . Converter output at node PF+ (the junction of C17||C16 and D4) is connected to sub-circuit FBA pin PF+. The return line of sub-circuit FBA pin BR− is connected to pin BR− of sub-circuit PFB. This feed back is non-isolated; network values are selected for a substantially constant 385-Volt output at PF+ relative to BR−. The high-voltage haversine from the rectifier section BR pin BR+ is connected to sub-circuit PFB pin BR+. The haversine is used with an internal multiplier by PFB to make the converter ACDCPF appear resistive to the AC line. Sub-circuits LL 1 , BR, PFB, AMP, Q1, OTP, FBA, IFB and PFT 1 A perform power factor corrected AC to DC conversion. The regulated high voltage output of this converter may be used use to power one or more external converters connected to the PF+ and BR− nodes. The NSME sub-circuit PPT 1 A provides efficient boost action at high power levels in a very small form factor. Sub-circuit FBA provides high-speed feedback to the converter the speed of the boost stage provides precise output voltage regulation and active ripple rejection. This configuration provides power factor corrected input transient protection, rapid line-load response, excellent regulation, and quiet efficient operation at high temperatures.
[0100] [0100]FIG. 5 is a graph comparing typical currents in saturating and non-saturating magnetic elements. As the inductance does not radically change at high temperatures and currents in the NSME, the large current spikes due to the rapid reduction of inductance common in saturating magnetics is not seen. As a result, destructive current levels, excessive gap leakage, magnetizing losses, and magnetic element heating are avoided in NSME.
[0101] [0101]FIG. 6 is a schematic for non-isolated low side switch buck converter sub-circuit NILBK. Sub-circuit NILBK consists of resistor R20, diode D6, capacitor C6, FET transistor Q111, sub-circuit CP (FIG. 26), sub-circuit PFT 1 A (FIG. 18A), sub-circuit IFB (FIG. 40B), sub-circuit AMP (FIG. 29) and sub-circuit PWFM (FIG. 33).
Table Element Value/part number R20 100 k ohms R20 STA1206 DI Q111 IRFP460 C6 10 uf
[0102] External power source VBAT connects to pins DCIN+ and DCIN−. From DCIN+ through resistor R20 connects to sub-circuit CP pin CP+, sub-circuit AMP pin GA+ and to sub-circuit PWFM pin PWFM+. Resistor R20 provides startup power to the converter before regulator sub-circuit CP reaches it full 18-volt output. VBAT negative is connected to pin DCIN− connects to sub-circuit PWFM pin PWFM 0 , sub-circuit AMP pin GA 0 , Q111 source, sub-circuit IFB pin FBE, sub-circuit CP pin CT 0 , and sub-circuit PFT 1 pin S 1 CT. Magnetic element winding node S 1 H of sub-circuit PFT 1 A is connected to CP pin CT 1 A. Magnetic element winding node S 1 CT of sub-circuit PFT 1 is connected to CP pin CT 0 . Magnetic element winding node S 1 H of sub-circuit PFT 1 A is connected to CP pin CT 2 A. The regulated 18 volts from sub-circuit CP+ is connected to R20, sub-circuit AMP pin GA+ and to sub-circuit PWFM pin PWFM+. Sub-circuit PWFM is designed for variable pulse width operation. PWFM is configured for maximum pulse width 90-95% with no feedback current from sub-circuit IFB pin FBC. Increasing the feedback current reduces the pulse-width and output voltage from converter NILBK. Sub-circuit PWFM clock/PWM output pin CLK is connected to the input pin GA 1 of buffer sub-circuit AMP. The output of sub-circuit AMP pin GA 2 is connected to the gate of Q111. Input node DCIN+ connects to the cathode of flyback diode D6, sub-circuit IFB pin OUT+, resistor RLOAD, capacitor C6 and pin B+ . The drain of Q111 is connected to sub-circuit PFT 1 pin P 1 B and the anode of D6. Pin P 1 A of sub-circuit PFT 1 A is connected to capacitor C6, RLOAD, sub-circuit IFB pin OUT− and to node B−. With sub-circuit PWFM pin CLK high buffer AMP output pin GA 2 charges the gate of transistor switch Q111. Switch Q111 conducts charging capacitor C10 through NSME PFT 1 A from source VBAT and storing energy in PFT 1 A. Feedback output pin FBC from sub-circuit IFB is connected to sub-circuit PWFM pulse-width adjustment pin PW 1 . Sub-circuit IFB removes current from PW 1 commanding PWFM to reduce the pulse-width or on time of signal CLK. After sub-circuit PWFM reaches the commanded pulse-width PWFM switches output pin CLK low turning “off” Q111 stopping the current into PFT 1 A. The energy not transferred into regulator sub-circuit CP load is released from NSME PFT 1 A into the now forward biased diode D 6 charging capacitor C6. By modulating the “on” time of switch Q111 the converter buck voltage is regulated. Regulated voltage is developed across Nodes B− and B+. Sub-circuit IFB provides the isolated feedback voltage to the sub-circuit PWFM. When sub-circuit IFB senses the converter output (nodes B+ and B−) is at the designed voltage, current from REF is removed from PM 1 . Sinking current from PM 1 commands the PWFM to a shorter pulse-width thus reducing the converter output voltage. In the event the feedback signal from IFB commands the PWFM to minimum output. Gate drive to switch Q111 is removed stopping all buck activity capacitor C6 discharges through RLOAD. Input current from VBAT is sinusoidal making the converter very quiet. In addition the switch Q111 is not exposed to large flyback voltage. Placing less stress on the switches thereby increasing the MTBF. Sub-circuit NILBK takes advantage of the desirable properties of the NSME in this converter topology. Adjusting the NSME 100 (FIG. 18A) primary inductance and component values in sub-circuit IFB determines the output buck voltage.
[0103] [0103]FIG. 8 is a schematic for a tank coupled single stage converter sub-circuit TCTP. Sub-circuit TCTP consists of resistor R20 and RLOAD, capacitor C10, Darlington transistors Q10 and Q20, sub-circuit CP (FIG. 26), sub-circuit PFT 1 (FIG. 18), sub-circuit OUTB (FIG. 25A), sub-circuit IFB (FIG. 40B) and sub-circuit PWFM (FIG. 33).
Table Element Value/part number R20 5 k ohms Q10 TST541 Q20 IRFP460 C10 1.8 uf
[0104] External power source VBAT connects to pins DCIN+ and DCIN−. From DCIN+ connects to Q10 collector then through resistor R20 connects to sub-circuit CP pin CP+ and to sub-circuit PWFM pin PWFM+. Resistor R20 provides startup power to the converter before regulator sub-circuit CP reaches it full 18-volt output. VBAT negative is connected to pin DCIN− ground/return node GND. Node GND connects to sub-circuit PWFM 0 pin PWFM 0 , Q20 collector, C10, sub-circuit CP pin CT 0 and sub-circuit PFT 1 pin S 1 CT. Magnetic element winding node S 1 H of sub-circuit PFT 1 is connected to CP CT 1 A. Magnetic element winding node S 1 L of sub-circuit PFT 1 is connected to CP CT 2 A. Magnetic element winding node S 1 CT of sub-circuit PFT 1 is connected to CP pin CT 0 . Magnetic element winding node S 2 H of sub-circuit PFT 1 is connected to CP pin CT 2 A. The regulated 18 volts from sub-circuit CP+ is connected to R20 and to sub-circuit PWFM pin PWFM+. Sub-circuit PWFM is designed for a constant 50% duty cycle variable frequency generator. Sub-circuit PWFM clock output pin CLK is connected to the base of Q10 and Q20. The emitters of Q10 and Q20 are connected to sub-circuit PFT 1 pin P 1 B. This forms an emitter follower configuration. Pin P 1 A of sub-circuit PFT 1 is connected through tank capacitor C10 to node GND. With PWFM CLK pin high forward biased transistor Q10 supplies current to the tank from BAT 1 charging capacitor C10 through NSME PFT 1 and transferring energy into PFT 1 . Sub-circuit PWFM switches CLK low turning “off” Q10 stopping the current into PFT 1 . Energy not transferred into the load is released from NSME PFT 1 into the now forward biased PNP transistor Q20 back into capacitor C10. Thus any energy not used by the secondary loads is transferred back to the primary tank to be used next cycle. When the switching occurs at the resonant frequency large circulating currents develop in the tank. Also C10 is charged and discharged to very large voltages. Oscillograph in FIG. 35 is the actual voltage developed across capacitor C10 with VBAT equal to 18 volts. A very large 229-Volts peak to peak was developed across the nodes P 1 A and P 1 A of NSME PFT 1 . The large primary voltage generates large biases in the NSME PFT 1 to be flux harvested by the windings 102 and 103 (FIG. 18) and transferred to a load or rectifier sub-circuit OUTB. Magnetic element winding node S 2 L of sub-circuit PFT 1 is connected to OUTB C 8 b. Magnetic element winding node S 2 H of sub-circuit PFT 1 is connected to C 8 B of sub-circuit OUTB node OUT−. Node OUT− is connected to RLOAD, pin B− and to sub-circuit IFB pin OUT−. Rectified power is delivered to pin OUT+ of OUTB and is connected to RLOAD, pin B+ and to sub-circuit IFB pin OUT+. Sub-circuit IFB provides the isolated feedback signal to the sub-circuit PWFM. Frequency control pin FM 1 of sub-circuit PWFM is connected to sub-circuit IFB pin FBE. Internal reference pin REF of sub-circuit PWFM is connected to sub-circuit IFB pin FBC. PWFM is designed to operate at the resonate frequency of the tank. When sub-circuit IFB senses the converter output is at the designed voltage, current from REF is injected into FM1. Injecting current into FM 1 commands PWFM to a lower frequency. Operating below resonance reduces the amount of energy added to the primary tank thus reducing the converter output voltage. In the event the feedback signal from IFB commands the PWFM to 0 Hz all primary activity stops. Input current from VBAT is sinusoidal making the converter very quiet. In addition the switches Q10 and Q20 are never exposed to the large circulating voltage (FIG. 35). Placing less stress on the switches thereby increasing the MTBF. Sub-circuit TCTP takes advantage of the desirable properties of the NSME in this converter topology. Adjusting secondary turns allows TCTP to generate very large AC or DC output voltages as well as low-voltage high current outputs.
[0105] [0105]FIG. 9 is a schematic for non-isolated low side switch boost converter sub-circuit NILSBST. Sub-circuit NILSBST consists of resistor R20 and RLOAD, diode D 6 , capacitor C6, FET transistor Q111, sub-circuit CP (FIG. 26), sub-circuit PFT1A (FIG. 18A), sub-circuit FBI (FIG. 41), sub-circuit AMP (FIG. 29) and sub-circuit PWFM (FIG. 33).
Table Element Value/part number R20 100 k ohms Q111 IRFP460 D6 STA1206 DI C6 200 uf
[0106] External power source VBAT connects to pins DCIN+ and DCIN− From DCIN+Resistor R20 connects to sub-circuit CP pin CP+, sub-circuit AMP pin GA+ and to sub-circuit PWFM pin PWFM+. Resistor R20 provides startup power to the converter before regulator sub-circuit CP reaches it full 18-volt output. VBAT negative is connected to pin DCIN− and ground return node GND. Node GND connects to sub-circuit PWFM pin PWFM 0 , sub-circuit AMP pin GA 0 , Q111 source, sub-circuit FBA pin BR−, sub-circuit FBA pin FBA, sub-circuit CP pin CT 0 , capacitor C6, resistor RLOAD, transistor Q111 source, and sub-circuit PFT 1 pin S 1 CT . Magnetic element winding node S 1 H of sub-circuit PFT 1 A is connected to CP pin CT 1 A Magnetic element winding node S 1 CT of sub-circuit PFT 1 is connected to CP pin CT 0 . Magnetic element winding node S 2 H of sub-circuit PFT 1 A is connected to CP pin CT 2 A. The regulated 18 volts from sub-circuit CP+ is connected to R20, sub-circuit AMP pin GA+ and to sub-circuit PWFM pin PWFM+. Sub-circuit PWFM is designed for variable pulse width operation. PWFM is configured for maximum pulse width 90-95% (maximum boost voltage) with no feedback current from sub-circuit FBI. Increasing the feedback current reduces the pulse-width reducing the boost voltage and reducing the output from converter NILSBST. Sub-circuit PWFM clock/PWM output pin CLK is connected to the input pin GA 1 of buffer sub-circuit AMP. The output of sub-circuit AMP pin GA 2 is connected to the gate of Q111. Input node DCIN+ connects to the NSME PFT 1 A pin P 1 A. The drain of Q11 is connected to sub-circuit PFT 1 A pin P 1 B and the anode of D6. Cathode of diode D6 is connected to sub-circuit FBA pin PF+, resistor RLOAD, C6 and pin BK+. With sub-circuit PWFM pin CLK high buffer AMP output pin GA 2 charges the gate of transistor switch Q111. Switch Q111 conducts reverse biasing diode D6 capacitor C10 stops charging through NSME PFT 1 A from source VBAT. During the time Q111 is conducting, energy is stored in NSME sub-circuit PFT 1 A. Feedback output pin FBC from sub-circuit FBI is connected to sub-circuit PWFM pulse-width adjustment pin PW 1 Sub-circuit FBI removes current from PW 1 commanding PWFM to reduce the pulse-width or on time of signal CLK. After sub-circuit PWFM reaches the commanded pulse-width PFFM switches CLK low turning “off” Q111 stopping the current into PFT 1 A. The energy not transferred into regulator sub-circuit CP load is released from NSME PFT 1 A into the now forward biased diode D6 charging capacitor C6. By modulating the “on” time of switch Q111 the converter boost voltage is regulated. Regulated voltage is developed across Nodes B− and B+. Sub-circuit IFB provides the feedback current to the sub-circuit PWFM. When sub-circuit IFB senses the converter output (nodes B+ and B−) is at or greater than the designed voltage, current is removed from PM 1 . Sinking current from PM 1 commands the PWFM to a shorter pulse-width thus reducing the converter output voltage. In the event the feedback signal from IFB commands the PWFM to minimum output. Gate drive to switch Q111 is removed stopping all boost activity capacitor C6 charges to VBAT. Input current from VBAT is sinusoidal making the converter very quiet. In addition the switch Q111 is not exposed to large flyback voltage. Placing less stress on the switches thereby increasing the MTBF. Sub-circuit NILBK takes advantage of the desirable properties of the NSME in this converter topology. Adjusting the NSME 100 (FIG. 18A) primary inductance and component values in sub-circuit IFB determines the output boost voltage.
[0107] [0107]FIG. 10 is a schematic for a two stage isolated DC to DC boost controlled push-pull converter BSTPP. Sub-circuit BSTPP consists of diode D14, capacitor C14, FET transistor Q1 4 , sub-circuit REG (FIG. 36), sub-circuit BL 1 (FIG. 18B), sub-circuit IFB (FIG. 40B), sub-circuit AMP (FIG. 29), sub-circuit DCAC 1 and sub-circuit PWFM (FIG. 33). External power source VBAT connects to pins DCIN+ and DCIN−.
Table Element Value/part number Q31 IRFP460 D14 STA1206 DI C14 10 uf
[0108] From pin DCIN+ connects to sub-circuit REG pin RIN+ and sub-circuit BL 1 pin P 1 A. Voltage regulator sub-circuit output pin +18V connects to sub-circuit AMP pin GA+ and to sub-circuit PWFM pin PWFM+. Sub-circuit REG provides regulated low voltage power to the controller and to the main switch buffers. VBAT negative is connected to pin DCIN− and ground return node GND. Node GND connects to sub-circuit PWFM pin PWFM 0 , sub-circuit AMP pin GA 0 , Q14 source, capacitor C14, sub-circuit IFB pin FBE, sub-circuit REG pin REG 0 , sub-circuit DCAC 1 pin DC−. Sub-circuit PWFM (FIG. 33) is designed for variable pulse width operation. The nominal frequency is between 20-600 Khz PWFM is configured for maximum pulse width 90% (maximum boost voltage) with no feedback current from sub-circuit FBI. Increasing the feedback current reduces the pulse-width reducing the boost voltage and reducing the output from converter BSTPP. Sub-circuit PWFM clock/PWM output pin CLK is connected to the input pin GA 1 of buffer sub-circuit AMP (FIG. 29). The output of switch speed up buffer sub-circuit AMP pin GA 2 is connected to the gate of Q14. Input node DCIN+ connects to the NSME BL 1 pin P 1 A. The drain of Q14 is connected to sub-circuit BL 1 pin P 1 B and the anode of D14. Cathode of flyback diode D14 is connected to sub-circuit DCAC 1 pin DC+ and C14. With sub-circuit PWFM pin CLK high buffer AMP output pin GA 2 charges the gate of transistor switch Q14. Switch Q14 conducts reverse biasing diode D14 capacitor C14 stops charging through NSME BL 1 from source VBAT. During the time Q14 is conducting, energy is stored in NSME sub-circuit BL 1 . Feedback output pin FBC from sub-circuit IFB is connected to sub-circuit PWFM pulse-width adjustment pin PW 1 Sub-circuit IFB removes current from PW 1 commanding PWFM to reduce the pulse-width or “on” time of signal CLK. After sub-circuit PWFM reaches the commanded pulse-width PFFM switches CLK low turning “off” Q14 stopping the current into BL 1 . The energy is released from NSME BL 1 into the now forward biased flyback diode D14 charging capacitor C14. By modulating the “on” time of switch Q14 the converter boost voltage is regulated. Regulated voltage is developed across C14 Nodes DC+ and GND is provided to the isolated constant frequency push-pull DC to AC converter sub-circuit DCAC 1 (FIG. 2). Sub-circuit DCAC 1 provides efficient conversion of the regulated boost voltage to a higher or lower voltage set by the magnetic element-winding ratio. The center tap of the push-pull output magnetic is connected to, sub-circuit OUTB pin OUT−, RLOAD, sub-circuit IFB pin OUT− and the pin OUT− forming the return line for the load and feedback network. Output of sub-circuit DCAC 1 pin ACH is connected to sub-circuit OUTB pin C 7 b. Output of sub-circuit DCAC 1 pin ACL is connected to sub-circuit OUTB pin C 8 b. Sub-circuit OUTB provides rectification of the AC power generated by sub-circuit DCAC 1 . Since the non-saturating magnetic converter has low output ripple, minimal filtering is required by OUTB. This further reduces cost and improves efficiency as losses to filter components are minimized. Sub-circuit IFB provides the isolated feedback current to the sub-circuit PWFM. When sub-circuit IFB senses the converter output (nodes OUT+ and OUT−) is greater than the designed/desired voltage, current is removed from node PM 1 Sinking current from PM 1 commands the PWFM to a shorter pulse-width thus reducing the converter output voltage. In the event the feedback signal from IFB commands the PWFM to minimum output. Gate drive to switch Q14 is removed stopping all boost activity capacitor C14 charges to VBAT. As the non-saturating does not saturate the destructive noisy current “spikes” common to prior art are absent. Input current from VBAT to charge C14 is sinusoidal making the converter very quiet. In addition the switch Q14 is not exposed a potentially destructive current spike. Placing less stress on the switches thereby increasing the MTBF. Sub-circuit BSTPP takes advantage of the desirable properties of the NSME. Adjusting the NSME BL 1 (FIG. 18B) sets the amount of boost voltage available to the final push-pull isolation stage. Greater efficiencies are achieved at higher voltages. The final output voltage is set by the feedback set point and the turns ratio of the push-pull element PPT 1 (FIG. 19). FIG. 11 is a graph of permeability as a function of temperature for typical prior art magnetic element material. The high permeability material in FIG. 11 exhibits large changes in permeability of almost 100% over a 100C range as compared to the less than 5% change for the material in FIG. 17. The increase in permeability at high temperatures of the prior art material increases the flux density resulting in core saturation for a constant power level. (See FIG. 12) Thus the prior art core must be derated at least 100% to operate over extended temperatures. The instant invention takes advantage of the desirable properties of the NSME. Eliminating the need to derate the magnetic element. As the magnetic element performs better at high temperatures, currently limited by melting wire insulation.
[0109] [0109]FIG. 12 is a graph of flux density as a function of temperature for typical prior art magnetic element material. The reduction of maximum flux density with temperature is typical of the saturating magnetic element prior art material. Thus the prior art core is commonly derated at least 100% to operate over extended temperatures. Resulting in a larger more expensive design, and or the requirement to cool the core.
[0110] [0110]FIG. 12A is a graph of magnetic element losses for various flux densities and operating frequencies typical of prior art magnetic element material.
[0111] [0111]FIG. 13 is a graph showing standard switching losses. The hashed area represents the time when the switch is in a resistive state. The hashed area is proportional to the amount of energy lost each time the output switch operates. Total power lost is the product of the loss per switch times the switching frequency.
[0112] [0112]FIG. 14 is a graph showing the inventions switching losses. The hashed area represents the time when the switch is in a resistive state. The smaller hashed area is due to the action of the buffer in FIG. 29 and the snubber isolation diode D805 in FIG. 30. Generally the NSME has a wider usable frequency band and can be magnetized from higher primary voltages. Higher operating voltages have proportionally smaller currents for a given power level thus proportionally lower losses. Switching losses more closely resemble I 2 R losses. Most switching loss occurs during turn “on” and turn “off” transitions; total switching losses are reduced proportionally by the lower switching frequencies and faster transition times characteristic of the disclosed NSME converters. In addition the properties of the NSME allow operation at temperature extremes beyond the tolerance of standard prior art magnetics and their geometry's. The combined contributions of the above yields a converter that requires little or no forced air-cooling. (See FIGS. 15, 16, and 17 )
[0113] [0113]FIG. 15 is a graph of the NSME magnetization curves for Kool Mu material. The invention makes advantageous use of the available saturation range of the NSME.
[0114] [0114]FIG. 16 is a graph of the Kool Mu NSME losses for various flux densities and operating frequencies. It can be seen from the data that much higher flux densities are available per unit losses over the prior art.
[0115] [0115]FIG. 17 is a plot of permeability vs. temperature for several Kool Mu materials. This data demonstrates the usefulness and stability of the magnetic properties over temperature.
[0116] [0116]FIG. 18 is a schematic representation of the non-saturating magnetic boost element PFT 1 . Sub-circuit PFT 1 consists of a primary winding 100 around a NSME 101 with two center-tapped windings 102 and 103 .
Table Element Value/part number 100 55 turns 203 uh 101 2 × 77932-A7 102 14 turns 102 14 turns
[0117] The primary winding 100 has nodes P 1 B and P 1 A for connections to external AC source. Secondary 102 winding has center-tapped node S 1 CT and node S 1 H and S 1 L connections to the upper and lower halves respectively. Secondary 103 winding has center-tapped node S 2 CT and node S 2 H and S 2 L connections to the upper and lower halves respectively. Both 102 and 103 are connected to external full-wave rectifier assemblies. Magnetic element magnetic element 101 comprises a non-saturating, low permeability magnetic material. The permeability is on the order of 26 u with a range of 1 u to 550 u, as compared to the prior art, which ranges from 1500 to 5000 u. Flyback management is of concern when using NSME in a boost converter because the magnetic element generates high drain source voltages across the primary switch during the reverse recovery time of the flyback (output) diode. The magnitude per cycle of flyback current from NSME is greater for a given input magnetizing force relative to the prior art. (See FIG. 5) For example, Kool Mu torroids (Materials from Magnetics) are suitable for this application. This material is not identified by way of limitation. The material comprises, by weight, 85% iron, 6% aluminum, and 9% silicon. Further, the magnetic element may be air, (permeablity=1); a molypermalloy powder, (MPP) a high flux MPP, a powder, a gapped ferrite, a tape wound, a cut magnetic element, a laminated, or an amorphous magnetic element. Unlike the prior art, the NSME is temperature tolerant in that the critical parameters of permeability and saturability remain substantially unaffected during extreme thermal operation over time. Some materials such as air also exhibit little or no change in permeability or saturation levels over time, temperature, and conditions. The prior art uses high permeability saturable materials often greater than 2000 u permeability. These magnetics exhibit undesirable changes in permeability and saturation during operation at or near rated output making operation at high power levels and temperature difficult. See the permeability vs. temperature FIG. 11. This deficiency is overcome by the use of expensive oversized magnetic elements or output current sharing with multiple supplies. (See the graph b sat vs. temperature FIG. 12) This invention takes advantage of the desirable properties of NSME. See the permeability vs. temperature FIG. 17. Prior art saturating magnetic element commonly is operating at frequencies greater than 500 KHz to achieve greater power levels. As a result practitioners experience exponentially greater core losses (see FIG. 12A) at high frequencies. NSME support operation at lower frequencies 20-600 KHz further reducing switching losses and magnetic element losses allowing operation at even higher temperatures. See the loss density vs. flux density FIG. 16. Unlike the prior art, the instant invention uses voltage mode control with over-current shutdown. Material selection is also based upon mass and efficiency. By increasing the mass of the magnetic element, more energy is coupled more efficiently. Since there are reduced losses, the dissipation profile follows I2R/copper losses. The magnetic element is operated at duty cycles of 0%+ to 90%, which, when used to control the primary side push-pull voltage, results in efficiencies on the order of 90%.
[0118] [0118]FIG. 18A is a schematic representation of the NSME PFT 1 A Sub-circuit transformer PFT 1 A consists of a primary winding 100 around a NSME 101 with a center-tapped winding 102.
Table Element Value/part number 100 55 turns 230 uh 101 2 x 77932-A7 102 14 turns
[0119] The primary winding 100 has nodes P 1 B and P 1 A for connections to external AC source. Secondary 102 winding has center-tapped node S 1 CT and node S 1 H and S 1 L connections to the upper and lower halves respectively. Winding 102 are typically connected to external full-wave rectifier assemblies. Magnetic element 101 comprises a non-saturating, low permeability magnetic material. The permeability is on the order of 26 u with a range of 1 u to 550 u, as compared to the prior art, which is on the order of 2500 u.
[0120] Flyback management is of concern when using such a magnetic element because the magnetic element generates high drain source voltages acrofss the primary switch during the reverse recovery time of the flyback diode. Flyback current is available for longer periods after the primary switch opens. (See FIG. 5) For example, Kool Mu (Materials from Magnetics are suitable for this application. This material is not identified by way of limitation. The material comprises, by weight: 85% iron, 6% aluminum, and 9% silicon. Further, the magnetic element may be air; (air magnetic element permeablity=1); a molypermalloy powder (MPP) magnetic element; a high flux MPP magnetic element; a powder magnetic element; a gapped ferrite magnetic element; a tape wound magnetic element; a cut magnetic element; a laminated magnetic element; or an amorphous magnetic element. During operation the temperature of the NSME rises, the permeability slowly decreases, thereby increasing the saturation point. Some materials such as air exhibit no or very small changes in permeability or saturation levels. Unlike prior art using high permeability materials greater than 2000 u permeability rapidly increases at high temperatures. See the permeability vs. temperature FIG. 11. Prior art also suffers from reduced magnetic element saturation levels at high temperatures, making operation at high power levels and temperature difficult and may require the use of expensive oversized magnetic elements. See the graph bsat vs. temperature FIG. 12 this invention takes advantage of the desirable NSME properties. See the permeability vs. temperature FIG. 17. Operation at lower frequencies 20-600 KHz reduces switching losses and magnetic element losses allowing operation at higher temperatures. See the loss density vs. flux density FIG. 16. Unlike the prior art, the instant invention uses voltage mode control with over-current shutdown. Material selection is also based upon mass and efficiency. By increasing the mass of the magnetic element, more energy is coupled more efficiently. Since there are reduced losses, the dissipation profile follows I2R/copper losses. The magnetic element is operated at duty cycles of 0%+ to 90%, which, when used to control the primary side push-pull voltage, results in efficiencies on the order of 90%. FIG. 18B is a schematic representation of the NSME BL 1 Sub-circuit BL 1 consists of a winding 100 around a NSME 101.
Table Element Value/part number 107 40 turns 50 uh 101 2 x 77932-A7
[0121] Magnetic element BL 1 may also be constructed from one or more magnetic elements in series or parallel. Assuming minimal mutual coupling the total inductance is the arithmetic sum of the individual inductances. For elements in parallel the (assuming minimal mutual coupling) the total inductance is the reciprocal of the arithmetical sum of the reciprocal of the individual inductances. In this way multiple magnetic elements may be arranged to meet packaging, manufacturing, and power requirements. The primary winding 100 has nodes P 2 B and P 2 A for connections to external AC source. Magnetic element 101 comprises a non-saturating, low permeability magnetic material. The permeability is on the order of 26 u with a range of 1 u to 550 u, as compared to the prior art, which is on the order of 2500 to 5000 u. Flyback management is of concern when using such a magnetic element because the magnetic element generates high drain source voltages across the primary switch during the reverse recovery time of the flyback diode. Flyback current is available for longer periods after the primary switch opens. (See FIG. 5) For example, Kool Mu (Materials from Magnetics are suitable for this application. This material is not identified by way of limitation. The material comprises, by weight: 85% iron, 6% aluminum, and 9% silicon. Further, the magnetic element may be air (air magnetic element permeablity=1); a molypermalloy powder (MPP) magnetic element; a high flux MPP magnetic element; a powder magnetic element; a gapped ferrite magnetic element; a tape wound magnetic element; a cut magnetic element; a laminated magnetic element; or an amorphous magnetic element. During operation temperature of the magnetic element rises, the permeability slowly decreases, thereby increasing the saturation point. Some materials such as air exhibit no or very small changes in permeability or saturation levels. Unlike prior art using high permeability materials greater than 2000 u permeability rapidly increases at high temperatures. See the permeability vs. temperature FIG. 11. Prior art also suffers from reduced magnetic element saturation levels at high temperatures, making operation at high power levels and temperature difficult and may require the use of expensive oversized magnetic elements. (See the graph b sat vs. temperature FIG. 12) This invention takes advantage of the desirable NSME properties. (See the permeability vs. temperature FIG. 17.) Prior art often operates at high switching frequencies 100-1000 kHz to avoid the saturation problem. Only to increase switching and core losses. (See FIG. 12A) This inventions use of the desirable NSME properties allows operation at lower frequencies 20-600 KHz further reducing switching losses and magnetic element. See the loss density vs. flux density FIG. 16. Unlike the prior art, the instant invention uses voltage mode control with over-current shutdown. Material selection is also based upon mass and efficiency. By increasing the mass of the magnetic element, more energy is coupled more efficiently. Since there are reduced losses, the dissipation profile follows I2R/copper losses.
[0122] [0122]FIG. 18C is a schematic representation of a distributed NSME PFT 1 D. This is shown to exemplify distributed magnetics enable advantageous high voltage converter design variations that support form factor flexibility and multiple parallel secondary outputs from series coupled voltage divided primary windings across multiple NSME. This magnetic strategy is useful in addressing wire insulation, form factor and packaging limitations, circuit complexity and manufacturability. In this example a 500 W converter is required to fit in a low profile package. Sub-circuit PFTD 1 consists of three magnetic elements 120, 121 and 124 with series connected primaries.
Table Element Value/part number 113 77352-A7 122 23 Turns 123 23 Turns 112 67 uh (55 turns) 114 77352-A7 116 67 uh (55 turns) 117 77352-A7 118 67 uh (55 turns)
[0123] AC voltage is applied to 112 pin P 1 B then from P 1 C through conductor 115 to 116 pin P 1 D. Winding 116 pin P 1 E is connected through conductor 119 to 118 pins P 1 F then to pin P 1 A Original Sub-circuit PFT 1 (FIG. 18) consists of a primary winding 100 around a NSME 101 with two center-tapped windings 122 and 123. By way of example sub-circuit PFT 1 D will be implemented as three magnetic elements. For a 500 watt expression a total inductance of 203 uH is required in winding 100 (FIG. 18). Dividing the primary inductance by the number of elements, in this case three requires elements 112, 116 and 118 have 67 uH of inductance. The energy storage is equally distributed over the magnetic assembly 120, 121 and 124. The 500 watt converter in (FIG. 1) employs two (Kool Mu part number 77932 2-A7) 0. 9 oz (25 gram) NSME to form 101 (FIG. 18). Sub-circuit PFT 1 magnetic element 101 (FIG. 18) may be expressed as three 0.5-0.7 oz (14-19 gram) elements. Three 0.5-oz Kool Mu elements (part number 77352-A7) were selected. To realize 67 uH of primary inductance 55 turns are required for elements 112, 116 and 118. The primary circuit has nodes P 1 B and P 1 A for connections to external AC source. Secondary 102 winding has center-tapped node S 1 CT and node S 1 H and S 1 L connections to the upper and lower halves respectively. Secondary 123 winding has center-tapped node S 2 CT and node S 2 H and S 2 L connections to the upper and lower halves respectively. Both 122 and 123 are connected to external full-wave rectifier assemblies. Magnetic element magnetic element 120, 121 and 124 comprises a non-saturating, low permeability magnetic material. The permeability is on the order of 26 u with a range of 1 u to 550 u, as compared to the prior art, which is on the order of 2500 u. Flyback management is of concern when using such a magnetic element because the magnetic element generates high drain source voltages across the primary switch during the reverse recovery time of the flyback diode. Flyback current is available for longer periods after the primary switch opens. (See FIG. 5) For example, Kool Mu (Materials from Magnetics are suitable for this application. This material is not identified by way of limitation. The material comprises, by weight: 85% iron, 6% aluminum, and 9% silicon. Further, the magnetic element may be air (air magnetic element permeablity=1); a molypermalloy powder (MPP) magnetic element; a high flux MPP magnetic element; a powder magnetic element; a gapped ferrite magnetic element; a tape wound magnetic element; a cut magnetic element; a laminated magnetic element; or an amorphous magnetic element. During operation the temperature of the NSME, the permeability slowly decreases, thereby increasing the saturation point. Some materials such as air exhibit no or very small changes in permeability or saturation levels. Unlike prior art using high permeability materials greater than 2000 u permeability rapidly increases at high temperatures. See the permeability vs. temperature FIG. 11. Prior art also suffers from reduced magnetic element saturation levels at high temperatures, making operation at high power levels it and temperature difficult and may require the use of expensive oversized magnetic elements. (See the graph b sat vs. temperature FIG. 12) This invention takes advantage of the desirable NSME properties. See the permeability vs. temperature FIG. 17. Prior art saturating magnetic element commonly is operating at frequencies greater than 500 KHz to achieve greater power levels. As a result practitioners experience exponentially greater core losses (see FIG. 12A) at high frequencies. NSME allows operation at lower frequencies 20-600 KHz further reduces switching losses and magnetic element losses allowing operation at even higher temperatures. (See the loss density vs. flux density FIG. 16) Unlike the prior art, the instant invention uses voltage mode control with over-current shutdown. Material selection is also based upon mass and efficiency. By increasing the mass of the magnetic element, more energy is coupled more efficiently. Since there are reduced losses, the dissipation profile follows I2R/copper losses. The magnetic element is operated at duty cycles of 0%+to 90%, which, when used to control the primary side push-pull voltage, results in efficiencies on the order of 90%.
[0124] [0124]FIG. 19 is a schematic representation of the non-saturating push-pull magnetic element sub-circuit PPT 1 Sub-circuit PPT 1 consists of a center-tapped primary winding 104 around a NSME 106 with one secondary center-tapped winding 105 .
Table Element Value/part number 106 77259-A7 105 10 Turns 104 70 Turns
[0125] The primary winding 104 has nodes P 2 H and P 2 L for connections to external AC sources, and common center-tap node P 2 CT. Secondary 105 winding has center-tapped node SCT and nodes SH and SL connections to the upper and lower halves respectively. The invention is not limited to a single output. More secondary windings may be added for additional outputs. Secondary 105 is connected to an external full-wave rectifier assembly (Example FIG. 25 or 26 ). The magnetic element magnetic element 106 comprises a non-saturating, low permeability magnetic material. The permeability is on the order of 26 u with a range of 1 u to 550 u, as compared to the prior art, which is on the order of 2500 u. Flyback management is of concern when using such a magnetic element as high drain source voltages across the primary switch are generated during the reverse recovery of the flyback diode. The falling flyback current is available for a longer period. (See FIG. 5) For example, Kool Mu (magnetic elements from Magnetics are suitable for this application. This material is not identified by way of limitation. The material comprises, by weight; 85% iron, 6% aluminum, and 9% silicon. Further, the magnetic element may be air (comprise an air magnetic element); a molypermalloy powder (MPP) magnetic element; a high flux MPP magnetic element; a powder magnetic element; a gapped ferrite magnetic element; a tape wound magnetic element; a cut magnetic element; a laminated magnetic element; or an amorphous magnetic element. During operation the temperature of the NSME rises, the permeability slowly decreases, thereby increasing the saturation point. Unlike prior art using high permeability materials greater than 2000 u permeability rapidly increases at high temperatures. See the permeability vs. temperature FIG. 11. Prior art also suffers from reduced magnetic element saturation levels at high temperatures, making operation at high power levels and temperature difficult and may require the use of expensive oversized magnetic elements. (See the bsat vs. temperature FIG. 12) This invention takes advantage of the desirable NSME properties. (See the permeability vs. temperature FIG. 17) Operation at lower frequencies 20-600 KHz reduces switching losses and magnetic element losses allowing operation at higher temperatures. See the loss density vs. flux density FIG. 16. Unlike the prior art, the instant invention uses voltage mode control with over-current shutdown. Material selection is also based upon mass and efficiency. By increasing the mass of the magnetic element, more energy is coupled more efficiently. Since there are reduced losses, the dissipation profile follows I2R/copper losses. The magnetic element primary is driven in a push-pull fashion at a duty cycle of 48-49% resulting in efficient use of the magnetic element volume.
[0126] [0126]FIG. 19A is a schematic representation of the non-saturating push-pull magnetic element sub-circuit PPT 1 . Sub-circuit PPT 1 consists of a center-tapped primary winding 134 around a NSME 136 with one secondary center-tapped winding 135 .
Table Element Value/part number 136 77259-A7 135 10 Turns 134 70 Turns
[0127] The primary winding 134 has nodes P 2 H and P 2 L for connections to external AC sources, and common center-tap node P 2 CT. Secondary 135 winding has center-tapped node SCT and nodes SH and SL connections to the upper and lower halves respectively. The invention is not limited to a single output winding. More secondary windings may be added for additional outputs. Secondary 135 is connected to an external full-wave rectifier assembly such as OUTA (FIG. 25), OUTB (FIG. 25A) and OUTBB (FIG. 25B). The magnetic element 136 comprises a non-saturating, low permeability magnetic material. The permeability is on the order of 26 u with a range of 1 u to 550 u, as compared to the prior art, which is on the order of 2500 u. Flyback management is of concern when using such a magnetic element as high drain source voltages across the primary switch are generated during the reverse recovery of the flyback diode. The falling flyback current is available for a longer period. (See FIG. 5) For example, Kool Mu (magnetic elements from Magnetics are suitable for this application. This material is not identified by way of limitation. The material comprises, by weight; 85% iron, 6% aluminum, and 9% silicon. Further, the magnetic element may be air (comprise an air magnetic element); a molypermalloy powder (MPP) magnetic element; a high flux MPP magnetic element; a powder magnetic element; a gapped ferrite magnetic element; a tape wound magnetic element; a cut magnetic element; a laminated magnetic element; or an amorphous magnetic element. During operation the temperature of the NSME rises, the permeability slowly decreases, thereby increasing the saturation point. Unlike prior art using high permeability materials greater than 2000 u permeability rapidly increases at high temperatures. See the permeability vs. temperature FIG. 11. Prior art also suffers from reduced magnetic element saturation levels at high temperatures, making operation at high power levels and temperature difficult and may require the use of expensive oversized magnetic elements. (See the bsat vs. temperature FIG. 12) This invention takes advantage of the desirable NSME properties. (See the permeability vs. temperature FIG. 17) Operation at lower frequencies 20-600 KHz reduces switching losses and magnetic element losses allowing operation at higher temperatures. See the loss density vs. flux density FIG. 16. Unlike the prior art, the instant invention uses voltage mode control with over-current shutdown. Material selection is also based upon mass and efficiency. By increasing the mass of the magnetic element, more energy is coupled more efficiently. Since there are reduced losses, the dissipation profile follows I2R/copper losses. The magnetic element primary is driven in a push-pull fashion at a duty cycle of 48-49% resulting in efficient use of the magnetic element volume.
[0128] [0128]FIG. 20 lightning input protection and filter sub-circuit LL
[0129] [0129]FIG. 20 is a schematic showing the inventions filter and lightning input protection circuit for an AC line connected converter. The protection sub-circuit LL comprises a Spark gap A1, diodes D20 and D21, capacitor C1 and magnetic 15 elements L1 and L2.
Table Element Value/part number L1 375 uH L2 375 uH C61 0.01 uF C60 0.01 uF A1 400V Spark Gap C1 0.1 uF D20 1000V/25A D21 1000V/25A D22 1000V/25A D23 1000V/25A C2 1.8 uf
[0130] The AC line is connected to node LL 2 The common input frequencies of DC to 440 Hz may be extended beyond this range with component selection. Node LL 2 is connected to NSME L 1 then to node LL 5 , the spark gap A1, anode of diode D22 and the cathode of diode D20. Filter capacitor C60 is connected between node LL 0 and LL 6 . Filter capacitor C61 is connected between node LL 0 and LL 5 . The low side of AC line is connected to node LL 1 then to magnetic element L2 the other side L2 is connected to spark gap A1, anode of diode D23 and the cathode of diode D21 and to node LL 6 Capacitor C1 is connected to earth ground C1 attenuates noise generated by the converter. The use of non-saturating magnetic allows the input magnetic elements to absorb very large voltages and currents commonly generated by lightning, often without causing spark gap A1 to clamp. During UL testing sixty 16 ms 2000V pulses were applied between LL 1 and LL 2 without realizing spark gap A1 was missing with out damage. During normal operation the NSME L1 flux density is a few hundred gauss. The 75 u material from the graph of Flux Density v. Magnetizing Force (FIG. 15) will accept flux densities at least 50 times greater with out limitation. This is an example of the magnetic elements ability to perform well at flux densities many times greater than prior art. Elements L1 and L2 will block differential or common mode line transients. In the event of a very large or long duration line to neutral transient, spark gap A1 will clamp the voltage to a safe level of about 400V. The NSME L1 and L2 have the added benefit of reducing conducted noise generated by the converter.
[0131] [0131]FIG. 21 alternate lightning input protection sub-circuit LLA
[0132] [0132]FIG. 21 is a schematic showing the inventions alternate lightning protection sub-circuit for an AC line connected converter. The protection circuit comprises a fuse F1, Spark gap A1, capacitors C1, C60 and C61 and NSME L3.
Table Element Value/part number L3 750 uH C61 0.01 uF C60 0.01 uF F1 10A A1 400V Spark Gap C1 0.1 uF D20 1000V/25A D21 1000V/25A D22 1000V/25A D23 1000V/25A C2 1.8 uf
[0133] High side of AC line is connected to node LL 2 , fuse F1 the load side of the fuse is connected to NSME L3 and to capacitor C61. The load side L3 is connected to spark gap A1 and the cathode of diode D20 and anode of D22 forming node LL 5 . The low side of AC line is connected to node LL 6 , capacitor C60, spark gap A1, and the cathode of diode D 21 and anode of D23. The anodes of diodes D20 and D21 are connected to Capacitor C1. Capacitor C1 is connected to earth ground. C1 attenuates radiated noise or EMI generated by the converter. The cathode of diodes D22 and D23 are connected to Capacitor C2. Capacitor C2 decouples high frequency harmonic currents from the line. Capacitors C1, C61 and C60 are connected to earth ground node LL 0 . The use of non-saturating magnetics allows the input magnetic element to absorb very large voltages and currents commonly generated on the AC line by lightning. A transient on the AC line will be limited by capacitors C60 and C61 and blocked by the non-saturating magnetic L3. In the event of a very large or long duration line to neutral transient, magnetic element L3 will allow the voltage to rise across spark gap A1, the spark gap will clamp the voltage to a of safe level protecting the rectifier diodes D20-D23. The NSME L3 has the added benefit of reducing conducted noise generated by the converter. C1 connected to the ground plane is effective in attenuating conducted and radiated EMI.
[0134] [0134]FIG. 22 AC line rectifier sub-circuit BR
[0135] [0135]FIG. 22 is a schematic showing the inventions AC line rectifier. The rectifier sub-circuit BR 1 comprises diodes D20, D21, D22 and D23 and capacitor C2.
Table Element Value/part number D20 1000V/25A D21 1000V/25A D22 1000V/25A D23 1000V/25A C2 1.8 uf
[0136] An AC or DC signal from the input filter is connected to bridge rectifier to nodes BR 1 and BR 2 . Node BR 1 connects diode D22 anode to D20 cathode. Node BR 2 connects diode D23 anode to D21 cathode. Node BR+ connects diode D22 cathode to D23 cathode. Node BR− connects diode D20 anode to D21 anode. The common input frequencies of DC to 440 Hz may be extended beyond this range with component selection. Capacitor C2 is selected to improve power factor for a particular operating frequency and to de-couple switching currents from the line. Diodes are selected to reliably block the expected line voltage and current demands of the next converter stage.
[0137] [0137]FIG. 23 controller sub-circuit PFA
[0138] [0138]FIG. 23 is the inventions AC to DC controller sub-circuit. Sub-circuit PFA consists of resistors R313 and R316, capacitors C308, and C313 and PWM controller IC U 1 A.
Table Element Value/part number C311 0.1 uf C308 .01 uf R313 15k ohms R316 15k ohms C313 4700 pf R308 25k ohms U1A MIC38C43 (Micrel)
[0139] Control element U1A connects to a circuit with the following series connections: from pin 1 to feedback node/pin PF 1 then to capacitor C308 then to the pin 2 node of U1A. Internal 5.1-volt reference U1A pin 8 or node PFA 2 through resistor R308 to the pin 4 node. U1A pin 4 is connected through capacitor C313 to return node BR−. This arrangement allows the PFC output to be pulse width modulated with application of voltage to PF 1 . External feedback current applied to U1A pin 1 and node PF 1 . Node PFVC is connected to resistor R313 to pin 3 of U1A . Resistor R316 is connected to pin 3 then to return node BR−. Power pin 7 is connected to node PFA+. Control element switch drive U1A pin 6 is connected to node PFCLK. Return ground node of U1A pin 5 is connected to return node BR−. In the event of a component failure in the primary feed networks such as IPFFB (FIG. 40), FBA (FIG. 40A), IFB (FIG. 40B) and FBI (FIG. 41). The output voltage of the boost stage may rapidly increase to destructive levels. Fast over voltage feedback networks IOVFB (FIG. 40C) or OVP 2 (FIG. 42B) increases the current into PF 1 thereby limiting the output voltage to a safe level. In addition latching type over voltage protection networks such as OVP (FIG. 42), OVP 1 (FIG. 42A) and OVP 2 (FIG. 42B) maybe used. The latching type kills power to the control circuit thereby stopping the boost action. The latching type networks require power to be cycled to the converter to reset the latch. IFB Input node PFVC is connected to resistor R313 to internal zero crossing detector connected to pin 3 and through R316 to return node BR−. PFVC is connected to a magnetic element winding referenced to BR−. A new conduction cycle is started each time the bias in the magnetic element goes to zero. Power factor corrected is realized by chopping the input at a high frequency. The average pulse width decreases at higher line voltage and increases at lower voltage for a given load. Frequency is lower at line peaks and higher around zero crossings. In this way the converter operates with a high input power factor.
[0140] [0140]FIG. 24 Controller with power factor corrected sub-circuit PFB FIG. 24 is the alternate power factor controller sub-circuit. Sub-circuit PFB consists of resistors R313, R339, R314, R315, R328, R340, R341 and R346, diode D308, capacitors C310, C318, C338, C340, C341 and C342, transistor Q305, and control element IC U1B.
Table Element Value/part number Q305 BCX70KCT R339 432k ohms C338 0.22 uf C318 0.22 uf R314 2.2 MEG ohms R315 715k ohms C341 0.33 uf C342 0.01 uf C340 0.001 uf R328 1 MEG ohms R346 7.15k ohms D308 10BQ040 R340 449k ohms R313 22k ohms U1B MC34262 (Motorola) R341 499k ohms
[0141] Control element U1B connects to a circuit with the following series connections: from pin 1 to node/pin PF 1 to capacitor C338 in series with resistor R339, and then to the pin 2 node of U1B. Pin 1 is the input to an internal error amplifier and connection to external feedback networks. (See FIGS. 40, 40A, 40 B, 40 C and 41 ) Increasing the voltage on pin 1 decreases the pulse width of the PFCLK node pin 7 . Resistor R328 is connected to the fullwave rectified AC line haversine voltage on node BR+ then to U1B pin 3 and then to resistor R346 in parallel with capacitor C342 to return node BR−. Node PFSC connects to series resistors [R341+ R340] which are connected to U1B pin 4 then to diode D308 in parallel with capacitor C340 to return node BR−. Power to PFC controller is applied to node PFB+and to U1B pin 8 . Output clock node PFCLK is connected to U1B pin 7 , to external buffer sub-circuit AMP (FIG. 29). Transistor Q305 collector is connected to the pin 2 node of U1B. The base is connected in series through resistor R314 to capacitor C318, then to the pin 2 node of U1B. The base is also connected to [C310||R315], then to return node BR− Emitter of Q305 is connected to return node BR−. Transistor Q305 provides a soft start compensation ramp to the controller error amp reducing the stress and DC overshoot in the converter at power up. Capacitor C341 is connected from U1 pin 2 to return node BR−. U1B pin 1 is connected to pin PF 1 , capacitor C338 in series with resistor R339 to transistor Q305 collector and to U1 pin 2 . Current switched by PFC power switch Q1 (FIGS. 4 & 3) is sensed by R26 (see FIG. 4). Series resistors [R340+R341] to U1B pin 4 connect voltage developed across R26. This voltage is compared to an internal 1.5-volt reference, comparator output turns off the switch drive pin 7 of U1B during times of high current that occur during startup or during very high load or low line conditions. Capacitor C340 is connected between U1 pin 4 to return node BR− filter high frequency components. Schottky diode D308 connected between U1 pin 4 to return node BR− protects the controller (U1 pin 4 ) substrate from negative current injection. Maximum switch current value is set by R26 over currents are automatically limited in each cycle by the PFC controller. The rectified fullwave haversine at pin 3 of U1B is multiplied by the error voltage on pin 2 . The product is compared to the magnetic element/switch current measured by R26 on pin 4 . Gate drive on pin 7 turns off when the sensed magnetic element current increases to the current comparator level. This action has the effect of modulating the switch Q1 “on” time tracking the AC line voltage. External feedback networks are connected to node PF 1 . In the event of a component failure in the primary feed network such as IPFFB (FIG. 40), FBA (FIG. 40A), IFB (FIG. 40B) and FB 1 (FIG. 41). The output voltage of the boost stage may rapidly increase to destructive levels. Fast over voltage feedback networks IOVFB (FIG. 40C) or OVP 2 (FIG. 42B) increases the current into PF 1 thereby limiting the output voltage to a safe level. In addition latching type over voltage protection networks such as OVP (FIG. 42), OVP 1 (FIG. 42A) and OVP 2 (FIG. 42B) maybe used. The latching type removes power to the control circuit thereby stopping the boost action. The latching type networks require power to be cycled to the converter to reset the latch. Modulating the voltage at PF 1 changes the duty cycle of the PFC and the final output voltage. In this way the PFC may be used as a pre-regulator to additional output stages.
[0142] [0142]FIG. 25 Output rectifier and filter sub-circuit OUTA
[0143] [0143]FIG. 25 is a schematic of a full wave rectified output stage and filter sub-circuit OUTA. The rectifier stage consists of diodes D80 and D90. The filter consists of resistor R21, magnetic element L30 and capacitors C26, C27, C28, C29, C30, C31 and C32.
Table Element Value/part number D80 40CTQ150 D90 40CTQ150 R21 100 ohms C26 500 pf C27 200 pf C28 0.1 uf C29 10,000 uf C30 10,000 uf C31 0.1 uf C32 200 pf L30 10 uh
[0144] Input node/pin C 8 B is connected to the high side of external center-tapped magnetic element secondary winding. Node C 8 B connects to anode of diode D8 and to capacitors C26 and C27 in the following arrangement. Capacitor C27 is connected across diode D80, capacitor C26 is connected in series to R21. Input node/pin C8B is connected to the low side of external center-tapped magnetic element secondary winding. Pin C8B is connected to anode of diode D9 and to resistor R21, capacitor C32 is connected across diode D90. Capacitors C27 and C32 is a small value to reduce high frequency noise generated by rapid switching the high speed rectifier D80 and D90 respectively. Capacitor C26 and resistor R21 are used to further dissipate high frequency energy. Anode of diodes D80 and D90 is connected to parallel capacitors C281 IC29 and NSME L30. Capacitors C28 and C31 are solid dielectric types selected for low impedance to high frequency signals. Capacitors C29 and C30 are larger polarized types selected for low impedance at low frequencies and for energy storage. Magnetic element L3 is connected to diode D8 cathode the second terminal of L30 is connected to parallel capacitors C31 and C30 and pin OUT+. Node OUT+ is the output positive and is connected to external feedback sense line to isolated feedback network. The other side of parallel capacitors [C28||C29||C30||C31] is connected to pin OUT− and the center-tap of the magnetic element secondary forming the return node. The combination of capacitors [C28||C29], L30 and capacitors [C30||C31] form a low pass pi type filter. Sub-circuit OUTA performs efficient fullwave rectification and filtering.
[0145] [0145]FIG. 25A Output rectifier sub-circuit OUTB
[0146] [0146]FIG. 25A is a schematic of a full wave rectified output stage. The rectifier stage consists of diodes D80 and D90 and capacitors C931 and C928.
Table Element Value/part number D80 40CTQ150 D90 40CTQ150 C928 .01 uf C931 10,000 uf
[0147] Input node/pin C 8 B is connected to high side of external center-tapped magnetic element secondary winding. Node C7B connects to anode of diode D80. Input node/pin C8B is connected to low side of external center-tapped magnetic element secondary winding is connected to anode of diode D90. Node OUT− is the negative output and return line to the external isolated feedback network and load not shown. Cathodes of diodes D80 and D90 are connected to parallel capacitors C931 and C928. Capacitor C928 is a solid dielectric type selected for low impedance to high frequency signals. Capacitor C931 is a larger polarized selected for low impedance to low frequency signals and for energy storage. Node OUT+ is the output positive and is connected to external feedback sense line to isolated feedback network. The other side of parallel capacitors C928 ||C931 is connected to the center-tap of the magnetic element secondary forming the node OUT−. The use of the NSME for the push-pull magnetic element requires only minimal filtering after the rectifiers.
[0148] [0148]FIG. 25B AC rectifier and filter sub-circuit OUTB
[0149] [0149]FIG. 25B is a schematic diagram of an alternate final sub-circuit OUTB comprises diodes D40, D41, D42 and D43 and capacitor C931 and C928.
Table Element Value/part number D40 40CTQ150 D41 40CTQ150 D42 40CTQ150 D43 40CTQ150 C928 .01 uf C931 10,000 uf
[0150] An AC or DC signal is connected to nodes C7B and C8b. Node C7B connects diode D41 anode to D40 cathode. Node C 8 b connects diode D42 anode to D43 cathode. Node OUT+ connects diode D42 cathode to D43 cathode. Node OUT− connects diode D40 anode to D43 anode. Diodes are selected to reliably block the expected line voltage and current demands of the load. For low voltage outputs, Schottky type diodes are used due to their low forward voltage drop. Higher voltages would use high-speed silicon diodes due to their ability to withstand high peak inverse voltage (PIV). The use of the NSME for the push-pull magnetic element requires only minimal filtering after the rectifiers. Capacitor C928 is shown schematically as a single device. Capacitor C931 is a larger polarized selected for low impedance to low frequency signals and for energy storage a typical value may be 200 uF. To increase the capacitance or reduces the output impedance multiple capacitors may be used. C931 is a solid dielectric type and is selected for it's low impedance to high frequencies. As is selected to reduces noise for a particular operating frequency and power level. Capacitor C928 is selected for the operating frequency and power level. Sub-circuit OUTB performs AC to DC rectification and filtering at slightly lower efficiency due to the extra junctions.
[0151] [0151]FIG. 26 Floating 18_Volt DC control power sub-circuit CP Sub-circuit CP consists of diodes D501, D502 and D503, resistor R507, regulator Q504, and capacitors C503, C504, C505, C506, and C507.
Table Element Value/part number C503 .33 uF C504 100 uF D501 MURS120T3 C505 .33 uf Q504 LM7818A C508 100 uf C507 100 uf D503 MURS130T3 D502 MURS120T3
[0152] Node CT 1 A connects to anode of D503 and to the upper external center tapped secondary winding. Node CT 2 A connects to anode of D502 and to the lower external center tapped secondary winding. Node CT 0 connects to the external winding center tap. Node CT 0 is also the return line and it connects to Q504 pin 2 , and capacitors C503, C504, C505, C506, and C507. The cathode of each of diodes D502 and D503 is connected to resistor R507. R507 is then connected to the pin 1 (input) node of voltage regulator Q504. Voltage regulator Q504 Pin 3 is the 18 vdc regulated DC output is connected to the anode of blocking diode D501. Three-pin voltage regulator Q504 is of the type LM7818 a common device made by a number of manufacturers. Capacitors C503, C505, C506 are 0.1 uF solid dielectric type and are used to filter high frequency ripple and to prevent Q504 from oscillating. The junction of C503, C504 and D501 cathode is the output node CP 1 +. Isolated 18-volt DC is available between nodes CT 0 and CP+. Used for regulator circuits and output switch drive during normal operation. FIG. 27 second Floating 18_Volt DC push-pull control power sub-circuit CPA. Sub-circuit CPA consists of diodes D601, D602 and D603, resistor R607, regulator B604 and capacitors C603, C604, C605, C606, C607 and C608.
Table Element Value/part number C603 .33 uF C604 100 uF D601 MURS12OT3 C605 .33 uF Q604 LM7818A C608 100 uF C607 .22 uF R607 7.5 ohms D603 MURS120T3 D602 MURS120T3
[0153] Node CT 1 B connects to anode of D603 and to the upper external center tapped secondary winding. Node CT 2 B connects to anode of D602 and to the lower external center tapped secondary winding. Node CT 20 connects to the external winding center tap. Node CT 0 is also the return line and it connects to Q604 pin 2 , and capacitors C603, C604, C605, C606, and C607. The cathode of each of diodes D602 and D603 is connected to resistor R607. R607 is then connected to the pin 1 (input) node of voltage regulator Q604. Voltage regulator Q604 Pin 3 is the 18 vdc regulated DC output and is connected to the anode of blocking diode D601. Capacitors C603, C605, C606 are solid dielectric type and are used to filter high frequency ripple and to prevent Q604 from oscillating. The junction of C603, C604 and D601 cathode is the output node CP 1 +. Isolated 18-volt DC is available between nodes CT 20 and CP 2 +. To be used for regulator circuits and output switch drive during normal operation.
[0154] [0154]FIG. 28 over temperature protection sub-circuit OTP
[0155] [0155]FIG. 28 is the main switch over temperature protection sub-circuit OTP. The sub-circuit OTP comprises thermal switch and resistors R711 and R712.
Table Element Value/part number THS1 67F105 (105C) R711 20 ohms R712 20 ohms
[0156] Gate drive power is applied to input node GAP and to thermal switch THS 1 . Maximum FET gate voltage requires the input power voltage be less than 20 volts, the voltage selected was 18 volts. The other side of THS 1 is connected to parallel resistors [R711||R712 ]. A single resistor may represent the resistors. The figure depicts the surface mount arrangement. The other side of [R711||R712] connects to output node TS+. Normally closed thermal switch TS 1 is in contact with main switch transistor Q 1 . In the event of temperature greater than 105C THS 1 opens, thus removing power to the buffer sub-circuit AMP 1 (FIG. 29) causing switch Q 1 to default to a blocking state protecting the boost switch should the optional cooling fan fail or the circuit reach high temperatures. In this instant invention the speed up buffer AMP (FIG. 29) non-saturating magnetics (FIGS. 18, 18A and 19 ) allows the main switch and to run cooler than prior art for a given power level. When switch temperature returns to normal range THS 1 will close, allowing the PFC to resume normal operation. Under normal load and ambient temperatures the thermal switch THS 1 should never open.
[0157] [0157]FIG. 29 PFC Buffer Circuit sub-circuit AMP, AMP 1 , AMP 2 , AMP 3
[0158] Switch drive command from PFCLK (FIGS. 23 and 24 ) or PWFM (FIG. 33) control elements are connected to a gate buffer circuit. The sub-circuit AMP is comprised of power FET Q702, Darlington pair Q703, capacitors C709 and C715, and resistors R710 and R725.
Table Element Value/part number C715 1000 pf C709 33 uF Q702 NOS355NCT Q703 FZT705CT R710 0 ohms R725 22.1 k ohms
[0159] DC Power is applied to node GAT+ to transistor Q702 drain and to capacitor C709, which goes to ground. Maximum gate voltage requires the input power voltage must be less than 20 volts, 18-volts was selected. Input node GA 1 is connected to the gate of FET Q702 is connected to the base of BJT 1 of the Darlington pair Q703 and to capacitor C715. C715 is connected across the Darlington pair from the base, pin 1 , to the collectors, pins 2 and 4 , Q703 collector node is also connected to ground. The emitter of BJT 2 is connected to the gate of FET Q 1 . The source of FET Q702 is connected through small optional series resistor R710 to the gate of the output switch or node GA 2 . Some power FET's under certain load may tend to oscillate when driven from a low impedance source such as this buffer. A small resistance of approximately 2 ohms or less may be required with out significant slowing of the switch. In most cases in R710 is replaced with a zero ohm jumper. Resistor R725 is connected from node GA 0 and source of Q702. The input switching signal to node GAP is in range of 20 kHz to 600 kHz. Very fast “on” times are realized by proving a low impedance to rapidly charge the output switch gate connected to node GA 2 . Capacitor C709 provides additional current when Q702 switches on. Transistor Q703 provides low impedance to rapidly remove the charge from the gate greatly reducing the “off” time. This particular topology provides output switch rise times on the order of 10 ns, as compared to the industry standard rise time of 250 ns. The corresponding fall time is <10 nS, again as compared to an industry fall time of 200-300 ns (See FIGS. 13 and 14 ). In the event the converter is operated at very high ambient temperatures a thermal switch may be placed in series with input power pin GA+. This allows the switch transistor to be gracefully disabled. Sub-circuit AMP greatly reduces switching losses allowing converter operation in some cases with out the common prior art forced air-cooling.
[0160] [0160]FIG. 30 snubber sub-circuit SN
[0161] [0161]FIG. 30 is a schematic diagram of a snubber sub-circuit of the invention. The snubber sub-circuit SN is comprised of diodes D804 and D805 and resistors R800, R817, R818, and capacitors C814 and C819.
Table Element Value/part number R800 12 ohms R817 1 mohm R818 1 mohm C814 33 pF C819 560 pF D805 MUR160
[0162] Node SNL 2 connects to the drain terminal of the external output switch and to flyback side of the inductive load. Input node SNL 2 connects to R800 in series with capacitor C819 to node SNOUT. Diode D805 anode is connected to node SNL 2 with resistors [R817||R818] in parallel with D805. Resistors R817 and R818 may be combined to a single resistor. The cathode of D805 is connected to capacitor C814 that connects to node/pin SNL 1 . Node SNL 1 connects to the supply side of external load magnetic element. The other leg of external magnetic element is connected to the anode of D805 and the anode side of external flyback diode D4. The one MEG ohm resistors R817 and R818 bleed the charge from C814 resetting it for the next cycle. Capacitor C819 and resistor R800 captures the high frequency event from the transition of external flyback diode D4 and moves part of the energy into the external holdup capacitor connected to node SNOUT. Since external flyback diode D4 and D805 isolate the drain of the output switch, faster switching occurs because the output switch does not have to slew the extra capacitance of a typical drain/source connected snubber circuit. Note that this circuit does not attempt to absorb the flyback in large RC networks that convert useful energy to losses. Nor does it attempt to stuff the flyback to ground, adding capacitance and slowing the output switch and increasing switching losses. This sub-circuit is used with it's mirror SNB (FIG. 32) across the external push-pull switches. This design returns the some of the flyback energy back to the input supply or output load. The “snubbering” action slows the rise of the flyback giving time for the external flyback diode to start conduction. The circuit efficiently manages high frequency flyback pulses.
[0163] [0163]FIG. 30A diode snubber sub-circuit DSN
[0164] [0164]FIG. 30A is a schematic diagram of a diode snubber sub-circuit of the invention. The snubber sub-circuit DSN is comprised of diodes D51, D52, D53, D54 and D55 and capacitors C51, C52, C53, C54 and C55.
Table Element Value/part number C51 220 pf 100 v C52 220 pf 100 v C53 220 pf 100 v C54 220 pf 100 v C55 220 pf 100 v D51 Schottky 1-2 ns 100 v SMBSR1010MSCT D52 Schottky 1-2 ns 100 v SMBSR1010MSCT D53 Schottky 1-2 ns 100 v SMBSR1010MSCT D54 Schottky 1-2 ns 100 v SMBSR1010MSCT D55 Schottky 1-2 ns 100 v SMBSR1010MSCT
[0165] Pin SNL 2 is connected to the anode of D51 the cathode of D51 is connected to the anode of D52 the cathode of D52 is connected to the anode of D53 the cathode of D53 is connected to the anode of D54 the cathode of D54 is connected to the anode of D55 the cathode of D55 is connected to pin SNOUT. Capacitors are connected across each diode forming a series parallel combination of [D51||C51]+[D52||C52]+[D53||C53]+[D54||C54]+[D55||C55]. Node SNL 2 connects to the drain terminal of the external output switch and to flyback side of the inductive load. The external fly-back rectifier diode D4 (FIGS. 1, 3 and 4 ) anode is connected to node SNL 2 . Node SNOUT connects to the storage capacitors [C16||C17] (FIGS. 1, 3 and 4 ) and to the cathode of the flyback diode D4. External diode D4 in parallel with DSN forms a hybrid diode. The Schottky diode has the desirable characteristics of fast recovery time (less than 6 nanoseconds (6* 10 Λ −9)) and low forward voltage drop (0.4-0.9 Volts) at high currents. The Schottky diode suffers from limited reverse blocking voltage currently 100 V maximum. Each diode will block 100 V; the parallel capacitors distribute the reverse voltage equally across the diode string. As the reverse junction capacitance of each diode is less than 10 pf much smaller than the parallel capacitor. Thus the reverse voltage is nearly equally divided across the diodes. To guarantee even voltage division 5% or better capacitor matching is required. High precision is common and inexpensive for small capacitors. Different blocking voltages may be achieved by adjusting the number of diode/capacitor pairs. By way of example not as a limitation 500 V was selected. The main fly-back rectifier diode D4 will block high voltages but suffers from long reverse recovery time 50-500 nanoseconds is common in fast recovery diodes. What is needed is a diode with low voltage drop, high blocking voltage and very short recovery time. The snubber DSN in parallel with the main fly-back rectifier comes very close to that ideal diode. The total blocking voltage is achieved by the adding the individual diode blocking voltages. The recovery time is determined by the slowest diode in the string often less than 5 nanoseconds. The low forward voltage drop is achieved when the slower main rectifier begins conduction. Low capacitance is also realized, as the capacitance is ⅕ of the individual capacitors. This hybrid diode begins rectification immediately after the main switch stops conduction and the non-saturating magnetic begins releasing its energy. This effectively limits the high voltage flyback over shoot to less than 40-70 volts. This keeps the switch well inside it's safe operating area (SOA) allowing the switch to be run at higher voltages for higher output power and additional efficiency gain, or to use a less expensive lower voltage switch while keeping the same voltage margins. Since external flyback diode D4 and D805 isolate the drain of output switch, faster switching occurs because the output switch does not have to slew the extra capacitance of the typical snubber circuit. Note that this circuit does not attempt to absorb the flyback in large RC networks that generate additional heat. Nor does it attempt to stuff the flyback to ground, adding capacitance and slowing the output switch, increasing switching losses. Sub-circuit DSN may be used in parallel with any slower rectifier such as flyback diode D4 to assist the main rectifier. This providing additional protection to the switch and rectifying the portion of the flyback pulse before the main rectifier begins condition. That high frequency energy ends up as heat or radiated noise.
[0166] [0166]FIG. 31 snubber sub-circuit SNA
[0167] [0167]FIG. 31 is a schematic diagram of a snubber sub-circuit of the invention. The snubber sub-circuit SNA is comprised of resistor R810 and R811 and capacitors C820 and C821.
Table Element Value/part number R810 500 pF C811 330 pF C820 12 ohm C821 10 ohm
[0168] Node SNA 1 connects to series resistor R810 to capacitor C820 to node SNA 2 then to capacitor C821 and series resistor R811 to node SNA 3 . Node SNA 1 connects to the external magnetic element center tap. Node SNA 2 connects to the drain terminal of the external output switch and to flyback side of the inductive load. Node SNA 3 connects to the source terminal of the external output switch. Resistor R810 and C820 attempt to absorb part of the flyback to reduce voltage transients across the switch. Part of the flyback is returned to ground by C821. This sub-circuit is used with itis mirror SNA (FIG. 31) across the external push-pull switches. The “snubbering” action slows the rise of the flyback giving time for the external rectifier diodes D 8 and D 9 of FIGS. 25 or 25 A to start conduction. The circuit efficiently manages high frequency flyback pulses.
[0169] [0169]FIG. 32 snubber sub-circuit SNB
[0170] [0170]FIG. 32 is a schematic diagram of a snubber sub-circuit of the invention. The snubber sub-circuit SNB comprises resistor R820 and R821 and capacitors C840 and C841.
Table Element Value/part number C840 500 pF C841 330 pF R820 12 ohm R821 10 ohm
[0171] Node SNB 1 connects to series resistor R820 to capacitor C820 to node SNA 2 to capacitor C841 and to series resistor R821 to node SNB 3 . Node SNB 1 connects to the external magnetic element center tap. Node SNB 2 connects to the drain terminal of the external output switch and to flyback side of the inductive load. Node SNB 3 connects to the source terminal of the external output switch. Resistor R820 and C840 attempt to absorb part of the high frequency flyback to reduce voltage transients across the switch. C841 and R821 return part of the flyback to ground. The “snubbering” action slows the rise of the flyback giving time for the external rectifier diodes D8 and D9 of FIG. 25 or 25 A to start conduction. The circuit efficiently manages high frequency flyback pulses.
[0172] [0172]FIG. 33 Pulse/Frequency modulator PWFM
[0173] [0173]FIG. 33 is the inventions PWM (pulse width modulator) and FM (frequency modulator) sub-circuit. Sub-circuit PWFM consists of resistors R401, R402, R403, and R404 capacitors C401, C402, C403, C404, C405 and C406, controller IC U400 and diode D401.
Table Element Value/part number R404 50 k ohms C406 100 uf C401 0.22 uF C403 0.01 uF C405 2200 pF C404 470 pF C402 0.22 uF R403 50 k ohms D401 RLS139 (low leakage) R401 2.2 MEG ohms R402 150 k ohms U400 MIC38C43
[0174] Control element U400 connects to a circuit with the following series connections: from pin 1 to feedback pin PW 1 then to the wiper of adjustable resistor R404 to return node PWFM 0 . Resistor R404 may be replaced with two fixed resistors. Capacitor C403 is connected from pin 2 to pin 1 . Capacitor C403 is used to filter the error amp output. The upper half of resistor R404 is connected to node REF 1 pin 8 the 5.0-Volt internal reference. Internal 5.0-volt reference U400 pin 8 or Node REF 1 is connected to the upper half of resistor R403 and through capacitor C402 to return node PWFM 0 . The reference provides current to external feed back networks. Wiper of R403 connects to node FM 1 to pin 4 , through R402 to pin 3 , and through C404 to return node PWFM 0 . Resistor R403 may be replaced with two fixed resistors. Pulse width timing capacitor C404 connects pin 3 to return node PWFM 0 . Low leakage diode D401 anode is connected to pin 3 cathode to output pin 6 node CLK. Resistor R 404 sets the nominal pulse width of output pin 6 node CLK. The pulse width can be adjusted from 0 (off) to 95%. Resistor R403 and C404 determine the nominal operating frequency. With application of power 20-volts between Nodes PWFM+and PWFM 0 controller U400 generates an internal 5.0 reference voltage to pin 7 node REF 1 . Output pin 6 node CLK is set high approximately 20-volts (see oscillograph trace G6 segment 60 FIG. 34). C404 starts to charge through R 401 until the voltage across C404 at pin 3 reaches the comparator level (see oscillograph trace G1 segment 61 FIG. 34) at resetting the pin 6 low (see oscillograph trace G6 segment 62 FIG. 34). Capacitor C404 rapidly discharges though D401 (see oscillograph trace G1 segment 63 FIG. 34). Pin 3 remains 0.6-volts above PWFM 0 node during the period pin 6 is low (see oscillograph trace G1 segment 64 FIG. 34). On the rising edge of pin 6 capacitor C 405 begins to rapidly charge until the voltage in pin 4 reaches the internal comparator level (see oscillograph trace G4 segment 65 FIG. 34). The comparator triggers internal transistor to rapidly discharge C404 (see oscillograph trace G4 segment 66 FIG. 34). The cycle repeats with output pin 6 being set high. External feedback current applied to U400 pin 1 and node PW 1 (see oscillograph trace G1 segment FIG. 34) follows the actual output voltage. Oscillograph trace G1 segment 67 (FIG. 34) is the period when the output switch conducting storing energy in the NSME. Oscillograph trace G1 segment 68 (FIG. 34) is the period when the output switch is off allowing storing energy in the NSME to be transferred to the storage capacitor. Application of external current source or feed back network to pin 1 or node PW 1 allows the pulse width to be modulated. Removing current from PW 1 lowers the comparator level causing the comparator to trigger at lower voltages across C404 reducing the pulse width. Introducing current into node PW 1 increases pulse width from nominal to maximum of 95%. Resistor R404 and C404 determine the nominal pulse width. This design allows the CLK output to be pulse width modulated. Application of external feed back network to pin 4 or node FW 1 allows the frequency to be modulated. Removing current from FW 1 slows the charging of C405. Longer charging time lowers the frequency from the nominal setting. This arrangement allows the CLK output to frequency modulated. When used with a resonant controller, R403 and C405 determine the nominal frequency typically equal to the tank resonant frequency. The external feedback is configured to lower the frequency from nominal (maximum output) to zero frequency “off”. When used as a pulse-width controller the nominal is set to maximum pulse width of about 90% feedback reduces the pulse-width. Sub-circuit PWFM may be simultaneously frequency and pulse width modulated. This configuration and mode of operation is unique to this instant invention. Feeding back of the output to the error amplifier is a unique mode of operation for control element U400. Sub-circuit PWFM combines large dynamic range, precise control and fast response.
[0175] [0175]FIG. 34 Oscillograph traces of the PWFM (FIG. 33) controller in the pulse-width modulation mode.
[0176] [0176]FIG. 35 Oscillograph trace of the TCTP (FIG. 8) resonant converter primary voltage. FIG. 35 is an oscillograph trace of the voltage developed across capacitor C10 (FIG. 8). In this embodiment the supply VBAT was only 18-volts.
[0177] The primary 100 (FIG. 18) inductance 203 uH was achieved by 55 turns on a 26 u 2.28 oz. KoolMu magnetic element 101 . The secondary winding 103 (FIG. 18) is 15 turns on core 101 . A 5.5-watt load is connected to winding 103 . The NSME primary 100 (FIG. 18) developed an excitation voltage of 229 volts peak more than 10 times VBAT. Tank converters TCTP and TCSSC (FIG. 7) take advantage of the desirable properties of the non-saturating magnetic to develop large flux biases. The useful large flux may harvested into useful power by addition of “flux nets” windings to the magnetic element.
[0178] [0178]FIG. 36 Regulated 18_Volt DC control power sub-circuit REG Sub-circuit REG consists of resistor R517, regulator Q514 and capacitors C514, C515, C516, C518, and C517.
Table Element Value/part number Q514 LM7818 C515 0.1 uF C517 0.1 uF C514 10 uF C518 10 uF
[0179] Pin REG 0 connects to the external power source return. Node REG 0 is also the return line it connects to Q514 pin 2 , and capacitors C518, C 514 , C515, and C517. Resistor R517 is connected to the pin 1 (input) node of voltage regulator Q514 and to input pin RIN+. Voltage regulator Q514 Pin 3 is the 18vdc regulated DC output is connected to the capacitors C515, C514 and output pin 18V. Capacitors C515, C517 are solid dielectric type is used to filter high frequency ripple and to prevent Q514 from oscillating. Sub-circuit REG provides regulated power for control circuits and output switch buffer AMP (FIG. 29).
[0180] [0180]FIG. 37 is a schematic for a non-isolated high side switch buck converter sub-circuit HSBK. FIG. 37 is a non-isolated high side switch buck converter sub-circuit HSBK. This converter topology consists of a non-isolated high efficiency buck stage, which provides regulated power to an efficient push-pull isolation stage. Sub-circuit HSBK consists of diode D8, capacitor C8, FET transistor Q31, sub-circuit TCTP (FIG. 8), sub-circuit BL 1 (FIG. 18B), sub-circuit IFB (FIG. 40B), sub-circuit AMP (FIG. 29) and sub-circuit PWFM (FIG. 33).
Table Element Value/part number C68 250 uf D68 MUR820 Q31 IRF540N
[0181] External power source VBAT connects to pins DCIN+and DCIN−. Pin DCIN+ connects to transistor Q31 source, sub-circuit PWFM pin PWFM 0 , sub-circuit AMP pin GA 0 , and sub-circuit IFB pin FBE, sub-circuit TCTP pins DCIN+ and B−. Regulated 18-volt output from sub-circuit TCTP pin B+ connects to sub-circuit AMP pin GA+and to sub-circuit PWFM pin PWFM+. This provides the positive gate drive relative to the source of Q31. Power source VBAT return is connected to pin DCIN−, sub-circuit TCTP pin DCIN−, diode D68 anode, capacitor C68, RLOAD, sub-circuit IFB pin OUT−, output pin B− and ground/return node GND. Sub-circuit PWFM is designed for adjustable pulse-width operation from 0 to 90%, maximum pulse width occurs with no feedback current to pin PW 1 . Increasing the feedback current reduces the pulse-width and output voltage from converter HSBK. Sub-circuit PWFM clock/PWM output pin CLK is connected to the input pin GA 1 of buffer sub-circuit AMP. The output of sub-circuit AMP pin GA 2 is connected to the gate of Q31. The drain of Q31 is connected to sub-circuit BL 1 pin P 1 B and the cathode of D68. Pin P 1 A of sub-circuit BL 1 is connected to capacitor C8, sub-circuit IFB pin OUT− and RLOAD. With sub-circuit PWFM pin CLK high buffer AMP output pin GA 2 charges the gate of transistor switch Q31. Switch Q31 conducts charging capacitor C68 through NSME BL 1 from source VBAT and storing energy in BL 1 . Feedback output pin FBC from sub-circuit IFB is connected to sub-circuit PWFM pulse-width adjustment pin PW 1 . As the output voltage reaches the designed level sub-circuit IFB removes current from PW 1 commanding PWFM to reduce the pulse-width or on time of signal CLK. After sub-circuit PWFM reaches the commanded pulse-width PWFM switches output pin CLK low turning off Q31 stopping the current into BL 1 . The stored energy is released from NSME BL 1 into the now forward biased diode D68 charging capacitor C68. By modulating the on time of switch Q31 the converter “bucks” applied voltage and efficiently regulates to a lower voltage. Regulated voltage is developed across Nodes B− and B+. Sub-circuit IFB provides the isolated feedback voltage to the sub-circuit PWFM. When sub-circuit IFB senses the converter output (nodes B+ and B−) is at the designed voltage more current is conducted by the phototransistor. Sinking current from PM 1 commands the PWFM to a shorter pulse-width thus reducing the converter output voltage. In the event the feedback signal from IFB commands the PWFM to minimum output. Gate drive to switch Q31 is removed stopping all buck activity capacitor C 68 discharges through RLOAD. Input current from VBAT is sinusoidal making the converter very quiet. As such the switch Q31 is not exposed to large current spikes common to saturating magnetic prior art. Thus placing less stress on the switches thereby increasing the MTBF. Sub-circuit HSBK takes advantage of the desirable properties of the NSME in this converter topology.
[0182] [0182]FIG. 38 is a schematic for an isolated two-stage low side switch buck converter sub-circuit LSBKPP. This converter topology consists of a high efficiency low-side switch buck stage, which provides regulated power to an efficient push-pull isolation stage. An efficient center-tap fullwave rectifier provides rectification. Sub-circuit LSBKPP consists of diode D46, capacitor C46, FET transistor Q141, sub-circuit REG (FIG. 36), sub-circuit OUTB (FIG. 25A), sub-circuit BL 1 (FIG. 18B), sub-circuit TCTP (FIG. 8), sub-circuit IFB (FIG. 40B), sub-circuit AMP (FIG. 29), sub-circuit DCAC 1 , and sub-circuit PWFM (FIG. 33).
Table Element Value/part number C46 250 uf D46 MUR820 Q141 IRF540N
[0183] External power source VBAT connects to pins DCIN+ and DCIN−. From pin DCIN+connects to sub-circuit REG pin RIN+, D46 cathode, capacitor C46, sub-circuit TCTP (FIG. 8) pin DCIN+, and sub-circuit DCAC 1 pin DC+. Voltage regulator sub-circuit REG output pin +18V connects to sub-circuit AMP pin GA+ and to sub-circuit PWFM pin PWFM+. Sub-circuit REG provides regulated low voltage power to the controller and to the main switch buffer. VBAT negative is connected to pin DCIN− and ground return node GND. Node GND connects to sub-circuit PWFM pin PWFM 0 , sub-circuit AMP pin GA 0 , Q141 source, sub-circuit IFB pin FBE, sub-circuit REG pin REG 0 and sub-circuit TCTP pin DCIN−. Sub-circuit PWFM (FIG. 33) is designed for variable pulse width operation. The nominal frequency is between 20-600 Khz PWFM is configured for maximum pulse width 90% (maximum buck voltage) with no feedback current from sub-circuit IFB. Increasing the feedback current reduces the Q111 on time reducing the voltage to the push-pull stage and the output from converter LSBKPP. Sub-circuit PWFM clock output pin CLK is connected to the input pin GA 1 of buffer sub-circuit AMP (FIG. 29). The output of switch speed up buffer sub-circuit AMP pin GA 2 is connected to the gate of Q141. Floating isolated 18-volt power from sub-circuit TCTP pin B+ connects to sub-circuit DCAC 1 pin P 18 V. The drain of Q141 is connected to sub-circuit BL 1 pin P 1 A and the anode of D46. The return line of sub-circuit DCAC 1 pin DC− connects to sub-circuit BL 1 pin P 1 B, sub-circuit TCTP pin B− and C46. With sub-circuit PWFM pin CLK high buffer AMP output pin GA 2 charges the gate of transistor switch Q141. Switch Q141 conducts reverse biasing diode D46; capacitor C46 starts charging through NSME BL 1 from source VBAT. During the time Q141 is conducting, energy is stored in NSME sub-circuit BL 1 . Charging C46 provides power to final push-pull converter stage DCAC 1 . The output of the output rectifier sub-circuit OUTB is connected to feedback sub-circuit IFB output pin FBC from sub-circuit IFB is connected to sub-circuit PWFM pulse-width adjustment pin PW 1 . Sub-circuit IFB removes current from PW 1 commanding PWFM to reduce the pulse-width or on time of signal CLK. After sub-circuit PWFM reaches the commanded pulse-width PFFM switches CLK low turning off Q141 stopping the current into BL 1 . The energy is released from NSME BL 1 into the now forward biased flyback diode D46 charging capacitor C46. By modulating the on time of switch Q141 the converter voltage is regulated. Regulated voltage is developed across C46 Nodes DC+ and GND. Providing energy to the isolated constant frequency push-pull DC to AC converter sub-circuit DCAC 1 (FIG. 2). Sub-circuit DCAC 1 provides efficient conversion of the regulated buck voltage to a higher or lower voltage set by the magnetic element winding sub-circuit PPT 1 (FIG. 19) ratio. The center tap of the push-pull output magnetic is connected to, sub-circuit OUTB pin OUT−, RLOAD, sub-circuit IFB pin OUT− and the pin OUT− forming the return line for the load and feedback network. Output of sub-circuit DCAC 1 pin ACH is connected to sub-circuit OUTB pin C 7 B. Output of sub-circuit DCAC 1 pin ACL is connected to sub-circuit OUTB pin C 8 B. Sub-circuit OUTB provides rectification of the AC power generated by sub-circuit DCAC 1 . As the non-saturation magnetic converter is very quite minimal filtering is required by OUTB. This further reduces cost and improves efficiency as losses to filter components are minimized. Sub-circuit IFB provides the isolated feedback current to the sub-circuit PWFM. When sub-circuit IFB senses the converter output (nodes OUT+ and OUT−) is greater than the designed/desired voltage, current is removed from node PM 1 . Sinking current from PM 1 commands the PWFM to a shorter pulse-width thus increasing the buck action and reducing the first stage converter output voltage. In the event the feedback signal from IFB commands the PWFM to minimum output. Gate drive to switch Q141 is removed stopping all buck activity capacitor discharging C46. Input current from VBAT to charge C46 is sinusoidal making the converter very quiet. In addition the switch Q141 is not exposed a potentially destructive current spike. Placing less stress on the switches thereby increasing the MTBF. Sub-circuit LSBKPP takes advantage of the desirable properties of the NSME in this converter topology. Adjusting the NSME BL 1 (FIG. 18B) sets the amount of buck voltage available to the final push-pull isolation stage. Greater efficiencies are achieved at higher voltages. The final output voltage is set by the turns ratio of the push-pull element PPT 1 (FIG. 19). Converter LSBKPP provides efficient conversion from high voltage sources into high current isolated output.
[0184] [0184]FIG. 39 is a schematic for an isolated two-stage low side switch buck converter sub-circuit LSBKPPBR. This converter topology consists of a non-isolated high efficiency low-side switch buck stage, which provides regulated power to an efficient push-pull isolation stage. A fullwave bridge rectifier provides rectification. Sub-circuit LSBKPPBR consists of diode D6, capacitor C6, FET transistor Q111, sub-circuit REG (FIG. 36), sub-circuit OUTBB (FIG. 25B), sub-circuit BL 1 (FIG. 18B), sub-circuit TCTP (FIG. 8), sub-circuit IFB (FIG. 40B), sub-circuit AMP (FIG. 29), sub-circuit DCAC 1 (FIG. 2), and sub-circuit PWFM (FIG. 33).
Table Element Value/part number C6 250 uf D6 MUR820 Q111 IRFP
[0185] External power source VBAT connects to pins DCIN+ and DCIN− From pin DCIN+ connects to sub-circuit REG pin RIN+, D6 cathode, capacitor C6, sub-circuit TCTP (FIG. 8) pin DCIN+, and sub-circuit DCAC 1 pin DC+. Voltage regulator sub-circuit REG output pin +18V connects to sub-circuit AMP pin GA+ and to sub-circuit PWFM pin PWFM+. Sub-circuit REG provides regulated low voltage power to the controller and to the main switch buffer. VBAT negative is connected to pin DCIN- connects to sub-circuit PWFM pin PWFM 0 , sub-circuit AMP pin GA 0 , Q111 source, sub-circuit IFB pin FBE, sub-circuit REG pin REG 0 , sub-circuit TCTP pin DCIN−. Sub-circuit PWFM (FIG. 33) is designed for variable pulse width operation. The nominal frequency is between 20-600 Khz PWFM is configured for maximum pulse width 90% (maximum buck voltage) with no feedback current from sub-circuit IFB. Increasing the feedback current reduces the Q111 on time reducing the voltage to the push-pull stage and the output from converter LSBKPPBR. Sub-circuit PWFM clock output pin CLK is connected to the input pin GA 1 of buffer sub-circuit AMP (FIG. 29). The output of switch speed up buffer sub-circuit AMP pin GA 2 is connected to the gate of Q111. Floating isolated 18-volt power from sub-circuit TCTP pin B+ connects to sub-circuit DCAC 1 pin P 18 V. The drain of Q111 is connected to sub-circuit BL 1 pin PA 1 and the anode of D6. The return line of sub-circuit DCAC 1 pin DC− connects to sub-circuit BL 1 pin P 1 B, sub-circuit TCTP pin B− and C6. With sub-circuit PWFM pin CLK high buffer AMP output pin GA 2 charges the gate of transistor switch Q111. Switch Q111 conducts reverse biasing diode D6; capacitor C6 starts charging through NSME BL 1 from source VBAT. During the time Q111 is conducting, energy is stored in NSME sub-circuit BL 1 . Charging C6 provides power to final push-pull converter stage DCAC 1 . The output of the output rectifier sub-circuit OUTBB is connected to feedback sub-circuit IPB output pin FBC from sub-circuit IFB is connected to sub-circuit PWFM pulse-width adjustment pin PW 1 . Sub-circuit IFB removes current from PW 1 commanding PWFM to reduce the pulse-width or on time of signal CLK. After sub-circuit PWFM reaches the commanded pulse-width PFFM switches CLK low turning off Q111 stopping the current into BL 1 . The energy is released from NSME BL 1 into the now forward biased flyback diode D 6 charging capacitor C6. By modulating the on time of switch Q111 the converter voltage is regulated. Regulated voltage is developed across C6 nodes DC+ and DC−. Providing energy to the isolated constant frequency push-pull DC to AC converter sub-circuit DCAC 1 (FIG. 2). Sub-circuit DCAC 1 provides efficient conversion of the regulated buck voltage to a higher or lower voltage set by the magnetic element winding sub-circuit PPT 1 (FIG. 19) ratio. The return node of the sub-circuit OUTBB pin OUT− is connected to RLOAD, sub-circuit DCAC 1 pin ACO, sub-circuit IFB pin OUT− and the pin OUT−. Node OUT− is the return line for the load and feedback network. Output of sub-circuit DCAC 1 pin ACH is connected to sub-circuit OUTBB pin C 7 B. Output of sub-circuit DCAC 1 pin ACL is connected to sub-circuit OUTBB pin C 8 B. Sub-circuit OUTBB provides rectification of the AC power generated by sub-circuit DCAC 1 . As the disclosed non-saturation magnetic converter has minimal output ripple, less filtering is required by OUTBB. This further reduces cost and improves efficiency as losses in filter components are minimized. Sub-circuit IFB provides the isolated feedback current to the sub-circuit PWFM. Open collector output of IFB pin FBC connects to PWFM pin PW 1 . When sub-circuit IFB senses the converter output (nodes OUT+ and OUT−) is greater than the designed/desired voltage, current is removed from node PM 1 . Sinking current from PM 1 commands the PWFM to a shorter pulse-width thus increasing the buck action and reducing the first stage converter output voltage. In the event the feedback signal from IFB commands the PWFM to minimum output. Gate drive to switch Q111 is removed stopping all buck activity capacitor discharging C6. As the NSME does not saturate the destructive noisy current spikes common to prior art are absent. Input current from VBAT to charge C6 is sinusoidal making the converter very quiet. In addition the switch Q111 is not exposed a potentially destructive current spike. Placing less stress on the switches thereby increasing the MTBF. Sub-circuit LSBKPPBR takes advantage of the desirable properties of the NSME in this converter topology. Adjusting the NSME BL 1 (FIG. 18B) sets the amount of buck voltage available to the final push-pull isolation stage. Greater efficiencies are achieved at higher voltages. The final output voltage is set by the turns ratio of the push-pull element PPT 1 (FIG. 19). Converter LSBKPPBR provides efficient conversion from high voltage sources such as high power factor AC to DC converters such as sub-circuit ACDCPF (FIG. 4).
[0186] [0186]FIG. 40 PFC over voltage feed back sub-circuit IPFFB
[0187] [0187]FIG. 40 is the schematic of the inventions isolated over voltage feed back network sub-circuit IPFFB. Sub-circuit IPFFB consists of Resistors R926, R927, R928, R929 and R930, capacitor C927, zener diodes D928 and D903, transistor Q915 and opto-isolator U903.
Table Element Value/part number U903 NEC2501 Q915 FZT705CT D903 ML5248B (18 v) D928 1SMB5956BT3 (200 v) R926 20 k ohms R927 10 k ohms R928 10 k ohms R929 10 k ohms R930 20 k ohms
[0188] Node PF+ connects through resistor R927 to cathode of D903 and anode of opto-isolator U 903 . Cathode of diode D903 is connected to pin PF+. Resistor R928 is connected from anode of D928 to base of Q915. Capacitor C927 is connected in parallel with zener diode D903. Resistor R928 limits maximum base current. Resistor R929 is connected between base and emitter of Q915. Resistor R929 is used to shunt excess zener leakage current from the base common in high voltage diodes. Two hundred-volt zener diode cathodes D928 are connected to pin PF+. Anode of D928 is connected to R930 and R928. Resistor R930 provides a path for leakage current from 200-volt zener D928. Resistor R926 limits the maximum current to U903 internal light emitting diode to about 10 ma. Resistor R927 sets the maximum zener current at maximum boost voltage of approximately 200-volts to 20 ma. Transistor Q915 is biased off when the voltage from node PF+ and PF− is less than the zener voltage of 200-volts. Transistor is in a cutoff or non-conducting state no current is injected to U903 LED. The internal phototransistor is also in a non-conducting state. The attached external control sub-circuit is not commanded to change its output. With 200 volts or more applied to nodes PF+ and PF− reverse biased zener diode D928 injects current into the base of Q915. Resistor R927, capacitor C927 and diode D903 provide 18-volts to the collector of Q915. Transistor Q915 conducts current into U903 LED injecting base current into the U903 phototransistor. Modulating the LED current is reflected as variable impedance between FBC and FBE. This phototransistor may be connected as a variable current source or impedance. This sub-circuit senses excessive boost voltage and quickly feeds back to the control sub-circuit (See PFA (FIG. 23), PFB (FIG. 24) or (PWFM FIG. 33)) automatically reducing the boost voltage.
[0189] [0189]FIG. 40A is a schematic diagram of the non-isolated boost output voltage feed back sub-circuit FBA. Sub-circuit FBA consists of Resistors R1120, R1121, R1122, R1123 and R1124.
Table Element Value/part number R1123 499 k ohms R1124 499 k ohms R1122 6.65 k ohms R1121 499 k ohms R1120 1MEG ohms
[0190] Input node PF+ connected to series resistor [R1123+R1124] then to parallel resistors [R20||R21||R22] to the return node BR−. Resistors R1120, R1121, R1122, R1123 and R1124 values are selected for a nominal input voltage of 385-volts and output feed back voltage of 3.85. (See oscillograph G1 FIG. 34) Resistors R1120, R1121, R1122, R1123 and R1124 are shown in surface mount configuration but can be combined into two thru hole-resistors. Feedback output node PF 1 is connected to node PF 1 of sub-circuit PFA (FIG. 23) or PFB (FIG. 24). Return pin BR− is connected to BR− of PFA (FIG. 23) or PFB (FIG. 24). Nodes FBE and FBC it may also be connected between nodes FM 1 pin PWFM 0 or PW 1 pin PWFM 0 of control sub-circuit PWFM (FIG. 33).
[0191] [0191]FIG. 40B output voltage feed back sub-circuit IFB
[0192] [0192]FIG. 40B is the schematic of the inventions isolated low voltage feed back network sub-circuit FBA. Sub-circuit IFB consists of Resistors R900, R901 and R902, zener diode D900, Darlington transistor Q900 and opto-isolator U900.
Table Element Value/part number U900 NEC2501 Q900 FZT705CT D900 IN5261BDICT R900 1 k ohms R902 4 k ohms R901 40 k ohms
[0193] Node OUT+ connects cathode of D900 to R901. Anode of diode D900 is connected to series resistor R900 to base of Darlington transistor Q900. Resistor R902 is connected from base to emitter to Q900. Resistor R901 connects to anode of opto-isolator U900 LED (light emitting diode) the cathode is connected to Q900 collector. Emitter of Q900 is the return current path and connects to pin/node OUT−. Resistor R901 limits the maximum current to U900 internal light emitting diode to 20 ma. Resistor R902 shunts some of the zener leakage current from the base. Zener diode voltage selection sets the converter output voltage a typical value maybe 48-volts. The zener voltage is the final desired output minus two base emitter junction drops (1.4V). Once the OUT+ node reaches the zener voltage a small base current biases Q900 into a conducting state turning“on” opto-isolator U900 internal LED. Resistor R900 limits the maximum base current to Q900. Resistors R900 and R901 are selected to bias Darlington transistor Q900 collector current with nominal voltage across nodes OUT+ and OUT−. Change in voltage between OUT+ and OUT− modulates the opto-isolator U900 LED current in turn changing the base current of U900 internal photo transistor. Phototransistor emitter is node FBE collector is node FBC. Modulating the LED current is reflected as variable impedance between FBC and FBE. This phototransistor may be connected as a variable current source or impedance. When used with control sub-circuit PFA (FIG. 23), PFB (FIG. 24) or (PWFM FIG. 33) the phototransistor is connected as a current shunt. Higher voltage applied to OUT+ and OUT− nodes increases the feedback shunt current commanding the control sub-circuit (See PFA (FIG. 23) or PFB (FIG. 24) or PWFM (FIG. 33)) to reduce the pulse-width or frequency. IFB accomplishes high speed feed back due to the very high gain of the Darlington transistor and the rapid response of the internal converter stage(s) active ripple reduction and excellent load regulation are achieved.
[0194] [0194]FIG. 40C is the schematic of the alternate PFC isolated over voltage feed back network sub-circuit IOVFB. Sub-circuit IOVFB consists of resistors of R917, R938, R939 and R940, diode D911, Darlington transistor Q914 and opto-isolator U905.
Table Element Value/part number U905 NEC2501 Q914 FZT705CT R938 160 k ohms R939 70 k ohms D911 1N5261BOTCT R940 50 k ohms R917 40 k ohms
[0195] The output of the PFC at pin PF+ is connected to R917 then to collector of Q914. Resistor R917 sets the maximum current to U905 light emitting diode. Resistor R938 is connected from return node PF+ to zener diode D911 cathode and R938. Resistor R939 is connected from return node PF− to zener diode D911 cathode and R938. Anode of D911 is connected to wiper arm of adjustable resistor R940. One leg of R940 is connected to the base of transistor Q914 the other to R939 and U905 LED anode and R939. Emitter of Q914 is connected to anode of U904. Adjustable resistor R940 sets the maximum or trip voltage before transistor Q914 is biased on. Providing current to U905 LED. Phototransistor emitter is node FBE collector is node FBC. Modulating the LED current is reflected as variable impedance between FBC and FBE. This phototransistor is normally connected as a shunt to force the control element to a minimum output. This sub-circuit senses the boost voltage and feeds back to the PFC. Where excessive boost voltage forces the PFC to automatically reduce the boost voltage.
[0196] [0196]FIG. 41 output voltage feed back sub-circuit FBI
[0197] [0197]FIG. 41 is the schematic of the alternate low voltage feed back network sub-circuit FBI. Sub-circuit FBI consists of Resistors R81, R82 and R83, zener diode D80, NPN transistor Q80 and capacitor C80.
Table Element Value/part number R81 1k ohms D80 Zener Voltage = (Desired Output −0.65 V) Q80 BCX70KCT C80 1000 pf R82 1k ohms R83 715k ohms
[0198] Node OUT+ connects cathode of D80. Anode of diode D80 is connected to through resistor R83 to OUT− and resistor R82 to base of transistor Q80. Capacitor C80 is connected from base to pin OUT−. Capacitor C80 bypasses high frequency to noise to OUT−. Resistor R 81 is connected from emitter of Q80 to node OUT−. Resistor R 81 adds local negative feedback to reduces the effects of variation in transistor gain. Collector of Q80 is connected to pin FBC. The return current node connects to pins FBE and OUT−. Resistor R 82 limits the maximum base current protecting Q80. Resistor R83 shunts some of the zener leakage current from the base. Zener diode voltage selection sets the converter output voltage a typical value maybe 48 -volts. The zener voltage is the final desired output minus one base emitter junction drop (0.65-Volts). When the OUT+ node reaches the nominal level reverse biased zener starts to conduct injecting a small base current into Q80. Biasing transistor into a conducting state. Change in voltage between OUT+ and OUT− modulates Q80 collector current. During normal operation the zener diode is biased at it's knee thus small changes in voltage result in relatively large collector current changes. When sub-circuit FBI used with control sub-circuit PFA (FIG. 23), PFB (FIG. 24) or (FIG. 33) the transistor is connected as a current shunt. Higher voltage applied to OUT+ and OUT− nodes increases the feedback shunt current commanding the control sub-circuit (See PFA (FIG. 23) or PFB (FIG. 24) or PWFM (FIG. 33) to reduce the pulse-width or frequency. Sub-circuit FBI provides high-speed feedback and gain to ripple components. With the rapid response of the internal converter stage(s) active ripple reduction and excellent load regulation are achieved.
[0199] [0199]FIG. 42 over voltage protection sub-circuit OVP 1
[0200] [0200]FIG. 42 is the schematic of the inventions over voltage protection embodiment sub-circuit OVP 1 . Sub-circuit OVP 1 consists of SCR (silicon controlled rectifier) SCR1200, resistor R1200, capacitor C1200 and zener diodes D1200, D1202 and D1203.
Table Element Value/part number SCR1200 MCR2G5-10 D1203 BZT03-C200 (200 V) D1202 BZT03-C200 (200 V) D1200 IN4753 (5.1 v) C1200 220 pf R1200 10,0k ohms
[0201] Input pin PF+ is connected to cathode of zener diode D1203, anode of D1203 is connected to series zener diodes [D1202+D1200] then to gate of SCR1200. Noise attenuation network of [R1200||C1200] is connected from SCR SCR1200 gate to the return node BR−. Diodes D1102 and D1103 are both 200-volt; D1101 is a 5.1-volt type the sum of the zener voltages set the trip point of the OVP at 405-volts. Other trip voltages may be implemented by selecting other zener diode combinations. Capacitor C1200 and R1200 prevents leakage current and transients from accidentally tripping the OVP. In the event of very high AC line voltages or a component failure in a feed back loop (FIG. 40A, 40B, 40 C or 40 ) The boost voltage may quickly rise increase to levels dangerous to the output switch or output storage capacitors. When the output boost voltage of the at node PF+ rises above 405V, zener diodes D1203, D1202 and D1200 conduct a small current into the gate of SCR1200 turning SCR1200 on. Turning SCR1200 on places a low impedance path across the AC line through the rectifier sub-circuit BR (FIG. 22). SCR1200 and bridge rectifier diodes must be selected to withstand the short circuit currents that may exceed 100 amperes until the input fuse opens. Thus quickly limiting the boost output voltage to a safe level. This circuit should never operate under normal AC line voltages. By changing zener voltages this sub-circuit would also be suitable for use in the across the rectifier output to protect the load from an over voltage condition. Sub-circuits OVP 1 shuts down the converter with out opening the line fuse. Sub-circuit OVP may be used in combination with OVP 1 (FIG. 42A) as a fail-safe back up for critical loads.
[0202] [0202]FIG. 42A over voltage protection sub-circuit OVP 1
[0203] [0203]FIG. 42A is the schematic of the inventions over voltage protection embodiment sub-circuit OVP 2 . Sub-circuit OVP 2 consists of SCRs (silicon controlled rectifier) SCR1101 and SCR1100, resistors R1101 and R1102, capacitors C1100 and C1101 and zener diodes D1100, D1102 and D1103.
Table Element Value/part number SCR1101 S101E (Teccor) SCR1100 S601E (Teccor) D1103 BZT03-C200 (200 V) D1102 BZT03-C200 (200 V) D1100 IN4753 (5.1 v) R1100 16000 R1101 5.1K ohms R1102 5.1K ohms C1100 1200 pf C1101 1200 pf
[0204] Anode of SCR1101 is node/pin CP 18 V+ that is connected to external control DC source. Return node BR− is connected to SCR1101 cathode and capacitor C1100. Input node PF+ is connected to cathode of zener diode D1103 and to series resistor R1100 then to anode of SCR SCR1102. The anode of D1103 is connected to the cathode of D1102. The anode of D1102 is connected to the cathode of D1100. The cathode of SCR1100 is connected to the gate of SCR1101. The anode of D1103 is connected to series zener diodes [D1102+D1100] then to capacitor C1100 then to the return node BR−. Capacitor [C1200 ||R1200] prevents leakage current and transients from accidentally tripping OVPB. In the event of very high AC line voltages or a component failure in a feed back loop (IPFFB FIGS. 40 A, FBA 40 B, IFB 40 C or FBI FIG. 41) The boost voltage may quickly rise increase to levels dangerous to the output switch or output storage capacitors. When the output boost voltage of the at node PF+ rises above 405V, zener diodes D1103, D1102 and D1100 conduct a small current into the gate of SCR1101 latching SCR1101 on. Resistor R1100 provides holding current for SCR1101. Turning SCR1101 provides gate current to SCR1100, resistors R1100 and R1101 limits the gate current and provides the hold current to SCR1100. With gate current to SCR1100 the SCR is turned on providing a low impedance path from nodes CP 18 V+ to BR−. This action removes the regulated power to the main switch buffer and or PWM controllers PFA (FIG. 23) or PWFM (FIG. 33) and or buffer AMP (FIG. 29) thus turning off the main switch. The converter is held in an off state until boost voltage PF+ through R1100 can not maintain the holding current of SCR1101. Typically power must be removed from the system to reset SCR1101. The minimum holding current of SCR1101 is typically 5-10 ma. The action of OVP 1 quickly limits the boost output voltage to a safe level. This circuit should never operate under normal AC line voltages. By changing zener voltages this sub-circuit would also be suitable for use across the output rectifier to protect the load from an over voltage condition. Sub-circuit OVP 1 gracefully shuts down the converter requiring manual intervention to reset the fault.
[0205] [0205]FIG. 42B is the schematic of the isolated output over voltage feed back network sub-circuit OVP 2 . Sub-circuit OVP 2 consists of resistors of R970, R971, and R972, capacitor C970, zener diode D970, SCR SCR970, Darlington transistor Q970 and opto-isolator U970.
Table Element Value/part number D970 1N5261BOTCT U970 NEC2501 Q970 FZT705CT R970 160k ohms R971 10k ohms R972 22k ohms C970 200 pf
[0206] The output of the converter at pin OUT+ is connected to R972 and to the cathode of zener diode D970. The anode of D970 is connected to series resistor R970 then to base of Q970. Resistor R970 sets the maximum base current to Q970. Resistor R971 is connected between the anode of D970 and return node OUT− Anode of light emitting diode U970 is connected to resistor R972 then to OUT+. The cathode of U970 LED is connected to Q980 collector. Emitter of Q980 is connected to return node OUT−. Zener diode D960 sets the maximum or trip voltage before transistor Q970 is biased on providing current to U970 LED. Application of voltage greater than the zener voltage of D970 injects a small base current into Q970. Transistor Q970 turns on the internal LED of U970 placing phototransistor in a conducting state and low impedance to pins OVC and OVC. External push-pull driver sub-circuit PPG (FIG. 43) is shut down immediately by bringing pin PPEN high stopping the output stage. Sub-circuit OVP 2 senses the output voltage and quickly feeds back to the push-pull PFC. Where excessive boost voltage forces the PFC to automatically reduce the boost voltage. FIG. 42C is the schematic of the isolated output over voltage crowbar network sub-circuit OVP 3 . Sub-circuit OVP 3 consists of resistors of R980, R981, R982, R983, R984 and R985, capacitors C980, C981 and C982 zener diode D980, SCRs SCR980 and SCR981, Darlington transistor Q980 and opto-isolator U980.
Table Element Value/part number D980 1N5261BOTCT SR980 S601E (Teccor) U980 NEC2501 Q980 FZT705CT R980 160k ohms R981 10k ohms R982 22k ohms R983 51k ohms R984 1200 ohms R985 510 ohms C980 200 pf C981 1200 pf C982 1200 pf
[0207] The converter output is sensed at pin OUT+ reference to pin OUT−. Pin OUT+ is connected to resistor R 982 and to the cathode of zener diode D980. The anode of D980 is connected to series resistor R980 then to base of Q980. Resistor R980 limits the base current to Q980. Resistor R981 is connected between the anode of D980 and return node OUT− to provide a diode leakage current path. Anode of light emitting diode U980 is connected through resistor R982 then to OUT+. The cathode of U980 LED is connected to Q980 collector. Emitter of Q980 is connected to return node OUT−. Zener diode D960 sets the maximum or trip voltage before transistor Q980 is biased on providing current to U980 LED. Application of voltage greater than the zener voltage of D980 injects a small base current into Q980. Emitter of opto-isolator U980 is connected to the gate of SCR981 and through [R984||C982] to return node BR−. Transistor Q980 turns on the internal LED of U980 placing phototransistor in a conducting state and supplying gate current to SRC SCR981 from the external 18-volt source connected to pin CP 18 V+. Network [R984||C982] prevents false triggering of SCR SCR981. The cathode of SCR SCR981 is connected to the gate of SCR SCR980 and through [R985||C981] to return BR−. With SCR SCR981 turned on gate current is provided to low voltage SCR SCR980. High voltage boost output is connected to pin PF+ resistor R983 supplies hold current to SCR SCR981 holding SCR SCR980 on. SCR SCR980 is selected for low hold current and ability to block the maximum boost voltage on PF+. SCR SRC980 anode is connected to pin CP 18 V+. SCR SRC980 cathode is connected to return pin BR−. SCR980 clamps the low voltage supply CP (FIG. 26) or CPA (FIG. 27). With the low supply held down the gate drive to the main switch is disabled turning off the converter. With the main switch Q 1 (FIG. 1, 3 , 4 ) turned off holdup capacitor C17 charges to applied AC line peak. With pin PF+ held near line peak SCRs SCR 981 will hold SCR SCR 981 on until AC line power is removed to the converter. Sub-circuit OVP 3 senses the out of specification output voltage and quickly stop the converter thereby protecting the load and converter with out generating destructive currents like OVP (FIG. 42).
[0208] [0208]FIG. 43 Push-pull oscillator sub-circuit PPG FIG. 43 is the push-pull oscillator sub-circuit of the invention. The current implementation uses a Motorola MC33025 pulse width modulator IC to generate the clock signals to drive the push-pull output stage. Sub-circuit PPG consists of U14 a two-phase oscillator, resistors R126, R130, R131, R132, R133, R134, R135, R136 and R137, capacitors C143, C136, C139, C140, C141 and C142.
Table Element Value/part number U14 MC33025 R126 12k ohms R130 10 ohms R131 10 ohms R132 47k ohms R133 10k ohms R134 100k ohms R135 15k ohms R136 1.5 MEG ohms R137 15k ohms C136 0.22 uf C139 0.22 uf C140 0.22 uf C141 0.01 uf C142 0.001 uf C143 .33 uf
[0209] The current implementation uses a Motorola MC33025 pulse width modulator IC to generate the clock signals to drive the push-pull stage. But, any non-overlapping two phase fixed frequency generator could be used. Pin 1 of U14 is connected to [capacitor C143||Resistor R132] then to pin 3 . Resistor R134 connects the internal 5.1-volt reference output of U14 pin 16 to pin 1 . Resistors R135 in series with R137 from 5.1-volt reference to return node PPGO form a voltage divider; the center is connected to U 14 pin 2 placing pin 2 at 2.55-volts. Resistor R126 is connected from U14 pin 5 to return node PPGO. Resistor R133 is connected from U14 pin 1 to return node PPGO. Timing capacitor C142 is connected from U14 pins 6 and 7 to return node PPGO. Resistor R126 and capacitor C142 set the operating frequency of the internal oscillator. Timing resistor could be replaced with a JFET, MOSFET, transistor, or similar switching device to provide variable frequency operation. The drain of the transistor would be connected to pin 5 . The source would be connected to return node PPGO. The variable frequency command voltage/current is applied between gate and source. Capacitor C141 is connected from U14 pin 8 to return node PPGO. Capacitor C136 is connected from U14 pin 16 to return node PPGO. Capacitor C140 is connected from U14 pin 15 to return node PPGO. Capacitor C139 is connected from U14 pin 13 to return node PPGO. Resistor R136 is connected from U14 pin 9 to return node PPGO. U14 pins 10 and 12 is connected to return node PPGO. External power is connected to node/pin PPG+ to PWM (pulse width modulator) IC U14 on pin 15 through resistor R130 connected to the 18-volt control supply. Resistor R131 connected to pin 13 of U14 and PPG+ provides power to the totem-poll output stage. The power return line is connected to node PPGO. IC U14 is designed to operate at a constant frequency of approximately 20-600 Khz with a fixed duty cycle of 35-49.9%. Resistors R135, R137, R133 configure U14 to operate at maximum pulse width. A two-phase non-over lapping square wave is generated on pins 11 node PH 2 and pin 14 node PH 1 and delivered to speed-up buffers AMP described in FIG. 29. The two-phase generator is configured to prevent the issue of overlapping drive signals that would null the core bias and present excessive current to the switches. Sub-circuit PPG provides the drive to the push-pull switches making efficient use of the NSME. Although the present invention has been described with reference to a preferred embodiment, numerous modifications and variations can be made and still the result will come within the scope of the invention. No limitation with respect to the specific embodiments disclosed herein is intended or should be inferred. | A drive with a high impedance input, low impedance output is created. When a switching or driving action requiring the sourcing and sinking of current from a common node in a wide frequency range is desired, the invention allows the creation of a simple, efficient, two switch drive system that functions across a wide range of conditions. The circuit uses a discrete N-Channel FET paired with discrete PNP transistors. A high impedance input node is formed by connecting the FET gate to the transistor base. The differential threshold voltage that exists between the FET gate and the transistor base prevents the two devices from generating conflicting currents at the output node formed by the common source emitter. The circuit further lends itself to output waveform variations as may be required for various drive strategies by manipulating the input signal processing to custom modify the resulting output voltage and current. | 8 |
BACKGROUND OF THE INVENTION
This invention lies in the field of the flare burning of waste gases on demand. More particularly, it concerns means for controlling the flow of purge gas, to maintain sufficient pressure inside of the flare stack system so that there will be no influx of atmospheric air, such as might provide an explosive gas mixture inside of the flare stack.
Field flares for emergency relief of, and burning of, as much as 160,000#/minute of flammable gases for pressure-relief in avoidance of explosion, are parts of plants for processing petroleum, petro-chemicals and chemicals. Such flare systems are pressure-tight piping systems for conveying relieved gases to a sufficiently remote, and high enough area to allow safe burning. Because any entry of air to the flare system could create an extremely hazardous explosive condition, at a time when it is not venting, and the flow within the system is static, it is conventional practice to deliver to the flare piping system a quantity of `purge` or `sweep` gases to maintain, at all times, a slow flow of gases toward the discharge point of the flare to the atmosphere.
SUMMARY OF THE INVENTION
Natural gases are typically used as the purge-gases. This use of natural gases for twenty-four hours of each day, is not only wasteful of a precious natural resource, it is also very expensive and can represent an expenditure of many tens-of-thousands of dollars per year. Since air is caused to enter the flare system from the atmosphere only when there is a decrease in the temperature of the gas contained in the pressure-tight flare system, there is need for `purge` or `sweep` gases only when there is a decrease in the temperature of the internal gas content of the flare system. For this reason, there is no need for "around-the-clock" injection of purge gas for the purpose of avoiding entry of air to the flare system. But, to date, there has been no system for automated injection of purge gases to flare systems only as they are needed, due to gas system temperature decrease.
At constant pressure, the volume of a gas will vary as its absolute temperature varies. This is to say, that, if gas temperature decreases from 570° F. (absolute) to 520° F. (absolute), for example, the volume of the gas is reduced from 100% to 91.2%. If the gas is contained in a pressure-tight flare system, the pressure within the flare system would become less-than-atmospheric, and air would be drawn into the flare system to compensate for the temperature-induced volume decrease at atmospheric pressure. Thus, a potentially explosive condition would exist within the flare system.
On the other hand, if the temperature of the gases within the flare system should rise, for example, from 540° F. (absolute) to 560° F. (absolute), the volume of the contained gases would increase to 107.7% of its original volume, and the increased volume of gases would flow out of the flare discharge point to atmospheric pressure in order to restore atmospheric pressure within the flare system. From this discussion it becomes evident that a drop in temperature of the gas contained in a pressure-tight pipe system which is open to the atmosphere at its discharge end (the flare), causes in-draft of air in volume equal to the decrease in gas volume, to create danger of explosion within the flare system due to the presence of air in combustible mixture with gas. On the other hand, if the flare system gas temperature rises, there is outward movement of flare system gas to the atmosphere, and there is no danger of in-draft air. If the flare system gas temperature remains fixed, there is no movement of gas and, accordingly, there is no danger of air entry.
It thus becomes evident that around-the-clock entry of purge-gas to the flare system to provide volumetric avoidance of less-than-atmospheric pressure within the flare system is wasteful of purge gas, and is also unduly expensive, because purge gas is required for avoidance of air entry only as there is temperature decrease in the system contained gases, which is a relatively small part of the time. But, because there has been no automated system for admission of purge gases only during periods of temperature decrease, and because of the urgent need for flare safety, there has been constant admission of purge gases to flare systems as a standard procedure.
It is a primary object of this invention to provide a controlled system for the flow of purge gas into a waste gas flare system, so as to provide only a minimum quantity of purge gas, sufficient to prevent the influx of atmospheric air into the flare gas system when there is no venting of flare-relieved gases.
It is a still further object to provide the control so as to maintain at least atmospheric pressure inside of the flare stack system, with provision of a minimum quantity of purge gas.
These and other objects are realized and the limitations of the prior art are overcome in this invention by providing a pair of temperature sensors in the flare gas line. These two sensors are placed in close proximity. One is a fast-acting sensor, which responds rapidly to any change in temperature. The other is a slow-acting sensor, that responds slowly to a change in temperature. Thus, in combination, they provide a sensor system sensitive to change of temperature in the flare gas line.
The objective of the control is to sense whenever the temperature changes in a negative direction, that is, whenever there is a negative rate-of-change of the temperature in the vicinity of the sensors. When this happens, it is necessary to provide purge gas, and the rate of flow of purge gas should be substantially proportional to the magnitude of the negative rate-of-change. As the rate-of-change in the negative direction decreases, the flow of purge gas can decrease. Whenever the temperature is constant, or increasing, there is no need for the flow of purge gas, and the control system acts to stop the flow of purge gas.
Two embodiments are shown. In the first embodiment the temperature sensors are thermally responsive gas pressure cells. The first cell is fully exposed to the flow of flare gas. The second cell is identical in all respects to the first cell, except that it is thermally insulated from the flow of flare gas. Thus, it responds to temperature change in a much slower manner than the first cell.
The outputs of these pressure cells are pneumatic pressures, which are compared by means of a differential pressure controller, so that when the fast-acting sensor has a lower pressure than the slower-acting sensor, the control acts to allow the passage of purge gas. When the pressures are equal, or the fast-acting sensor is at a higher pressure than the slower-acting sensor, the supply of purge gas is cut off.
In a second embodiment the sensors are thermocouples which are identical, and which are inserted into identical metal thermowells. The slow acting sensor is identical to the fast acting sensor, except that, again, it is encased in thermal insulation, so that the thermocouple inside of the second thermowell acts much more slowly in response to a temperature change. The outputs of the two thermocouples are low electrical voltages. These voltages are compared in a suitable circuit, and a control signal is provided to open a valve in the purge gas line whenever the fast acting sensor, or thermocouple, shows a lower electrical potential than the slow acting sensor.
Still other methods of control can be utilized. For example, a single thermo-couple can be used in a single thermowell, with an appropriate electronic circuit which is sensitive to the rate-of-change of voltage supplied by the thermocouple. Thus, when the voltage drops, indicating a negative rate-of-change in temperature, the control operates to supply purge gas, and whenever the temperature or thermocouple voltage is constant, or increasing, the purge gas is cut off. By this means, purge gas is supplied only when the temperature is falling. Thus, a great savings in quantity and cost of purge gas can be obtained, since no flow of purge gas is required or is provided whenever the temperature in the flare gas line is constant or increasing.
Also, since it will be clear that no purge gas is required when the flow rate of waste gas is greater than a selected minimum, by means of a suitable flow meter controller, in combination with this differential temperature controller, the purge gas can be cut off while large flows of waste gas go to the stack.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects and advantages of this invention, and a better understanding of the principles and details of the invention will be evident from the following description, taken in conjunction with the appended drawings, in which:
FIG. 1 is a schematic diagram of one embodiment of this invention.
FIG. 2 is a view across the plane 2--2 of FIG. 1.
FIG. 3 is a schematic diagram illustrating a second embodiment of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the Drawings, and, in particular, to FIG. 1, there is indicated generally by the numeral 10, one embodiment of this invention. The flare gas line 12 is shown in cross-section, having a cylindrical pipe 14 welded to the side of the flare gas line 12. A flange 16 is provided on the side line 14. A blank flange cover 18 is adapted to be sealed over the flange 16.
Two sensors 20 and 22 are mounted to the blank flange cover 18. In the first embodiment these sensors are thermally responsive gas pressure cells. They are inserted in a transverse plane across the flare gas line 12, so as to be subject to, and measure the temperature of the flare gas which flows through the line.
With a standardized volume and quantity of gas inside of the cells 20 and 22, the pressure of the gas will vary as a function of the absolute temperature of the cell. The pressure inside the cell communicates by means of fine capillary lines 28 and 26, respectively, to a differential pressure controller 30. The differential pressure controller is part of a pneumatic control system, in which control air at a selected pressure is supplied by line 32 to the controller 30. Whenever the pressure in line 28 is less than in line 26, that is, whenever the fast response sensor 20 shows a lower pressure than the slow response sensor, it indicates that the temperature has a negative rate of change. The low pressure in line 28, compared to the higher pressure in line 26, causes the differential pressure controller 30 to open the supply of control air from line 32 into line 34, and to the control portion 36 of valve 38. Purge gas supplied over line 42 thus passes through the valve 38 to line 40 and into the flare gas line, as shown. However, the point of entry of the purge gas is preferably down line from the position of the sensors, so as not to affect the measurement of temperature of the gas flowing through the flare line.
FIG. 2 is a second view of the apparatus 10 of FIG. 1 taken across the plane 2--2 of FIG. 1. It shows the flare gas line 12, with arrows 44 indicating the flow of the flare gas. The flange cover 18 supporting the two gas cells 20 and 22 are clearly shown. It will be clear that FIG. 1 is a view taken across the plane 1--1 of FIG. 2.
Referring now to FIG. 3, there is shown a second embodiment indicated generally by the numeral 50. FIG. 3 shows an apparatus similar to that of FIG. 1, namely, the flare gas line 12, the side pipe 14, flange 16, and flange cover plate 18.
Here again, there are two temperature sensors. One is a thermocouple 58 inserted into a thermowell 52 of thin metal, so as to respond rapidly to the temperature of the gas flowing past the thermowell 52 along the inside of the flare gas line 12. A second identical thermocouple 56 inside of an identical thermowell 52 is provided. However, the second thermowell is completely covered with thermal insulation 54, so as to delay heat transfer from the gas to the thermowell metal 52 and then to the thermocouple. Thus, while a steady state temperature exists, both thermocouples 58 and 56 will show the same temperature. If there is a sudden lowering of temperature of the gas flowing past the two sensors, the fast-acting sensor 58 will respond more rapidly to the change in temperature than will the second slow-acting sensor 56.
Each of these sensors has a two-wire lead 64A, 64B and 62A, 62B, respectively, between which appears a low alue of electrical potential. The electrical potential is generated by the thermocouple, and is proportional to the absolute temperature of the junction of the two wires 58 and 56, respectively. The potentials provided on the outputs of the two thermocouples are applied in opposition to a conventional differential potential sensitive circuit, such as is well-known in the art. One such device could be an electrical bridge, for example. Thus, when the temperatures are equal, there will be no voltage difference appearing between the outer terminals of the thermocouples. However, if the fast-acting sensor 58 should be exposed to a lower temperature gas, its potential will drop while the slower-acting thermocouple 56 will not respond rapidly and, thus there will be an unbalanced voltage in the outputs of 62A-B and 64A-B to control device 60.
A thermocouple control box 60 is conventional, and will provide a corresponding control voltage or pneumatic output as desired, over line 70, to a control box 72, which operates the valve 38, to control the flow of purge gas from an input line 40, through an output line 42, to the flare gas line 12 when there is the described voltage unbalance between 62A-B and 64A-B. A power supply to the controller 60 is provided through lines 68, as is well-known in the art. If the controller operates pneumatically, then pressurized control air would be provided through line 66 in a manner similar to FIG. 1, for example.
What has been shown is an improved more efficient system, in which purge gas flow is provided only when required. The method of determining when such flow is required is by means of appropriate thermal sensors, that determine when the temperature inside of the purge gas system changes to a lower value, or the temperature has a negative rate of change. Whenever the rate of change is zero or positive the flare gas is shut off.
It will be clear also that a control using a single thermocouple, such as 58, in an uninsulated thermowell could be used in combination with an electronic circuit which determines the rate of change of potential on the thermocouple leads such as 64A, 64B. Whenever the circuit determines that there is a negative rate of change of potential, (or temperature) (or pressure as on sensor 20), the flow of purge gas is provided.
Also, it will be clear that no purge gas is required when the flow rate of waste gas is greater than a selected minimum. Thus, by means of a suitable flow meter controller, in combination with this differential temperature controller, the purge gas can be cut off while large flows of waste gas go to the stack.
While the invention has been described with a certain degree of particularity, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claims, including the full range of equivalency to which each element or step thereof is entitled. | In a flare system for waste gases, apparatus is provided for controlling the flow of purge gas into the flare gas line, as required, and not on a continuing basis. Sensor means are provided for detecting a change in temperature in the flare gas line, and means are provided for controlling the flow of purge gas whenever the temperature in the flare gas line changes to a lower value. No purge gas flow is required when the temperature is constant or when the temperature is rising. | 5 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This non-provisional patent application claims priority to the provisional patent application having Ser. No. 61/002,690, which was filed on Nov. 9, 2007.
BACKGROUND OF THE INVENTION
The framed freshener generally relates to air freshening devices and more specifically to a picture frame with an integral scented gel.
A variety of gel products are on the market, used mostly for toys, novelty, gifts, window clings, and decorative ornaments. The consumers are particularly attracted by the gel products due to their features of softness, color, and introduction of a scent or fragrance. These features, desired by consumers, are related to the nature of the gel product, which may contain mineral oil. Additionally, the careful selection of the composition of gel products has related the good dispersion between a scent or fragrance and the surface of the gel products for introduction into the atmosphere.
After setting a scented liquid into a thermal form cavity and forming a gel in a desired shape with the scent within its composition, a frame having a decorated surface and edge treatment includes the gel within the thermal form in an opening, aperture, or other space adjacent to other openings for mounting a photo or the like. The gel adjacent to a photo in a frame can then be located where suitable in a home or office.
Conventional picture frames typically consist of elongated members of wood, metal, or plastic arranged in a rectangular shape with the corners connected with adhesives or mechanical fasteners. The display photo is placed in the frame along with a transparent front panel of glass or plastic, matting if desired, and backing materials, which are further attached with more fasteners, and positioned behind the photo or artwork within the elongated members shaped into a frame, often rectangular but other shapes are possible. Particularly, the frame has a wire, or other suitable fastener appropriately secured, for use in hanging the picture on a wall or other vertical surface. Alternatively, the frame has a stand for supporting a picture upright upon a flat surface such as a shelf, table, or desk.
DESCRIPTION OF THE PRIOR ART
Some prior art patents relate to the use of gels related to picture frames. One is U.S. Pat. No. 6,395,125, upon the process for making a picture frame. The picture frame has a border printed upon the perimeter of transparent sheet material and then cut from the sheet. The border and a transparent window sheet are then adhered together upon a polymer sheet extending beyond the border. The polymer sheet is then folded behind the window and cut to provide a leg to hold the picture frame upright. A photo or other display is placed within the window. The polymer laminated picture frame though lacks the ability to provide a fragrance therefrom.
Then the U.S. Pat. No. 5,916,650, shows a removable display cover and method. This cover has a border printed upon a plastic sheet with a transparent window generally in the center of the cover. The cover has magnetic, static charge, or surface tension that sticks the cover to another surface. The cover is placed over a photo or other display, securing the photo upon the surface. This cover also does not provide a fragrance.
The present invention overcomes the disadvantages of the prior art and provides a fragrance carrying material within a picture frame. The framed freshener provides scent wherever the frame is located in a home, office, or other location. The fragrance may trigger stronger memories in cooperation with a photograph or other item displayed within the frame of the present invention.
SUMMARY OF THE INVENTION
Generally, the present invention of a framed freshener provides a thermal formed cavity holding a scented gel that fits into a picture frame. The sense of smell has been known to trigger long dormant memories. Coupling a certain fragrance with a photo or other item in a frame, the present invention seeks to foster memories in those who view the frame. Additionally, the thermal formed cavity holding a scented gel makes the frame holding it into a concealed, or unobtrusive, air freshening device. The present invention locates a fragrance source in a container, such as a thermal formed cavity or thermoplastic shell, and places the container in a suitably designed picture frame. The picture frame and the opening for the fragrance container can be die cut to a specific shape.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof that follows may be better understood and that the present contribution to the art may be better appreciated. The present invention also includes a gel composition, a tab on the shell, round, ovoid, irregular, rectangular and square shaped shells, a flange upon the perimeter of the shell for securement upon the matting of a frame, and a perforated die and a lid to control the release of fragrance from the invention and to prevent spillage. Additional features of the invention will be described hereinafter and which will form the subject matter of the claims attached.
Numerous objects, features and advantages of the present invention will be readily apparent to those of ordinary skill in the art upon a reading of the following detailed description of the presently preferred, but nonetheless illustrative, embodiment of the present invention when taken in conjunction with the accompanying drawings. Before explaining the current embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting.
One object of the present invention is to provide a framed freshener with an improved scented gel in a thermal formed cavity, or thermoplastic shell, that is then mounted into a picture frame.
Another object is to provide such a framed freshener with a scented gel that is flexible and removable from the picture frame.
Another object is to provide such a framed freshener within a picture frame that has an arrangement or design upon the surface of the thermal formed cavity, thermoplastic shell, or resulting gel by die cutting, molding, or other shape imposing methods.
Another object is to provide such a framed freshener with a scented gel that releases scent without electric or mechanical means.
These together with other objects of the invention, along with the various features of novelty that characterize the invention, are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and the specific objects attained by its uses, reference should be had to the accompanying drawings and descriptive matter in which there is illustrated a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
In referring to the drawings,
FIG. 1 shows a perspective view of the present invention;
FIG. 2 describes an exploded view of the present invention from the rear;
FIG. 3 is a top sectional view of the present invention;
FIG. 4 describes an exploded view of an alternate embodiment of the present invention; and,
FIG. 5 describes a front view of an alternate embodiment.
The same reference numerals refer to the same parts throughout the various figures.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present art overcomes the prior art limitations by providing a framed freshener 1 in FIG. 1 that has a picture frame 2 that provides a scent, fragrance, or freshener suitable for locating in a person's home or office as desired. The scent is provided from a gel 3 contained within a shell 4 and the shell is then placed within the picture frame. The gel is placed within the shell or container in liquid form and then sets to its final consistency in less than five minutes.
More particularly, the framed freshener has the gel 3 contained within a shell 4 or other thermal formed shell or cavity. The gel releases scents through perforated openings 4 a —also called lidding—in the shell, or container, and its own surfaces. Here the openings are shown in a flower petal like arrangement though other arrangements are possible. The shell is placed upon the rear of the frame 2 at an aperture 5 with an edge treatment 6 here shown as a bevel though other edge treatments are possible. In this embodiment, the shell is located and spaced apart from another picture P placed within the frame.
In further description, the gel 3 comprises a polymer, oil, and the like blended in liquid form. The gel is then pored into a thermal formed plastic shell container as opposed to a free standing form. The gel then attains any one of a variety of shapes, here the present invention has an ovoid shape, though rectangular and square are likely alternate shapes. The polymeric gel retains its features over time: flexibility, scent transmission rate, and color among others. The gels of the present invention are generally translucent, and preferably transparent, while remaining receptive to color dyes.
The composition of the present invention blends a mixture of polymers in combination with hydrocarbon oil to form a gel. The hydrocarbon oil can be, for example, a paraffinic oil, a naphthenic oil or a mineral oil. The hydrocarbon oils contain a fragrance that releases over time, in the present invention, for at least 96 hours. The present invention does not use electric resistance heat or mechanical ventilation to release the fragrance. The fragrance or scent naturally escapes the gel at a known rate subject to atmospheric conditions at the location of the framed freshener. The fragrance generally has a positive smell and can include flower based smells, spice based smells, pleasant organic materials, and the like. Low molecular weight polyalphaolefin maintains the rigidity of the gel while highly branched alpha olefin polymers bind the oil and increase the hardness of the gel. In the preferred embodiment, the gel has a translucent quality with a hint of color. Gels attain a color through dyeing, preferably an oil soluble dye. The color coordinates with that of the picture frame and the taste of the user of the invention.
In an alternate embodiment, generally for children, luminescent, fluorescent, pearlescent particles, glitters, metallic pigments, and optical brightener additives mixed into the gel preferably and upon the frame or thermoformed container alternatively, add a degree of fun to the invention. These additives provide shine, sparkling, and illumination of the gel or frame in darkness. Other useful additives are a light absorber to lengthen shelf stability of the gel and the picture frame when exposed to visible or ultraviolet light. If desired, thermochromic pigments may be added to the frame or the thermoformed plastic shell that change color at predetermined temperatures.
Mineral oils are highly refined, colorless, and odorless petroleum oils. A preferred mineral oil to mix with the polymers of the invention is “white” mineral oil. White mineral oil is generally recognized as safe for contact with human skin because people may touch the gel or its shell from time to time. Mineral oil may be characterized in terms of its density and viscosity, where light mineral oil is relatively less viscous than heavy mineral oil. The mineral oil of the present invention includes amounts ranging from about 5 to about 30% by weight, and preferably from about 10 to about 20% by weight.
The framed freshener 1 assembles from components shown in FIG. 2 . Here, the frame 2 has a generally rectangular shape with the rear surface 7 in view. The rear surface has a plurality of clips 8 spaced near the perimeter, with a minimum of one clip though three are shown. The clips rotate from the frame upon a backing 9 . The backing is also rectangular though of slightly less extent than the frame 2 so the backing fits within the perimeter of the frame. The backing has a stand 10 that unfolds, generally perpendicular to the frame that supports the frame upright in this embodiment as previously shown in FIG. 1 . The backing also has an aperture 11 of similar proportions to the shell 4 and slightly less than the proportions of the aperture 5 in the frame. The aperture 11 of the backing and the aperture 5 of the frame cooperate for ready release of scent from the gel 3 within the shell 4 . The scent can disperse from the front and the rear of the frame 2 .
The present invention assembles by placing the shell 4 into the aperture 5 with a flange 12 extending from the shell located towards the rear surface 7 . The flange has greater width and length than the apertures 5 , 11 so that the shell does not fall through the frame 2 and remains within the framed freshener 1 . A photo is then placed in another opening in the frame as desired. Then the backing 9 is placed upon the rear surface 7 , the shell 4 , and the photo P with the stand 10 positioned to open and then support the frame 2 upright. The clips 8 are turned with a portion behind the backing, thus securing the frame 2 , shell 4 , and photo P to the backing 9 . Additionally, the flange has a tab extending perpendicular therefrom to ease grasping of the shell for insertion into the aperture 5 by a person.
FIG. 3 illustrates a top, sectional view of the assembled framed freshener 1 with the stand folded. The clips 8 are turned so the backing 9 is pressed into the rear surface 7 of the frame 2 . In front of the backing, the shell 4 fits within the aperture 5 of the frame 2 . The shell remains within the frame as the flange 12 remains between the backing and the frame proximate the perimeter of the aperture 5 . The flange generally extends around the perimeter of the shell and is made from the same material as the shell. The flange generally suspends the shell within the apertures 5 , 11 for free flow of scent. To the side of the shell, or container, the present invention has a photo P in the other opening of the frame 2 . The photo is located within the backing, matting, and the frame. The backing extends across the back of the photo and matting, thus preventing the photo from falling out of the frame.
An alternate embodiment of the invention appears in FIG. 4 that has just the shell and no separate photo. As before, the frame 2 has a rear surface 7 with an aperture 5 and a plurality of clips 8 located upon the perimeter of the frame. The aperture 5 has an edge condition and admits the shell 4 , or other thermal formed cavity or container, into the aperture. The shell contains the gel 3 with a fragrance that is released through openings in the shell. A perimeter flange 12 upon the shell secures it within the frame as before. A backing 9 secures upon the shell and within the rear surface of the frame and under the clips 8 . This embodiment has two stands 10 that unfold oppositely from the backing. The stands in cooperation with the frame provide three contacts with a supporting surface so the frame remains upright. The backing has an aperture 11 that also permits free flow of scent from the shell or container. In assembly, the flange 12 of the shell is located between the frame and the backing so that the shell is suspended within the apertures 5 , 11 .
Another alternate embodiment takes form in FIG. 5 that has a shell 4 as one component in a stand 13 . The stand has a base 14 , generally round, with a raised central fitting 15 that receives three stems. Two stems are lateral stems 16 that extend upwardly and outwardly from the central fitting. The third stem is an upright stem 17 that extends generally perpendicular to the base. The stems 16 , 17 are generally cylindrical of narrow diameter. The lateral stems terminate in a ring 8 with an internal spring retainer 19 . The retainer engages an inner rim 18 a and stays within the ring. The retainer can support a photo or other item within the ring 18 or be used alone. Now the upright stem terminates opposite the base with an oval frame 19 . The upright stem 17 attaches to the oval frame at the end of the major axis. The oval frame contains the shell 4 within. As before, the shell 4 has a plurality of openings 4 a that admit scent from a gel 3 contained therein. As the oval frame is hollow, the shell can release scent from opening upon both sides of the shell. Here the openings 4 a have a flower like arrangement though other shapes are possible. This embodiment places the framed freshener high above the base 14 to maximize dispersion of the scent from the gel.
From the aforementioned description, a framed freshener has been described. The device is uniquely capable of providing a fragrance or scent from a picture frame wherever the frame is located. The fragrance comes from a gel contained within a thermoplastic shell, cavity, or container, placed within a picture frame. The framed freshener and its various components may be manufactured from many materials, including but not limited to, wood, steel, aluminum, polymers, polyvinyl chloride, high density polyethylene, polypropylene, ferrous and non-ferrous metals, their alloys, and composites, and the gel may include the various ingredients as described above and the like.
As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. Therefore, the claims include such equivalent constructions insofar as they do not depart from the spirit and the scope of the present invention. | A framed freshener provides a thermal formed cavity, or thermoplastic shell, carrying scented gel that fits into a picture frame. The present invention locates a fragrant gel in a thermal formed cavity or thermoplastic shell or container which is then placed within a suitably designed picture frame. Coupling a fragrance with a photo in a frame, the present invention seeks to foster memories in those who view the frame. Additionally, the shell carrying gel makes the frame a decorative air freshening device. The picture frame and the opening for the fragrance container can be die cut to any shape. An alternate embodiment has the shell supported in a wire frame upon a base. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the US National Stage of International Application No. PCT/DE03/003140, filed Sep. 22, 2003 and claims the benefit thereof. The International Application claims the benefits of German application No. 10245641.0 DE filed Sep. 30, 2002, both of the applications are incorporated by reference herein in their entirety.
FIELD OF INVENTION
[0002] The invention relates to a method for updating the local management system in at least one network element of a telecommunication network, wherein the local management system consists of at least a network element agent, which is stored in a network element management unit of the network element, and a network element manager.
BACKGROUND OF INVENTION
[0003] A multiplicity of data connections are set up, maintained and cleared down again via a plurality of interconnected network elements (NE). In this context, the network elements have the task of switching or establishing and administrating data connections. In telecommunication networks of this type, the control of the relevant network elements can be carried out via individual local management systems which are integrated in the network elements. Such a local management system is normally made up of two interacting management system modules, namely the network element agents and the network element managers.
[0004] The network element agent is integrated in a network element management unit within the network element which has to be managed, and manages individual management objects. Such management objects can contain information about the structure or the architecture of the network element, for example, or about the switching status of the relevant network element or of the telecommunication network. The network element agents also monitor and control these management objects—see the patent document U.S. Pat. No. 5,651,006, columns 1 to 3 concerning this, for example.
[0005] The network element manager manages and controls in particular the network element resources which are assigned to a network element agent. For this, the network element manager is connected to the network element agent via a data connection, wherein the exchange of the management data takes place via different network management protocols.
[0006] Two international network management standards, among others, are known in this context for telecommunication networks, namely the Bellcore (now Telcordia) management standard and the OSI (Open System Interconnection) management standard. Network management protocols and management interface specifications such as TL1 (Transactions Language 1) or Q3, for example, are derived from these management standards.
[0007] Such management interface specifications are subject to continuous changes, which result in updates in the already existing local management system modules, i.e. both in the network element agents and in the network element managers. Following the update of these local management system modules in the relevant network elements, incompatibilities can arise between the network element agent and the network element manager when the local management system is activated. Possible instances of conflict can arise because the network element agent does not recognize and therefore does not execute individual control commands of the network element manager, or because the true operating statuses of the network element are not correctly captured and reported by the updated network element agents.
[0008] Until now, updates of the two local management system modules have been performed independently and manually on the basis of the management interface specification which is present in ASCII code, i.e. the machine-readable code of the local management system modules is adapted to the changes individually by a network management specialist. After the individual updating of the two local management system modules is complete, the interaction between the two local management system modules is verified with the aid of system tests. This activity aims to demonstrate that the network element manager covers exactly the instruction set which is required in order to control the network element correctly. Following completion of the system tests, at least the network element agent or both local management system modules are loaded into the relevant network element via a data connection by means of customary instructions for software download.
[0009] Furthermore, the patent document U.S. Pat. No. 6,263,366 discloses a system and a method for translating TL1 messages, using a “mapper/parser” module, into messages or control commands which can be processed by the network management system. Using this “mapper/parser” module, the TL1 messages are automatically converted into equivalent alarm reports or equivalent event reports which can be further processed by the network management system.
SUMMARY OF INVENTION
[0010] The present invention addresses in particular the problem of specifying a novel method for updating a local management system in a network element, whereby incompatibilities between the updated network element agent and the updated network element manager can be avoided.
[0011] The problem is solved by the features in the independent claims.
[0012] The essential advantage of the method according to the invention is that an updated network element agent and an updated network element manager are created by a shared generation mechanism directly from a predetermined management interface specification, and at least the updated network element agent is loaded into the network element management unit of the network element which has to be updated. As a result of the claimed automatic and joint generation of the network element agent and the network element manager directly from the present management interface specification, compatibility between the two local management system modules is guaranteed, thereby significantly reducing the error susceptibility of the local management system which has to be updated. In addition, the time which is required to activate the local management system following the update is clearly reduced as a result of this.
[0013] It is particularly advantageous that the updated network element manager is stored in a central unit of the telecommunication network or is also loaded into the network element management unit of the network element which has to be updated.
[0014] It is also advantageous that the updated network element agent and the updated network element manager are loaded via a data connection, using a data transmission protocol, from a user computer into the network element management unit of the network element which has to be updated. This has the result that the loading of the updated local management system modules into the network element which has to be updated can take place automatically and without being geographically dependent.
[0015] The invention provides a further advantage in that an HTML management interface specification is additionally created by the shared generation mechanism in the hypertext markup language (HTML) format, and is stored together with the updated network element manager. Such an HTML management interface specification which is present in HTML format can be retrieved easily, and in its updated form, via a Web browser. As a result of this, only those functionalities of the local management system which are currently available for the relevant network element are shown.
[0016] Advantageous developments of the claimed method are described in the further patent claims.
BRIEF DESCRIPTION OF THE DRAWING
[0017] FIG. 1 —an exemplary embodiment of the method for updating a local management system in a telecommunication network element
DETAILED DESCRIPTION OF INVENTION
[0018] The method according to the invention is explained in greater detail below with reference to an exemplary embodiment. For this purpose, an exemplary embodiment of the method for updating a local management system MS in at least one network element NE of a telecommunication network TKN is explained with reference to a schematic block diagram. The block diagram exemplifies a central unit CU, e.g. a central server unit, belonging to a telecommunication network TKN, and one of a multiplicity of network elements NE which are present in the telecommunication network TKN. The network element NE has a network element management unit MSU, in which e.g. a network element agent NE-A and a network element manager NE-M are stored. The storage of the two local management system modules NE-A, NE-M can optionally also take place in separate units within the network element NE. The network element NE can be connected to the central unit CU of the telecommunication network TKN via a data connection.
[0019] The central unit CU has at least one storage unit SU, in which the current management interface specification IS is stored, preferably in the ASCII code. According to the invention, it is also possible to store different versions or only parts of the management interface specification IS. Provision is also made for the central unit CU to include a generating mechanism module GMM, in which is implemented the shared generating mechanism GM for directly generating the updated network element agent NE-A and the updated network element manager NE-M from the stored management interface specification IS. The shared generating mechanism GM is implemented at least partly by means of a parser in this context.
[0020] Provision is also made for the central unit CU to include a central network management system unit, for example, with the assistance of which the complete network management can be carried out centrally within the telecommunication network TKN.
[0021] In order to update the local management system MS of the one network element NE, the updated management interface specification IS, which is present in the ASCII data format, e.g. a Tl-1 interface specification, is loaded into the storage unit SU of the central unit CU. In the shared generating mechanism module GMM, which is connected to the storage unit SU via a data connection, the network element agent NE-A and the network element manager NE-M are directly generated as machine-readable code from the management interface specification IS which is present in ASCII code. Alternatively, this generation can be carried out in a separate unit—not shown in the figure—separately from the central unit CU of the telecommunication network TKN. The updated network element agent NE-A and the updated network element manager NE-M are then loaded directly into the network element management unit MSU of the network element NE which has to be updated, via a data connection or via a data interface of the central network management system NMS, wherein the network element manager NE-M can be “downloadably” stored alternatively in a central storage unit SU of the telecommunication network TKN or in a storage unit of a portable user computer PC.
[0022] The updated network element agent NE-A is alternatively loaded via a data connection using a data transmission protocol, e.g. the File Transfer Protocol (FTP), from a portable user computer PC into the network element NE which has to be updated or into the network element management unit MSU thereof.
[0023] In order to load the network element manager NE-M from the updated network element NE or a central storage unit, the updated network element manager NE-M is implemented as a JAVA applet, for example. As a result, the “downloading” of the network element manager NE-M can be carried out via the Internet data transmission protocol IP. Such a “download” is possible via any standard user computer PC which has a Web browser, and therefore the management of the updated network element NE, using the network element manager NE-M which is loaded onto the user computer PC, can be carried out geographically remotely from the network element NE that has to be managed. In this type of configuration, the JAVA applet is executed on the Web browser of the user computer PC. A data connection to the updated network element agent NE-A is then established via the network element manager NE-M which is executed in the Web browser, and control commands cc which are generated by the network element manager NE-M are transmitted directly, via the implemented network management protocol e.g. the Tl-1 interface protocol, to the network element agents NE-A which are executed in the network element management unit MSU. In the network element NE, the network element agent NE-A executes the received control commands cc, e.g. TL-1 control commands cc, whereby the actions which are assigned to the control commands cc are initiated in the network element NE.
[0024] In addition, an HTML management interface specification HTML-IS in the hypertext markup language format (HTML) is generated directly from the management interface specification IS, which is present in ASCII code, by the generating mechanism GM in the generating mechanism module GMM. This HTML management interface specification HTML-IS is “downloadably” stored, together with the updated network element manager NE-M, either directly in the network element NE which has to be updated or in a central storage unit of the telecommunication network TKN. Using such an HTML management interface specification HTML-IS, which can be displayed by means of a conventional Web browser, a user at a user computer PC can directly request the control commands cc or control options which are available for the relevant network element NE, thereby receiving information about the individual parameter options of the relevant control commands cc which are available. In a preferred embodiment of the invention, the HTML management interface specification HTML-IS and the network element manager NE-M are stored in a shared storage unit.
[0025] By virtue of the described method, the compatibility between the network element agent NE-A and the network element manager NE-M is already ensured at an early phase of the updating process, and therefore hardly any conflicts arise within the updated network element NE when the local management system MS is activated after the updating. Such an exact agreement or compatibility of the generated network element manager NE-M with the network element agent NE-A is ensured by virtue of the shared generation, with the assistance of the shared generating mechanism GM, directly from the current management interface specification IS.
[0026] In the illustrated exemplary embodiment, only the updating of a single network element NE is described by way of example, and the method according to the invention can alternatively be applied to updating a multiplicity of network elements NE which are present in a telecommunication network TKN.
[0027] Moreover, the network element agent NE-A and the network element manager NE-M can be directly generated in the network element NE which must be updated, by virtue of a shared generating mechanism GM which is provided in the relevant network element NE, wherein the current management interface specification IS can be either loaded from a central storage unit SU within the telecommunication network TKN or stored directly in the network element NE which must be updated. | The aim of the invention is to update a local management system in at least one network element of a telecommunication network, said local management system consisting of at least one network element agent stored in a management unit of the network element, and a network element manager. To this end, an updated network element agent and an updated network element manager are directly produced by a common generation mechanism from a pre-determined management interface specification. At least the updated network element agent is then loaded into the management unit of the network element to be updated. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of co-pending U.S. patent application Ser. No. 12/031843, filed Feb. 15, 2008, which is a divisional of co-pending U.S. patent application Ser. No. 09/851848, filed May 9, 2001, which is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] This invention relates to electronic trading markets. More particularly, this invention relates to ways to control the extent to which traders can manipulate electronic trading markets.
[0003] As electronic trading becomes more popular, there is an increasing need to control the extent to which traders can manipulate and abuse electronic trading markets. Currently, the trading of fixed-income securities, such as United States Treasuries, United Kingdom Gilts, European Government Bonds, and Emerging Market debts, and non-fixed income securities, such as stocks, is possible through electronic trading systems.
[0004] In one method of electronic trading, bids and offers are submitted by traders to a trading system. A bid indicates a desire to buy while an offer indicates a desire to sell. These bids and offers are then displayed by the trading system to other traders. The other traders may respond to these bids and offers by submitting sell (or hit) or buy (or lift or take) commands to the trading system. Once a bid or offer has been responded to by a sell or buy command, a trade has been executed.
[0005] Electronic trading can be conducted over any suitable communication system. For example, networked computers can be used to implement a trading system. Traders can submit bid, offer, hit, or lift commands via any suitable input device, such as a mouse, keyboard, or any other suitable device.
[0006] Electronic timers are sometimes used in electronic trading systems. In certain systems, a “trade-state” timer may be used to provide a period of exclusivity for two traders (called “current workers”) who are “working-up” a trade—i.e., adding size to a pending series of trades. This trade-state timer may be set to a predetermined time period. For example, for U.S. Treasuries, the trade-state timer may be set to twelve seconds. During a work-up trade, the current workers may have a right of first refusal to trade at a certain level. A current worker may submit a bid or an offer anytime during this trade state. However, during this period, no other trader may submit a bid or offer, or respond with a sell or buy command.
[0007] In some systems, “bid-offer” timers may be used to prevent traders from prematurely canceling bids and offers entered by the traders. The timers may give other traders an opportunity to respond to the bids and offers before they can be cancelled by the traders that submitted them. The timers may be set to a predetermined period. For example, in U.S. Treasuries, the bid-offer timer may be preferably set to four seconds. The bid-offer timer may begin when a trader has submitted a bid or offer to the trading system.
[0008] When these timers are used together in an electronic trading system, a bid-offer timer may begin when a current worker submits a bid or offer during a work-up trade. The submission of the bid or offer may be timed so that the bid-offer timer expires just prior to the time that the trade-state timer expires. Immediately upon expiration of the trade-state timer, the former current worker may then replace the current bid or offer with a lower bid or offer. At the same time, another trader may submit a sell or buy command in response to the current worker's first bid or offer. Since the current worker has replaced the first bid or offer, the new trader may unintentionally end up selling or buying at a different level than was expected. By canceling the earlier bid or offer and submitting a new bid or offer in order to deceive the new trader, the current worker is said to be “gaming” the market.
[0009] Many current trading markets allow traders to “game” the market. As explained above, one form of gaming is done by submitting a bid or offer to the market only to quickly replace it with a new bid or offer. This can be accomplished by manipulating the market timers.
[0010] The bids or offers may be any trade type. These may include all-or-none (AON), limit order (LMT), market order (MKT), market-if-touched (MIT), stop-order (STP), etc. More common in gaming is submitting a market order as a first bid or offer and then canceling and replacing the market order with a limit order. A market order buys or sells at the current trading price while a limit order buys or sells at a stated price or better off the current market.
[0011] In view of the foregoing, it would be desirable to provide systems and methods for controlling a trader's ability to manipulate electronic trading markets.
SUMMARY OF THE INVENTION
[0012] It is an object of this invention to provide systems and methods for controlling a trader's ability to manipulate electronic trading markets.
[0013] For background purposes only, a trading interface for an electronic trading system that may be used in accordance with the present invention is illustrated in Kirwin et al. U.S. patent application Ser. No. 09/745,651, filed Dec. 22, 2000, which is hereby incorporated by reference herein in its entirety.
[0014] In accordance with this invention, a variety of approaches to control gaming during electronic trading may be used. One approach compares a price difference between two bids or offers. A second approach manipulates the bid-offer and trade-state timers.
[0015] More particularly, the price approach may compare the prices of the new and old bids or offers by a trader upon receiving a request to replace a bid or offer. If the change in price is greater than some predetermined value set by the trading system, the trading system may only permit the bid or offer to be replaced by first entering a “cooling off” period. During this cooling off period, any attempt to sell or buy in response to the bid or offer may be suspended. In this way, a new trader has an opportunity to see the price change before submitting a sell or buy command. As an alternative, if the change in price is too great, the new bid or offer may be automatically removed from the market.
[0016] The time approach links the timeout of the bid-offer timer to the end of the trade-state timer, rather than the time when a bid or offer was submitted. In this approach, the bid-offer timer may be programmed to count down upon completion of the trade-state timer if a current worker submitted a bid or offer during the trade state. During this time, a new trader (seller or buyer) may respond to the bid or offer, and the current worker cannot cancel or replace the bid or offer during the trade-state timer or during the bid-offer timer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The above and other objects and advantages of the invention will be apparent upon consideration of the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like parts throughout, and in which:
[0018] FIG. 1 is a hardware implementation of an exemplary embodiment of an electronic trading system in accordance with the present invention;
[0019] FIG. 2 illustrates a detached trading view of a market cell containing a bid in accordance with the present invention;
[0020] FIG. 3 illustrates a detached trading view of a market cell when a trader has gamed the market in trading systems prior to the present invention;
[0021] FIG. 4 illustrates a detached trading view of a market cell when a seller responds to a bid in accordance with the present invention;
[0022] FIG. 5 is a flow diagram of an exemplary embodiment of a price approach in accordance with the present invention; and
[0023] FIG. 6 is a flow diagram of an exemplary embodiment of a timing approach in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0024] The present invention provides systems and methods for controlling gaming in electronic trading systems. One approach involves detecting a change in price between two bids or offers by the same trader and suspending trading for a predetermined amount of time if the price difference is too large, or removing the new bid or offer from the trading system. Another approach involves preventing a trader from canceling or replacing a bid or offer for a predetermined amount of time by linking the timers associated with entry and modifications of bid, offer, sell, and buy commands.
[0025] FIG. 1 illustrates one embodiment of an electronic trading system 10 according to the present invention. As shown, system 10 may include one or more user computers 12 , each of which may include a mouse 22 , that are connected by one or more communication links 14 and a computer network 16 to a trading server 18 .
[0026] In system 10 , trading server 18 may be a processor, a computer, a data processing device, or any other suitable server. User computer 12 may be a computer, processor, personal computer, computer terminal, personal digital assistant, a combination of such devices, or any other suitable data processing device. Mouse 22 may be any suitable pointing device capable of receiving user input. Computer network 16 may be any suitable network, including the Internet, an intranet, a wide area network (WAN), a local area network (LAN), a wireless network, a digital subscriber line (DSL) network, a frame relay network, an asynchronous transfer mode network (ATM), a virtual private network (VPN), etc. Communication links 14 may be any suitable communication links for communicating data between user computers 12 and trading server 18 , such as network links, dial-up links, wireless links, hard-wired links, etc.
[0027] All trading interactions between user computers 12 preferably occur via computer network 16 , trading server 18 , and communication links 14 . Traders at user computers 12 may conduct trading transactions using mice 22 , keyboards, or any other suitable devices.
[0028] FIGS. 2-4 illustrate market cells that may be displayed on a user computer 12 in accordance with the present invention. A market cell may include indications of the item to be traded, pending bids and/or offers for the item, the last trading price, and a field for entering trade commands. For ease of description, FIGS. 2-4 will be described in terms of bids although the same applies for offers as well.
[0029] FIG. 2 illustrates a detached trading view of a market cell 50 containing a market order bid entered by a trader for an item. As shown, a symbol 52 for the item to be traded (e.g., usg-5y) may be indicated. As also shown, the trader may have entered a market order bid 56 having a price of 98.21 for $10 million in 5 year bonds as well as a limit order bid 58 having a price of 98.14 for the same amount. The last trading price 60 for the item (e.g., 98.222) may also be indicated. “Command Line” 64 may be used by a trader to enter a bid, offer, sell, buy, cancel, or replace command, or any other suitable command. These commands may be entered using text, using dedicated buttons, or using any other suitable approach to execute trade commands.
[0030] FIG. 3 illustrates a detaching trading view of market cell 100 after a trader has gamed the market. Using the existing electronic trading system, a trader can manipulate the timers to replace market order bid 56 in FIG. 2 with the limit order bid 102 (bid 58 in FIG. 2 ) having a price of 98.15. Unaware of this change, a seller thinks he or she is responding to the 98.21 bid when he or she is actually responding to the 98.15 bid. The new price is indicated in last price column 106 .
[0031] FIG. 4 illustrates a detached trading view of a market cell 150 when a trader tries to cancel or replace bid 56 prior to a seller responding to the bid. Under the present invention, a trader who tries to cancel or replace a bid will either be prevented from changing the bid for a predetermined time period or trading for the item will be suspended, giving a potential seller notice of the new bid.
[0032] If a bid cannot be canceled for a predetermined time period, a seller may hit the bid as indicated by indicator 152 . As shown, the seller has sold $ 10 million of usg-5Y at a price of 98.21. The new trading price is reflected in the last price column 156 .
[0033] FIG. 5 is a flow diagram of a price approach to prevent gaming in accordance with the present invention. Process 200 begins at step 202 with one or more bids or offers already entered in the trading system. A bid or offer can be a market order, a limit order, any other type of order, or any combination of orders. At step 204 , the trading system may receive a request to cancel or replace a bid or offer. Next, at step 206 , the trading system may determine whether the trader has more than one order for the same item.
[0034] If the trader has more than one order, the trading system takes steps to prevent possible gaming. At step 208 , the trading system cancels the first bid or offer and replaces it with the second bid or offer. Next, at step 210 , the trading system compares the price of the canceled bid or offer with the new bid or offer. If the price change in the bids or offers is greater than some delta (e.g., 1/32nd, or any other suitable price difference), process 200 moves to step 212 where a cooling off period timer starts. During this cooling off period, if the trading system receives a request to sell or buy at step 216 , the sell or buy order is suspended at step 218 to give the seller or buyer notice of a change in bid or offer price.
[0035] After suspending the sell or buy order, or if the trading system has not received a request to sell or buy, process 200 checks whether the cooling period has ended at step 220 and if not, process 200 moves back to step 216 . The cooling off period may last any suitable amount of time (e.g., 2 seconds). If the cooling period has ended at step 220 , the new bid or offer is updated on the trading system and a seller or buyer can respond with a hit or lift at step 222 . Once a hit or lift is received, a trade occurs and process 200 ends at step 224 .
[0036] If the price change in bids or offers at step 210 is not greater than the predetermined delta, process 200 moves to step 226 where the trading system checks for a request to sell or buy. If there is a request to sell or buy (i.e., a seller or buyer responds with a hit or lift response) at step 228 , then a trade occurs and process 200 ends at step 230 . Process 200 may also end at step 230 immediately after step 226 if there is no request to sell or buy.
[0037] If the trading system determines that a user does not have more than one bid or offer for the same item at step 206 , process 200 cancels the bid or offer at step 232 . Since the trader no longer has a bid or offer in the market, process 200 ends at step 234 .
[0038] FIG. 6 is a flow diagram of a timing approach to control gaming according to the present invention. Process 300 begins at step 302 by starting a trade-state timer. At this point, the trading system for a particular item has entered a trade state. During this trade state several events may occur. One event may be a request to cancel or replace a current bid or offer at step 306 . If this occurs, the trader will be prevented from canceling or replacing the bid or offer, and a pop-up window may be displayed on the trader's screen indicating that he or she cannot cancel or replace the bid or offer until the trade state is over at step 308 . A second event may be a request to submit a hit or take at step 307 . If this occurs, a second trader will be able to submit a hit or take in response to the bid or offer at step 309 . Then at step 311 , the trading system will reset the trade-state timer. A third event may be a request to submit a bid or offer at step 310 . If this occurs, a trader will be able to submit a bid or offer at step 312 . If the trader currently has a bid or offer in the market, submitting a new bid or offer will not replace or cancel the existing bid or offer.
[0039] After step 308 , 311 , or 312 , or directly after step 302 (if none of the requests indicated in steps 306 , 307 , and 310 are made), process 300 moves to step 314 where the trading system determines whether the trade-state timer has ended. If the trade-state timer has not ended, process 300 remains in the trade state to wait for a request to cancel or replace an order at step 306 , a request to submit a hit or take at step 307 , a request to submit a bid or offer at step 311 , or for the timer to end at step 314 . If the trade-state timer has ended, process 300 moves to step 316 where the bid-offer timer starts. At this point, process 300 is in a bid-offer state. During the bid-offer state (e.g., 4 seconds or any other suitable time period), one of several things can occur. If process 300 receives a hit or lift response from a seller or buyer, a trade will occur at the bid or offer price made during the trade state at step 324 . Process 300 will then end at step 326 .
[0040] During the bid-offer state, process 300 can receive a request to cancel or replace an order at step 320 . If this occurs, similar to the trade state, the trader will be prevented from canceling or replacing the order, and a pop-up window, or any other suitable method, may be used to communicate this message to the trader at step 322 .
[0041] After step 322 , or directly after step 316 , process 300 may determine whether the bid-offer timer has ended at step 328 . If the timer has not ended, process 300 may remain in the bid-offer state to wait for a request to cancel or replace a bid or offer at step 320 , for a hit or lift response at step 324 , or for the timer to end at step 328 . If the bid-offer timer has ended, process 300 may then receive a request to cancel or replace an order at step 330 . If such a request is received, the bid or offer will be canceled and will be replaced by a new bid or offer at step 332 . Process 300 may then end at step 334 .
[0042] Gaming may be controlled to prevent as well as to promote gaming. Gaming may be promoted by creating liquidity in an illiquid market (e.g., by controlling and encouraging gaming to whatever degree the market will permit). An example for increasing liquidity may be to take an illiquid security, such as an old bond (e.g., 30 year United States Treasury bond), and permit gaming so that trades increase. The permitted sale may be based on a sliding scale of various elements that are controlled. The permitted sale may also occur by permitting the trade to increase until a specific volume is attained, or by generally permitting gaming for specific securities (such as the old bond) in illiquid markets.
[0043] Thus it is seen that systems and methods are provided to control gaming in electronic trading systems. One skilled in the art will appreciate that the present invention can be practiced by other than the described embodiments, which are presented for purposes of illustration and not of limitation, and the present invention is limited only by the claims which follow. | Systems and methods are provided to control gaming in electronic trading markets. These systems and methods alleviate the problem of a seller or buyer trying to act on a trader's original bid or offer only to trade at an unfavorable level after the trader changes the bid or offer. A pricing method suspends trading for a period of time if a price difference between two bids or offers by the same trader is too great. A timing method prevents a trader from canceling or replacing a bid or offer for a period of time. These methods provide a more fair and efficient way of executing electronic trades. | 6 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a technique of data transmission from a transmitting apparatus to a receiving apparatus, and more particularly, to a technique of data transmission control based on a permissible amount of transmissible data.
[0002] When data is transmitted from the transmitting apparatus to the receiving apparatus, it is necessary to perform flow control for controlling data transmission from the transmitting apparatus so that a buffer (receiving data buffer) provided for the receiving apparatus does not become full. In the past, as shown in Laid-open No. 61-63140, a flow control was performed in which a special character indicating whether data transmission is allowed or not is transmitted from the receiving apparatus to the transmitting apparatus to control data transmission. However, the following problems reside in the flow control performed by transmitting the special character. First, the flow control cannot be performed when a data transmission speed is high. Second, reliable control cannot be performed. Third, it is difficult to handle transaction processing.
[0003] Accordingly, as one of flow control systems used when data is transmitted from the transmitting apparatus to the receiving apparatus, there has been used credit-based flow control in which the receiving apparatus transmits a credit to the transmitting apparatus, and the transmitting apparatus transmits data whose amount corresponds to the received credit. In the credit-based flow control, the receiving apparatus generates a credit based on the amount of data processed in the receiving data buffer or an amount of available space of the receiving data buffer, and transmits the credit to the transmitting apparatus as a reception credit. At this time, the transmitting apparatus should receive data whose amount corresponds to the reception credit. The transmitting apparatus receives the reception credit from the receiving apparatus and adds the reception credit to a transmittable credit stored therein. When the transmittable credit is equal to or more than a credit corresponding to the amount of data to be transmitted (transmission credit), the transmitting apparatus transmits data to the receiving apparatus. The credit expresses an amount of data. In the technical field of the flow control for data transmission, the amount of data is not directly expressed in units of bytes or kilobytes, and the amount of data or the amount of data transmitted is often expressed in units of credits on the assumption that a predetermined amount of data is defined as one credit in advance. An example of the credit-based flow control is disclosed in Laid-open No. 2004-235728.
[0004] FIG. 7 shows an example of a configuration of a conventional flow control system in which data transmission is controlled by the credit-based flow control. The conventional flow control system performs flow control when data is transmitted from a transmitting apparatus to a receiving apparatus. The conventional flow control system is configured by a transmitting apparatus 101 for transmitting data and a receiving apparatus 102 for receiving data transmitted from the transmitting apparatus 101 . The transmitting apparatus 101 shown in FIG. 7 serves as an interface to the receiving apparatus. Similarly, the receiving apparatus 102 shown in FIG. 7 serves as an interface to the transmitting apparatus. Between the transmitting apparatus 101 and the receiving apparatus 102 , there are a data line through which data is transmitted and received as a data signal 109 and a signal line through which a credit is notified as a credit notification signal 110 from the receiving apparatus 102 to the transmitting apparatus 101 .
[0005] The receiving apparatus 102 includes a first-in, first-out (FIFO) receiving data buffer 107 for temporarily storing data received from the transmitting apparatus 101 , and a credit notification control circuit 108 for calculating a credit (reception credit) to be notified to the transmitting apparatus 101 . Data stored in the receiving data buffer 107 can be taken out from another circuit (not shown) included in the receiving apparatus. In the receiving apparatus 102 , when the received data which is stored in the receiving data buffer 107 is transmitted to another circuit of the receiving apparatus in order to process the received data, a reception data credit signal 111 which is used to notify of a credit corresponding to the amount of taken out received data is transmitted from the receiving data buffer 107 to the credit notification control circuit 108 . The credit notification control circuit 108 calculates a reception credit to be notified to the transmitting apparatus 101 , based on the reception data credit signal 111 , and notifies the transmitting apparatus 101 of the calculated reception credit.
[0006] The transmitting apparatus 101 includes a transmission data buffer 103 for storing transmission data, a transmission credit calculating circuit 104 for calculating and holding a credit of data stored in the transmission data buffer 103 as a transmission credit, a transmittable-credit calculating and holding circuit 105 for calculating and holding a transmittable credit in the transmitting apparatus 101 , and a flow control circuit 106 for performing flow control. Transmission data is sent from a circuit (not shown) provided in the transmitting apparatus and serving as a data transmission source to the transmission data buffer 103 . Transmission data is temporarily stored in the transmission data buffer 103 . The transmission data buffer 103 transmits the stored transmission data to the receiving apparatus 102 under the control of the flow control circuit 106 .
[0007] The transmission credit calculating circuit 104 notifies, when data is transmitted from the transmission data buffer 103 to the receiving apparatus 102 , the transmittable-credit calculating and holding circuit 105 of a credit corresponding to the amount of transmission data transmitted from the transmission data buffer 103 . The transmittable-credit calculating and holding circuit 105 subtracts the credit notified by the transmission credit calculating circuit 104 from the transmittable credit stored in the transmittable-credit calculating and holding circuit 105 when the transmission data buffer 103 transmits data to the receiving apparatus 102 . And, when the transmittable-credit calculating and holding circuit 105 receives the reception credit from the receiving apparatus 102 , the transmittable-credit calculating and holding circuit 105 adds the reception credit to the transmittable credit in order to update the transmittable credit. Note that, at the time of initialization of the flow control system, a credit corresponding to the capacity of the receiving data buffer 107 obtained when the receiving data buffer 107 is vacant is generally set up as a transmittable credit.
[0008] The flow control circuit 106 compares the transmittable credit stored in the transmittable-credit calculating with holding circuit 105 with the transmission credit stored in the transmission credit calculating circuit 104 , and performs the flow control according to a result of the comparison. Specifically, when the transmittable credit is equal to or larger than the transmission credit, the flow control circuit 106 orders the transmission data buffer 103 to transmit data to be transmitted to the receiving apparatus 102 . On the other hand, when the transmittable credit is smaller than the transmission credit, the flow control circuit 106 temporarily stops transmitting data until the transmittable credit becomes equal to or larger than the transmission credit.
[0009] Next, an operation of the conventional flow control system shown in FIG. 7 is described with reference to a flowchart shown in FIGS. 8A to 8C . FIG. 8A shows a data transmission process performed in the transmitting apparatus 101 and a transmittable credit update process performed in the transmittable-credit calculating and holding circuit 105 . FIG. 8B shows data receiving process performed in the receiving apparatus 102 and a credit update process performed in the credit notification control circuit 118 . FIG. 8C shows a transmittable credit update process performed by receiving a reception credit in the transmitting apparatus 101 . As described above, before a data transmission is started, the transmittable credit stored in the transmittable-credit calculating and holding circuit 105 is equal to the credit of the receiving data buffer 107 . In other words, the amount of available space of the receiving data buffer 107 is set up as the transmittable credit. The transmittable credit is referred to as a credit “B”, for example.
[0010] First, an operation of the transmitting apparatus 101 when the transmitting apparatus 101 receives data whose amount is expressed by the credit “A” from a transmission source circuit of the transmitting apparatus, or another system is described.
[0011] Referring to FIG. 8A , transmission data having the credit “A” is stored in the transmission data buffer 103 (step 201 ). The transmission credit stored in the transmission credit calculating circuit 104 is updated to “A” (step 202 ). The transmittable credit “B” stored in the transmittable-credit calculating and holding circuit 105 is compared with the transmission credit “A” (step 203 ). When “A” is equal to or smaller than “B” as a result of the comparison, the transmittable credit is equal to or larger than the transmission credit. In other words, the amount of available space of the receiving data buffer 107 is equal to or larger than the amount of data stored in the transmission data buffer 103 . Accordingly, the flow control circuit 106 transmits the data having the credit “A” from the transmission data buffer 103 to the receiving apparatus 102 (Step 204 ). After data is transmitted, the transmission data buffer 103 becomes vacant. By transmission data which has the credit “A”, the transmittable credit stored in the transmittable-credit calculating and holding circuit 105 is updated to ” (B minus A)” (step 205 ). On the other hand, when “A” is larger than “B” in Step 203 , the flow control circuit 106 does not transmit data and keeps waiting until “A” becomes equal to or smaller than the transmittable credit. Note that, in the case of the credit-based flow control, it is assumed that the transmission data having the credit “A” is transmitted to the receiving apparatus 102 as a group of data. Thus, an operation that the transmission data is split into pieces of partial data according to a space of the receiving data buffer 107 and the partial data is transmitted to the receiving apparatus 102 is not performed.
[0012] After the transmitting apparatus 101 transmits the transmission data having the credit “A” as described above, the receiving apparatus 102 receives the transmission data having the credit “A” (step 206 ). The received data is stored in the receiving data buffer 107 . When a circuit of the receiving apparatus 102 takes out the transmission data having the credit “A” from the receiving data buffer 107 , the credit stored in the credit notification control circuit 108 is updated to “A” (step 207 ). The credit notification control circuit 108 notifies the transmitting apparatus 101 of a reception credit “A” by using a credit notification signal 110 (step 208 ).
[0013] After the receiving apparatus 102 transmits the credit notification signal 110 , the transmittable-credit calculating and holding circuit 105 of the transmitting apparatus 101 receives the reception credit “A” from the receiving apparatus 102 (step 209 , FIG. 8C ). Then, the transmittable-credit calculating and holding circuit 105 adds “A” to the transmittable credit (the transmittable credit is “(B minus A) ” at the time just before the addition) stored therein to update the transmittable credit to “B” (which is equal to the sum of “(B minus A)” and “A”). The flowchart returns to Step 201 and repeats the above-described processing to transmit next transmission data.
[0014] In the flow control described above, the transmittable credit which represents an available space of the receiving data buffer 107 is compared with the credit of transmission data, and then the transmission data is transmitted to the receiving apparatus 102 . Thus, a buffer overflow of the receiving data buffer 107 is prevented. Note that, in this flow control system, receiving data is taken out from the receiving data buffer 107 . Except when a process for the reception credit corresponding to the receiving data taken out from the receiving data buffer 107 is not finished in the transmittable-credit calculating and holding circuit 105 , the transmittable credit generally matches a credit corresponding to the amount of available space of the receiving data buffer 107 .
[0015] There are cases in which the receiving apparatus 102 needs to stop data transmission while the above-mentioned flow control is being performed, regardless of the available space of the receiving data buffer 107 . Those cases include a case of changing the system configuration of the receiving apparatus 102 (for example, a crossbar route is changed to change the data routing destination). However, in the above-mentioned conventional credit-based flow control system, since whether to perform data transmission is judged in the transmitting apparatus 101 , it is impossible for the receiving apparatus 102 to instruct the transmitting apparatus 101 to stop data transmission from the transmitting apparatus 101 when the receiving data buffer 107 has available space. Further, there is a case in which, to evaluate a test data that is transmitted from transmitting apparatus 101 and has a quite small credit, it is desired to receive only data having a quite smaller credit than that corresponding to the amount of available space (i.e., transmittable credit) of the receiving data buffer 107 . However, since the receiving apparatus 102 cannot issue an instruction, data having larger amount than the test data is transmitted instead of the test data.
[0016] To stop data transmission from the transmitting apparatus without issuing a stop instruction from the receiving apparatus, there is a method in which when the receiving apparatus receives data, the receiving apparatus does not transmit a reception credit to the transmitting apparatus when the receiving apparatus receives data irrespective of whether data is taken out from the receiving data buffer. According to this method, the transmittable credit of the transmitting apparatus keeps decreasing every time the transmission data is transmitted to the receiving apparatus and finally becomes zero or a value close to zero. As a result, every piece of transmission data has a credit larger than the transmittable credit, so the transmitting apparatus does not transmit the transmission data to the receiving apparatus. A method of this type is disclosed in Laid-open No. 2004-72547, for example. However, with this method, it is impossible to properly grasp an elapsed time from when transmission of a reception credit from the receiving apparatus is stopped to when data transmission from the transmitting apparatus is stopped. Further, when transaction data is transmitted, a reply that includes a reception credit is returned from the receiving apparatus to the transmitting apparatus after the transmission data is transmitted from the transmitting apparatus to the receiving apparatus. If the reception credit is not transmitted to the transmitting apparatus, the reply is not returned. Accordingly, in a case of transaction processing having a time-out concept, the transmitting apparatus may detect a reply time-out and regard the reply time-out as a system failure. For example, the credit-based flow control is performed on PCI-Express used for an internal bus in a computer system or a bus which connects a computer system and an extension board. However, since a time-out concept resides therein, the receiving apparatus has to return a reply to a transaction issued by the transmitting apparatus within a fixed period of time. Thus, in the case of PCI-Express, the method of preventing data transmission from the transmitting apparatus without transmitting a reception credit to the transmitting apparatus cannot be used.
[0017] In Laid-open No. 09-200290, there is disclosed credit-based flow control in which data transmission from the transmitting apparatus is stopped by not transmitting information used to update a credit stored in the transmitting apparatus from the receiving apparatus.
[0018] Note that if a new signal line for transmitting a transmission stop instruction from the receiving apparatus to the transmitting apparatus is provided, the receiving apparatus can instruct the transmitting apparatus to stop data transmission, thereby solving the above-mentioned problem. However, providing the new signal line for transmitting a transmission stop instruction can cause a large increase in cost, and further, it maybe difficult to provide the new signal line. In addition, each of the transmitting apparatus and the receiving apparatus needs to be configured considering the new signal line. So, to stop data transmission by transmitting the transmission stop instruction through the new signal line is hardly applied to an existent flow control system or a system which uses an apparatus of different vendors.
SUMMARY OF THE INVENTION
[0019] As described above, in the conventional credit-based flow control system, it is impossible to stop or suppress data transmission by an instruction from the receiving apparatus. This problem is caused by a configuration in which a credit corresponding to the amount of available space or an increase in the amount of available space of the receiving data buffer is constantly notified from the receiving apparatus to the transmitting apparatus. However, even if transmission of a credit from the receiving apparatus to the transmitting apparatus is prevented, the receiving apparatus cannot predict the time when data transmission from the transmitting apparatus ends, and reply time-out occurs in the transaction which requires return of a reply. When the new signal line is provided to instruct to stop data transmission from the receiving apparatus to the transmitting apparatus, the cost increases, and modification of the hardware is required.
[0020] A system, comprising: a first apparatus; and a second apparatus which transmits first data having a first amount to said first apparatus, wherein said first apparatus comprises: a memory element which stored said first data; a first controller which transmits a first signal for adjusting said first amount when said first amount need to be adjusted or a second signal indicating a second amount of a second data extracted from said memory element when said first amount does not need to be adjusted, to said second apparatus through a signal line; and wherein said second apparatus comprises: a second controller which updates a third signal indicating a third amount of third data that said first apparatus permits of receiving, based on said first signal; and a third controller which determines to transmit said first data when said third amount is equal to or larger than said first amount.
[0021] An apparatus which receives first data having a first amount from another apparatus, comprising: a memory element which stored said first data; and a controller which transmits a first signal for adjusting said first amount when said amount need to be adjusted or a second signal indicating a second amount of a second data extracted from said memory element when said first amount does not need to be adjusted, to said another apparatus through a signal line.
[0022] An apparatus which transmits first data having a first amount to another apparatus having a memory element for storing said first data, comprising: a first controller which receives a first signal for adjusting said first amount when said another apparatus need to adjust said first amount or a second signal indicating a second amount of second data extracted from said memory element when said first amount does not need to be adjusted, from said another apparatus through a signal line; wherein said first controller updates a third signal indicating a third amount of third data that said another apparatus permits of receiving, based on said first signal; and a second controller which determines to transmit said first data when said third amount is equal to or larger than said first amount.
[0023] A system, comprising: a first apparatus; and
[0024] a second apparatus which transmits first data to said first apparatus, wherein said first apparatus comprises: a memory element which stores said first data; a first storage element which stores a first signal indicating a first amount of second data extracted from said memory element; a second storage element which stores a second signal indicating a second amount that is smaller than that of said first signal; a select circuit which transmits said first signal to said second apparatus while said first apparatus accepts a data transmission from said second apparatus, and transmits said second signal to said second apparatus when said first apparatus suspends said data transmission from said second apparatus; and
[0025] said second apparatus comprises: a third storage element which stores said first signal or said second signal as a third signal; a fourth storage element which stores a fourth signal indicating a third amount of third data that is ready to be transmitted to said first apparatus; and a controller which permits said data transmission when said third amount indicated by said fourth signal is equal to or smaller than that of said third signal.
[0026] A method for controlling a system having a first apparatus and a second apparatus transmitting first data having a first amount to said first apparatus, comprising: storing said first data in a memory element; transmitting a first signal for adjusting said first amount when said first amount need to be adjusted or a second signal indicating a second amount of a second data extracted from said memory element when said first amount does not need to be adjusted, to said second apparatus through a signal line; and updating a third signal indicating a third amount of said third data that said first apparatus permits of receiving, based on said first signal; and
[0027] determining to transmit said first data when said third amount is equal to or larger than said first amount.
[0028] A method of controlling a apparatus, comprising: receiving first data having a first amount from another apparatus; storing said first data in a memory element; and transmitting a first signal for adjusting said first amount when said amount of said data need to be adjusted or a second signal indicating a second amount of a second data extracted from said memory element when said first amount does not need to be adjusted, to said another apparatus through a signal line.
[0029] A method for controlling an apparatus which transmits first data having a first amount to another apparatus having a memory element for storing said first data, comprising: receiving a first signal for adjusting said first amount when said another apparatus need to adjust said first amount or a second signal indicating a second amount of second data extracted from said memory element when said first amount does not need to be adjusted, from said another apparatus through a signal line; updating a third signal indicating a third amount of said third data that said another apparatus permits of receiving, based on said first signal; and determining to transmit said first data when said third amount is equal to or larger than said first amount.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] Other feature and advantages of the invention will be made apparent by the following detailed description and the accompanying drawings, wherein:
[0031] FIG. 1 is a block diagram illustrating a configuration of a flow control system according to a first embodiment of the present invention;
[0032] FIG. 2 is a block diagram illustrating a configuration of a credit notification control circuit;
[0033] FIG. 3 is a block diagram illustrating a configuration of a transmittable-credit calculating and holding circuit;
[0034] FIG. 4A is a flowchart illustrating a process for suspending data transmission between a transmitting apparatus 301 and a receiving apparatus 302 and canceling the suspension of the data transmission;
[0035] FIG. 4B is a flowchart illustrating an operation of the transmitting apparatus 301 for updating a transmittable credit;
[0036] FIG. 5 is a block diagram illustrating a configuration of a flow control system according to a second embodiment of the present invention;
[0037] FIG. 6A is a flowchart illustrating an operation of a transmitting apparatus 701 for updating the credit;
[0038] FIG. 6B is a flowchart illustrating an operation of a receiving apparatus 702 for updating the credit;
[0039] FIG. 6C is a flowchart illustrating an operation of the transmitting apparatus 701 for updating the credit;
[0040] FIG. 6D is a flowchart illustrating a case in which the receiving apparatus 702 issues an instruction to suspend data transmission or to cancel the suspension;
[0041] FIG. 7 is a block diagram illustrating a configuration of a conventional flow control system based on a credit;
[0042] FIG. 8A is a flowchart illustrating flow control operation based on a transmittable credit;
[0043] FIG. 8B is a flowchart illustrating an operation of a receiving section for notifying a credit; and
[0044] FIG. 8C is a flowchart illustrating an operation of a transmitting section for updating a transmittable credit.
[0045] In the drawings, the same reference numerals represent the same structural elements.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] A first embodiment of the present invention will be described in detail below.
[0047] FIG. 1 illustrates a configuration of a flow control system based on a credit. In the flow control system, a flow control is performed by transmitting a reception credit from a receiving apparatus 302 to a transmitting apparatus 301 , similarly to the conventional flow control system shown in FIG. 7 . The flow control system according to the first embodiment is different from that of FIG. 7 because not only the reception credit capable of increasing a value of transmittable credit stored in the transmitting apparatus 301 but also the reception credit capable of decreasing the value of a transmittable credit can be transmitted from the receiving apparatus 302 to the transmitting apparatus 301 . Specifically, a credit having a negative value is transmitted from the receiving apparatus 302 to the transmitting apparatus 301 to update, for example, a value of the transmittable credit to 0 , to thereby suspend data transmission from the transmitting apparatus 301 irrespective of a credit of a transmission data stored in a transmission data buffer. In order to cancel the suspension of data transmission, it is only necessary to transmit a credit having an appropriate positive value to the transmitting apparatus 301 from the receiving apparatus 302 . Hereinafter, the flow control system shown in FIG. 1 is described in detail.
[0048] The flow control system shown in FIG. 1 includes the transmitting apparatus 301 which transmits data, and the receiving apparatus 302 which receives the data transmitted from the transmitting apparatus 301 . Between the transmitting apparatus 301 and the receiving apparatus 302 , there is provided at least one data line through which data is transmitted and received as a data signal 309 , and a plurality of signal lines through which a credit is notified by using a credit notification signal 310 from the receiving apparatus 302 to the transmitting apparatus 301 , each serving as an interface.
[0049] The receiving apparatus 302 includes a FIFO receiving data buffer 307 for temporarily storing receiving data, and a credit notification control circuit 308 for calculating a credit to be notified to the transmitting apparatus 301 . In a case in which the receiving data stored in the receiving data buffer 307 is transferred therefrom to an internal circuit (not shown) of the receiving apparatus 302 so as to be processed, a receiving data credit signal 3081 for notifying the credit of the transferred receiving data is transmitted from the receiving data buffer 307 to the credit notification control circuit 308 . Further, the receiving data buffer 307 transmits a receiving buffer credit signal 3080 for notifying the credit (i.e., receiving buffer credit) indicating the space currently available in the receiving data buffer 307 to the credit notification control circuit 308 . The credit notification control circuit 308 is configured so as to be supplied with a transmission suspension instruction signal 311 for instructing suspension of data transmission between the transmitting apparatus 301 and the receiving apparatus 302 from the internal circuit (not shown) of the receiving apparatus 302 .
[0050] As shown in FIG. 2 , the credit notification control circuit 308 includes a credit selector 3082 for selecting one of the receiving buffer credit signal 3080 and the receiving data credit signal 3081 in response to the transmission suspension instruction signal 311 , a credit storage register 3083 for storing the credit of one of the credit selected in the credit selector 3082 , and a sign storage register 3084 for storing “1” when the sign storage register 3084 receives the transmission suspension instruction signal 311 . A credit is represented by a binary signed integer. A negative credit has a most significant bit (MSB) of “1”, and a positive credit has a most significant bit of “0”. Accordingly, the credit notification control circuit 308 generates the credit by setting the content of the sign storage register 3084 for the most significant bit of the credit and setting the content stored in the credit storage register 3083 for lower-order bits. The credit notification control circuit 308 notifies the generated credit as a reception credit to the transmitting apparatus 301 .
[0051] The transmitting apparatus 301 includes a transmission data buffer 303 for storing transmission data, a transmission credit calculating circuit 304 for calculating the transmission credit, a transmittable-credit calculating and holding circuit 305 for calculating and holding the transmittable credit, and a flow control circuit 306 for performing the flow control. Transmission data temporarily stored in the transmission data buffer 303 is transmitted from an internal circuit of the transmitting apparatus 301 or from another system. The transmission data buffer 303 transmits the transmission data stored therein to the receiving apparatus 302 under the direction of the flow control circuit 306 . The transmission credit calculating circuit 304 calculates the transmission credit and, in a case in which the transmission data is transmitted from the transmission data buffer 303 , outputs a transmission data credit signal 3053 for notifying the transmittable-credit calculating and holding circuit 305 of the transmission credit. The flow control circuit 306 compares the transmittable credit held in the transmittable-credit calculating and holding circuit 305 with the transmission credit held in the transmission credit computing circuit 304 . In a case, in which the transmittable credit is equal to or larger than the transmission credit, the transmission data is transmitted to the receiving apparatus 302 . In a case in which the transmittable credit is smaller than the transmission credit, the transmission data is not transmitted until the transmittable credit becomes equal to or larger than the transmission credit.
[0052] As shown in FIG. 3 , the transmittable-credit calculating and holding circuit 305 includes a credit split circuit 3050 for splitting the credit that has received as a notification from the credit notification signal 310 into a code signal 3051 (i.e., MSB of the credit) and a credit signal 3052 (lower-order bits excluding MSB of the credit), a transmittable credit storage register 3054 for storing the transmittable credit, a transmittable credit calculating circuit 3055 for calculating the transmittable credit, and a code storage register 3056 for storing “1” in a case in which it is determined by the calculation in the transmittable credit calculating circuit 3055 that the transmittable credit has a negative value. The transmittable credit held in the transmittable credit storage register 3054 is notified to the flow control circuit 306 by a transmittable credit notification signal 3057 .
[0053] When the transmission data buffer 303 transmits the transmission data to the receiving apparatus 302 , the transmittable credit calculating circuit 3055 subtracts the credit notified by the transmission data credit signal 3053 from the transmittable credit stored in the transmittable credit storage register 3054 . Further, upon reception of the credit notification signal 310 having the code signal 3051 of “0” from the receiving apparatus 302 , the transmittable credit calculating circuit 3055 calculates the transmittable credit by adding the credit of the credit signal 3052 to the transmittable credit stored in the transmittable credit storage register 3054 and updates the transmittable credit. Further, upon reception of the credit notification signal 310 having the code signal 3051 of “1 from the receiving apparatus 302 , the transmittable credit calculating circuit 3055 calculates the transmittable credit by subtracting the credit of the credit signal 3052 from the transmittable credit stored in the transmittable credit storage register 3054 and updates the transmittable credit.
[0054] In this embodiment, one of the plurality of signal lines for the credit notification signal 310 is used for transmitting the code signal 3051 of the credit notification signal 310 from the receiving apparatus 302 to the transmitting apparatus 301 .
[0055] Next, an operation of the flow control system is described. In initializing the flow control system, the transmittable credit is generally assigned a credit corresponding to the space of the receiving data buffer 307 when the receiving data buffer 307 is vacant. In the flow control system, until the transmission data buffer 303 of the transmitting apparatus 301 receives the transmission data, a credit corresponding to the space of the receiving data buffer 307 (i.e., receiving buffer credit) is stored as a transmittable credit in the transmittable credit storage register 3054 . In this case, the credit is assumed to be “B”.
[0056] First, a process in a case in which the transmission suspension instruction signal 311 is not inputted to the credit notification control circuit 308 yet is described below. In this case, the content of the code storage register 3084 is “0” and the credit selector 3082 selects the receiving data credit signal 3081 . Therefore, the receiving data credit signal 3081 is stored in the credit storage register 3083 . As a result, a credit having the most significant bit of “0” and corresponding to an amount of data extracted from the receiving data buffer 307 is transmitted from the receiving apparatus 302 to the transmitting apparatus 301 as the reception credit. The most significant bit of the credit (the reception credit) is “0”, so the credit has a positive value. Also, in this case, the code signal 3051 is “0”. So, a credit corresponding to the credit signal 3052 is added to the transmittable credit. That is, a similar operation as that illustrated in FIGS. 8A to 8C is performed.
[0057] Next, referring to FIGS. 4A and 4B , explained is an operation of the credit notification control circuit 308 in a case in which the receiving apparatus 302 has received an instruction of suspending transmission with the transmitting apparatus or an instruction of canceling the suspension of transmission with the transmitting apparatus based on the transmission suspension instruction signal 311 is described below. FIG. 4A illustrates an operation of the receiving apparatus 302 in a case in which the receiving apparatus 302 has received the instruction of suspending transmission with the transmitting section or the instruction of canceling the suspension of transmission with the transmitting section based on the communication suspension instruction signal 311 . FIG. 4B illustrates an operation of the transmittable-credit calculating and holding circuit 305 for updating the transmittable credit upon reception of a credit which is sent from the receiving apparatus 302 .
[0058] As shown in FIG. 4A , the receiving apparatus 302 receives the instruction of suspending transmission with the transmitting apparatus based on the transmission suspension instruction signal 311 (Step 211 ). Then, the content of the code storage register 3084 is updated to “1” (Step 212 ). Since the content of the code storage register 3084 is “1”, the receiving buffer credit signal 3080 is selected by the credit selector 3082 (Step 213 ). Accordingly, the receiving buffer credit (“B” in this case) is stored in the credit storage register 3083 . The content of the code storage register 3084 and the content of the credit storage register 3083 are combined, and a credit “1B” having the most significant bit of “1” and the lower-order bits of “B” is notified to the transmitting apparatus 301 (Step 214 ). The most significant bit of the credit “1B” is “1” because the value stored in the code storage register 3084 is “1”. Since the most significant bit of the credit “1B” is “1”, the credit “1B” has a negative value even though the credit “1B” has an absolute value of “B”.
[0059] As described above, the receiving apparatus 302 transmits the credit notification signal 310 of the credit “1B” as the reception credit. Then, as shown in FIG. 4B , the transmittable-credit calculating and holding circuit 305 receives the credit “1B” (Step 215 ). The received credit is split into the code signal 3051 and the credit signal 3052 by the credit split circuit 3050 (Step 216 ). In this case, the code signal 3051 is “1” and the credit signal 3052 is “B”. Upon reception of the credit having the code signal 3051 of “1”, the transmittable credit calculating circuit 3055 subtracts the credit (“B”) notified by the credit signal 3052 from the value stored in the transmittable credit storage register 3054 . Therefore, the transmittable credit is “0”, which is obtained by subtracting “B” from “B”. As a result, the transmittable credit calculating circuit 3055 stores the transmittable credit of “0” in the transmittable credit storage register 3054 (Step 217 ). The transmittable-credit calculating and holding circuit 305 notifies the transmittable credit of “0” to the flow control circuit 306 using the transmittable credit notification signal 3057 (Step 218 ).
[0060] If the transmitting apparatus 301 receives the transmission data having the credit of “D” from the internal circuit or another system in a case in which “0” is set as the transmittable credit, the transmission data having credit of “D” is stored in the transmission data buffer 303 (Step 201 ), as shown in FIG. 8A . Next, the transmission credit stored in the transmission credit calculating circuit 304 is updated to “D” (Step 202 ), as shown in FIG. 8A . Then, the flow control circuit 306 compares the transmittable credit (“0” in this case) with the transmission credit (“D” in this case) in Step 203 . Herein, because “D” is larger than,“0”, the flow control is performed so as to wait in Step 203 without transmitting the transmission data until “D” becomes equal to or smaller than the transmittable credit.
[0061] As described above, when the receiving apparatus 302 receives the instruction of suspending transmission with the transmitting apparatus 301 based on the transmission suspension instruction signal 311 , the data transmission between the receiving apparatus 302 and the transmitting apparatus 301 is suspended.
[0062] Next, an operation for restarting the data transmission from the state where the data transmission between the receiving apparatus 302 and the transmitting apparatus 301 is suspended is described below.
[0063] As shown in FIG. 4A , the receiving apparatus 302 receives the transmission suspension instruction signal 311 indicating that the suspension of the data transmission needs to be canceled(Step 211 ). As a result, the code storage register 3084 in the credit notification control circuit 308 is updated to “0” (Step 212 ). The receiving buffer credit signal 3080 is selected by the credit selector 3082 (Step 213 ). Accordingly, the credit (“B” in this case) indicated by the receiving buffer credit signal 3080 is stored in the credit storage register 3083 . The credit “0B” is notified to the transmitting apparatus 301 (Step 214 ). The credit “0B” has the most significant bit of “0” and the lower-order bits of “B”. The most significant bit of “0” corresponds to the stored value of “0” in the code storage register 3084 .
[0064] The receiving apparatus 302 transmits the credit notification signal 310 of the credit “0B” as the reception credit. Then, as shown in FIG. 4B , the transmittable-credit calculating and holding circuit 305 receives the credit “0B” from the receiving apparatus 302 (Step 215 ). The received credit “0B” is split into the code signal 3051 (“0” in this case) and the credit signal 3052 (“B” in this case) by the credit split circuit 3050 (Step 216 ). Since the code signal 3051 is “0”, the transmittable credit calculating circuit 3055 adds the credit notified by the credit signal 3052 to the credit stored in the transmittable credit storage register 3054 . Therefore, the transmittable credit becomes “B”, which is obtained by adding “0” to “B”. Subsequently, the transmittable credit calculating circuit 3055 stores the transmittable credit “B” in the transmittable credit storage register 3054 (Step 217 ). The transmittable credit “B” is notified by the transmittable credit notification signal 3057 to the flow control circuit 306 (Step 218 ). After the transmittable credit “B” is notified to the flow control circuit 306 as described above, the data transmission from the transmission data buffer 303 to the receiving apparatus 302 is initiated according to the procedure shown in FIG. 8A .
[0065] The available space of the receiving data buffer 307 changes because data is extracted therefrom when the data transmission with the transmitting apparatus 301 is suspended. In this case, the credit storage register 3083 stores the receiving buffer credit used when the suspension of transmission was indicated based on the transmission suspension instruction signal 311 (Step 213 ). Further, in order to deal with the change of the available space of the receiving data buffer 307 due to the extraction of data while suspending the data transmission, the receiving data credit 3081 corresponding to the extracted data is transmitted to the transmitting apparatus 301 as a reception credit.
[0066] The operations when the instruction of suspending transmission with the transmitting apparatus 301 and the instruction of canceling the suspension of transmission with the transmitting apparatus 301 are received using the transmission suspension instruction signal 311 have been explained as above. In each case, both the transmittable credit and the receiving buffer credit are “B”. As long as the transmittable credit is set so as to correspond to the space of the receiving data buffer 307 when the system is initialized, the value of the transmittable credit is same as that of the receiving buffer credit, except for a case in which the cancellation of transmission is instructed or the like. However, in some cases, the transmittable credit and the receiving buffer credit included in the receiving buffer credit signal 3080 may be different from each other.
[0067] For example, the receiving data credit included in the receiving data credit signal 3081 should be transmitted to the transmitting apparatus 301 when data is extracted from the receiving data buffer 307 , but when the receiving data credit has not been transmitted completely the transmittable credit (“C” in this case) stored in the code storage register 3054 is smaller than the receiving buffer credit “B” of the receiving data buffer 307 . The transmittable credit “C” is smaller than the receiving buffer credit “B”. In this case, the transmitting apparatus 301 receives the credit “1B” from the receiving apparatus 302 (Step 215 ), and the transmittable credit calculating circuit 3055 performs calculation to obtain the transmittable credit “(C-B)” (Step 216 ). It means that the transmittable credit has a negative value. As a result, “1” is stored in the code storage register 3056 and the transmittable credit “(C-B)” is stored in the transmittable credit storage register 3054 (Step 217 ). The transmittable-credit calculating and holding circuit 305 notifies the transmittable credit “(C-B)” to the flow control circuit 306 by using the transmittable credit notification signal 3057 (Step 218 ). Also in this case, the transmission credit of transmission data is always larger than the transmittable credit. Therefore, the transmission of the transmission data is prevented.
[0068] Herein, a method for canceling the suspension of the data transmission in this case is explained. In a case in which the transmittable credit “(C-B)” having a negative value is stored in the transmittable credit storage register 3054 and “1” is stored in the code storage register 3056 , the transmitting apparatus 301 receives the credit “0B” from the receiving apparatus 302 (Step 215 ). The transmittable credit calculating circuit 3055 performs calculation, in which “B” is added to “(C-B)”, to obtain the transmittable, credit “C” (Step 216 ). It means that the transmittable credit has a positive value. Accordingly, “0” is stored in the code storage register 3056 and the transmittable credit “C” is stored in the transmittable credit storage register 3054 (Step 217 ). The transmittable-credit calculating and holding circuit 305 notifies the transmittable credit “C”, which is larger than 0, to the flow control circuit 306 by using the transmittable credit notification signal 3057 (Step 218 ). As a result, the transmitting apparatus 301 establishes a state where the transmitting apparatus 301 can transmit data to the receiving apparatus 302 . However, the transmission of the receiving data credit included in the receiving data buffer credit signal 3081 in order to deal with the extraction of data from the receiving data buffer 307 has not been finished at this time. Therefore, the transmittable credit “C” is smaller than the receiving buffer credit “B” corresponding the space of the receiving data buffer 307 . After that, by transmitting the receiving data credit included in the receiving data credit signal 3081 as the reception credit, the process for the receiving data credit is performed in the transmitting apparatus 301 according to the above-mentioned procedure shown in FIGS. 8A to 8C . As a result, the transmittable credit corresponds with the credit corresponding to the space of the receiving data buffer 307 . In consideration of reply time-out in transaction process, it is preferable that the receiving data credit included in the receiving data credit signal 3081 be initially transmitted to the transmitting apparatus 301 previous to the suspension of the data transmission between the transmitting apparatus 301 and the receiving apparatus 302 .
[0069] Also in a case in which the transmission data is transmitted from the transmission data buffer 303 to the receiving apparatus 302 but the transmission data has not been received by the receiving data buffer 307 , the transmittable credit may be smaller than the receiving buffer credit included in the receiving buffer credit signal 3080 . In this case, it is possible to suspend the data transmission from the transmitting apparatus 301 or to cancel the suspension by performing the similar process described above.
[0070] In this embodiment, it is possible not only to suspend the data transmission from the transmitting apparatus 301 but also to limit the amount of the transmission data transmitted from the transmitting apparatus 301 based on the instruction from the receiving apparatus 302 . To limit the amount of the transmission data, the credit corresponding to the amount of data which the receiving apparatus 302 wants to receive is set to “E”, and the credit having a negative value and an absolute value of “(B-E)” is transmitted to the transmitting apparatus 301 in order to give an instruction of limiting the data transmission. In order to cancel the limitation, the credit having a positive value and an absolute value of “(B-E)” is transmitted to the transmitting apparatus 301 .
[0071] In the above description, the credit transmitted from the receiving apparatus 302 to the transmitting apparatus 301 is represented by a binary signed integer. Alternatively, it is also possible to use a binary complement integer, which is generally used for operation performed by a computer. Whether the binary signed integer or the binary complement integer should be used may be determined based on the addition logic especially used for adding the reception credit to the transmittable credit in the transmittable-credit calculating and holding circuit 305 . In a case in which the binary complement integer is used, a complement calculation circuit for obtaining a complement of the receiving data credit signal 3081 is provided in the credit notification control circuit 308 whereby the complement of the receiving data credit signal 3081 may be inputted in the credit storage register 3083 .
[0072] Assume a case in which it is already possible for the transmitting apparatus 301 , upon receiving of a credit having a negative value, to reduce the value of the transmittable credit based on the value of the credit. In this case, when the flow control according to this embodiment is applied to a conventional system, it is preferable that only the receiving apparatus 302 may have the configuration described above. Considering the implementation of a general integer arithmetic operation, a transmitting apparatus 301 capable of reducing the value of the transmittable credit upon receiving the credit having a negative value can be regarded as wide spread. Therefore, it may be necessary to provide only the receiving apparatus 302 with the above-mentioned configuration in order to establish the flow control system according to this embodiment.
[0073] Subsequently, a flow control system according to a second embodiment of the present invention will be explained. In the second embodiment, the flow control system according to the present invention is applied to an interface of a PCI-Express protocol. FIG. 5 shows the flow control system according to the second embodiment.
[0074] The flow control system shown in FIG. 5 includes the transmitting apparatus 701 for transmitting a transmission data and a receiving apparatus 702 for receiving the transmission data transmitted from the transmitting apparatus 701 . Between the transmitting apparatus 701 and the receiving apparatus 702 , there are a plurality of data lines through which data itself is transmitted and received as a data signal 711 , and a plurality of signal lines through which credit notification signal 710 is transmitted from the receiving apparatus 702 to the transmitting apparatus 701 , each serving as an interface.
[0075] The receiving apparatus 702 includes a receiving data buffer 707 , an accumulator 722 , a CREDIT Received 709 , an accumulator 723 , a CREDIT Allocated 708 , a credit selector 712 . The receiving data buffer 707 of the FIFO type temporarily stores the data transmitted from the transmitting apparatus 701 . The accumulator 722 accumulates the credit of the data transmitted from the transmitting apparatus 701 every time the accumulator 722 receives the data transmitted from the transmitting apparatus 701 . The CREDIT Received 709 is a register for storing the accumulation result obtained by the accumulator 722 . The accumulator 723 accumulates the credit of data extracted from the receiving data buffer 707 . The accumulator 723 accumulates the credit every time the data is extracted from the receiving data buffer 707 and transmitted from the receiving data buffer 707 to the internal circuit of the receiving apparatus 702 . The CREDIT Allocated 708 is a register for storing the accumulation result obtained by the accumulator 723 . The credit selector 712 selects one of the credit stored in the CREDIT Allocated 708 and the credit stored in the CREDIT Received 709 . A transmission suspension instruction signal 713 for instructing suspension of data transmission between the transmitting apparatus 701 and the receiving apparatus 702 is supplied from the internal circuit of the receiving apparatus 702 to the credit selector 712 . The credit selector 712 selects one of the credit from the credit stored in the CREDIT Allocated 708 and the credit stored in the CREDIT Received 709 based on the transmission suspension instruction signal 713 . And, the credit selector 712 transmits the selected credit by using a credit notification signal 710 indicating the reception credit. The credit stored in the CREDIT Allocated 708 is a credit which is to be notified to the transmitting apparatus 701 based on PCI-Express standard when the data transmission between the transmitting apparatus 701 and the receiving apparatus 702 is not suspended.
[0076] The transmitting apparatus 701 includes a transmission data buffer 703 , an accumulator 721 , a CREDIT Consumed 704 , a CREDIT Limit 705 , a flow control circuit 706 . The transmission data buffer 703 temporarily stores the transmission data transmitted from the internal circuit of the transmitting apparatus 701 , an external system. The accumulator 721 accumulates the credit of the transmission data every time the transmission data is stored in the transmission data buffer 703 . The CREDIT Consumed 704 is a register for storing the accumulation result obtained by the accumulator 721 . The CREDIT Limit 705 is a register for storing the reception credit received from the receiving apparatus 702 . The flow control circuit 706 performs the flow control. The credit is notified from the receiving apparatus 702 point by point. When the credit notified from the receiving apparatus 702 changes, the credit stored in the CREDIT Limit 705 also changes immediately.
[0077] In PCI-Express protocol, each credit is accumulated by each of the accumulators 721 , 722 , and 723 using a circulation-type operation in which an overflow is ignored. The flow control circuit 706 compares the credit stored in the CREDIT Limit 705 with the credit stored in the CREDIT Consumed 704 . In a case in which the credit stored in the CREDIT Limit 705 is equal to or larger than the credit stored in the CREDIT Consumed 704 , the transmission data stored in the transmission data buffer 703 is transmitted. In a case in which the credit stored in the CREDIT Limit 705 is smaller than the credit stored in the CREDIT Consumed 704 , the data transmission is temporarily suspended. The suspension of the data transmission is continued until the credit stored in the CREDIT Limit 705 becomes equal to or larger than the credit stored in the CREDIT Consumed 704 .
[0078] The flow control system of this embodiment, in which the credit is calculated by accumulating, is greatly different from the flow control system shown in FIG. 1 , in which the credit is added or subtracted based on the amount of data transmitted or received, in terms of the calculation process of the credit. However, each credit of this embodiment corresponds to each credit in the flow control system shown in FIG. 1 . The credit stored in the CREDIT Consumed 704 corresponds to the transmission credit. The credit stored in the CREDIT Limit 705 corresponds to the transmittable credit. The credit stored in the CREDIT Allocated 708 corresponds to the receiving data credit. The credit stored in the CREDIT Received 709 corresponds to the receiving buffer credit.
[0079] Subsequently, an operation of the flow control system shown in FIG. 5 is explained referring to FIGS. 6A to 6D . FIG. 6A illustrates an operation of the data transmission and updating the credit stored in the CREDIT Consumed 704 performed in the transmitting apparatus 701 . FIG. 6B illustrates an operation of receiving the transmission data, updating the credit stored in the CREDIT Received 709 , and updating the credit stored in the CREDIT Allocated 708 , which are performed in the receiving apparatus 702 . FIG. 6C illustrates an operation of updating the credit stored in the CREDIT Limit 705 based on the credit notification signal 710 performed in the transmitting apparatus 701 . FIG. 6D illustrates an operation performed by the receiving apparatus 702 in a case in which the receiving apparatus 702 receives the transmission suspension instruction signal 713 indicating the instruction of suspending transmission with the transmitting apparatus 701 or the instruction of canceling the suspension of transmission with the transmitting apparatus 702 .
[0080] In a case in which the data is-not being transmitted and there is no credit unprocessed in the system, in PCI-Express, the credit stored in the CREDIT Allocated 708 corresponds to the credit stored in the CREDIT Limit 705 in general. In the following, the credit stored in the CREDIT Allocated 708 and the credit stored in the CREDIT Limit 705 are assumed to be “A”. Accordingly, the credit which is stored in the accumulator 723 is also “A”. Further, it is assumed that no transmission data has been transmitted to the transmission data buffer 703 and the credit stored in the CREDIT Consumed 704 and the credit stored in the CREDIT Received 709 are both “0”. Accordingly, the accumulator 721 and the accumulator 722 also stores the credit whose value is “0”.
[0081] First, a process performed in a case in which the transmitting apparatus 701 has received the transmission data of the credit “C” from the internal circuit of the transmitting apparatus, will be explained.
[0082] As shown in FIG. 6A , the transmission data of the credit “C” is stored in the transmission data buffer 703 (Step 221 ). The credit “C” is accumulated by the accumulator 721 and the credit stored in the CREDIT Consumed 704 is updated (Step 222 ). In this case, since the accumulator 721 has the initial value of “0”, the credit stored in the CREDIT Consumed 704 is updated to “C”. The flow control circuit 706 compares the credit “A” stored in the CREDIT Limit 705 with the credit “C” stored in the CREDIT Consumed 704 (Step 223 ). In a case in which “C” is equal to or smaller than “A” as a result of the comparison, the data of the credit “A” is transmitted to the receiving apparatus 702 based on the flow control performed by the flow control circuit 706 (Step 224 ). Meanwhile, in a case in which “C” is larger than “A”, the flow control is performed so as to wait in Step 223 without transmitting the transmission data until “C” becomes equal to or smaller than the credit stored in the CREDIT Limit 705 .
[0083] The transmitting apparatus 701 transmits data of the credit “C” as described above. Then, as shown in FIG. 6B , the receiving apparatus 702 receives data of the credit “C” (Step 225 ). The credit “C” is accumulated by the accumulator 722 to thereby update the credit stored in the CREDIT Received 709 (Step 722 ). In this case, since the accumulator 722 has the initial value of “0”, the credit stored in the CREDIT Received 709 is updated to “C”. Then, data of the credit “C” is transferred from the receiving data buffer 707 to the internal circuit of the receiving apparatus 702 . The credit “C” is accumulated by the accumulator 723 and the credit stored in the CREDIT Allocated 708 is updated to “(A+C)” (Step 227 ). The credit selector 712 selects the credit stored in the CREDIT Allocated 708 , and the credit “(A+C)” stored in the CREDIT Allocated 708 as the reception credit is notified to the transmitting apparatus 701 by using the credit notification signal 710 (Step 228 ).
[0084] When the receiving apparatus 702 transmits the credit notification signal 710 , the transmitting apparatus 701 receives the credit “(A+C)” from the receiving apparatus 702 (Step 229 of FIG. 6C ) The credit of the CREDIT Limit 705 is updated to “(A+C)” (Step 230 ). Then, the flowchart returns to Step 221 to repeat the above-mentioned process in order to transmit the subsequent transmission data.
[0085] Herein, it is assumed that the receiving apparatus 702 has received the instruction of suspending transmission with the transmitting apparatus 701 (Step 231 of FIG. 6D ). The instruction is notified by the transmission suspension instruction signal 713 . Then, the credit selector 712 selects the credit stored in the CREDIT Received 709 when the transmission suspension instruction signal 713 instructs the credit selector 712 to suspend transmission with the transmitting apparatus 701 . The credit “C” stored in the CREDIT Received 709 as the reception credit is notified to the transmitting apparatus 701 by using the credit notification signal 710 . The transmitting apparatus 701 receives the credit “C” from the receiving apparatus 702 (Step 229 FIG. 6C ). Then, the credit stored in the CREDIT Limit 705 is updated to “C” (Step 230 ). It is assumed that the transmitting apparatus 701 has received the transmission data of the credit “D” in a case in which the credit stored in the CREDIT Limit 705 is “C”. In this case,, the data of the credit “D” is stored in the transmission data buffer 703 (Step 221 of FIG. 6A ). Further, the credit stored in the CREDIT Consumed 704 is updated to “(C+D)” based on the accumulation performed by the accumulator 721 (Step 222 ). The flow control circuit 706 compares the credit “C” stored in the CREDIT Limit 705 with the credit “(C+D)” stored in the CREDIT Consumed 704 (Step 223 ). Since “(C+D)” is larger than “C”, the flow control is performed by the flow control circuit 706 so as to wait in Step 223 without transmitting the transmission data until “(C+D)” becomes equal to or smaller than the credit stored in the CREDIT Limit 705 .
[0086] As described above, based on the transmission suspension instruction signal 713 giving the instruction of suspending transmission with the transmitting apparatus 701 , the data transmission between the transmitting apparatus 701 and the receiving apparatus 702 is suspended. The process of suspending the data transmission is explained as follows.
[0087] In the above-mentioned process, the credit stored in the CREDIT Received 709 is the sum of the credit of the data received by the receiving data buffer 707 , that is, the sum of the credit of the transmission data which is supposed to be transmitted from the transmission data buffer 703 . Therefore, the credit stored in the CREDIT Received 709 is equal to or smaller than the sum of the credit (that is, the credit stored in the CREDIT Consumed 704 ) of the transmission data stored in the transmission data buffer 703 . Accordingly, by compulsorily making the credit stored in the CREDIT Limit 705 coincide with the credit stored in the CREDIT Received 709 , the data transmission is prevented.
[0088] Subsequently, explanation will be made on a process for canceling the suspension of transmission.
[0089] The receiving apparatus 702 receives the instruction of canceling the suspension of transmission with the transmitting apparatus 701 (Step 231 of FIG. 6D ). The instruction is notified by the transmission suspension instruction signal 713 . As a result, the credit selector 712 selects the credit “(A+C)” stored in the CREDIT Allocated 708 (Step 232 ). The credit notification signal 710 notifies the selected credit “(A+C)” to the transmitting apparatus 701 . As described above, the credit notification signal 710 is transmitted. Then, the transmitting apparatus 701 receives the credit “(A+C)” from the receiving apparatus 702 (Step 229 of FIG. 6C ). As a result, the credit stored in the CREDIT Limit 705 is updated to “(A+C)” (Step 230 ). The credit “(A+C)” is larger than the credit “C” of the transmission data. Therefore, it is possible to advance from Step 223 to Step 224 in FIG. 6A whereby the data transmission is restarted from the transmission data buffer 703 to the receiving apparatus 702 . In other words, by using the credit stored in the CREDIT Allocated 708 , which is a proper credit to be notified to the transmitting apparatus 701 , the operation of the flow control system performed in the normal conditions is restarted whereby the data transmission is restarted.
[0090] If a credit larger than the credit stored in the CREDIT Received 709 by a predetermined value is notified to the transmitting apparatus 701 instead of notifying the credit stored in the CREDIT Received 709 , the flow control system according to the second embodiment may be configured such that only the transmission data having a credit, which is equal to or smaller than the credit larger than the credit stored in the CREDIT Received 709 by the predetermined value, is transmitted from the transmitting apparatus 701 irrespective of the currently available space of the receiving data buffer 707 .
[0091] In a case in which the flow control system according to this embodiment is applied to the conventional system using PCI-Express, the conventional transmitting apparatus can be used as it is. Based on PCI-Express standard, the receiving apparatus 702 generally includes not only the CREDIT Allocated 708 being a register but also the CREDIT Received 709 being a register. Therefore, only by adding to the conventional receiving apparatus the credit selector 712 capable of being switched in response to the transmission suspension instruction signal 713 , it is possible to apply the conventional receiving apparatus to the flow control of the present invention.
[0092] According to the present invention, in a case of suspending or controlling the data transmission from the transmitting apparatus 301 , 701 in the receiving apparatus 302 , 702 , the receiving apparatus 302 , 702 notifies the credit capable of reducing the value of the transmittable credit (in a case of PCI-Express, CREDIT Limit) to the transmitting apparatus 301 , 701 . As a result, according to the flow control process under the normal conditions based on the credit of the transmitting apparatus 301 , 701 , the data transmission from the transmitting apparatus 301 , 701 to the receiving apparatus 302 , 702 is prevented or limited. Therefore, the present invention produces an effect of suspending the data transmission from the transmitting apparatus 301 , 701 at any time according to the instruction from the receiving apparatus 302 , 702 , irrespective of the available space of the receiving data buffer 307 , 707 , while eliminating a need to additionally provide a signal line for notifying the suspension of transmission.
[0093] Further, the flow control system of the present invention is different from the one in which the data transmission is suspended by not sending a reply which is supposed to be sent. Therefore, according to the present invention, a problem of reply time-out does not arise, and as a result, the reliable data transmission and flow control can be performed.
[0094] Further, in consideration of applying the flow control system of the present invention to the conventional system including the transmitting apparatus and the receiving apparatus of the conventional system, the flow control system of the present invention can be realized only by modifying the receiving apparatus. Therefore, according to the present invention, it is possible to save work and cost for implementation. | A system, comprising, a first apparatus; and a second apparatus which transmits first data of a first amount to said first apparatus, wherein said first apparatus comprises, a memory element which stores said first data, a first controller which transmits a first signal for adjusting said first amount when said first amount need to be adjusted or a second signal corresponding to a second amount of a second data extracted from said memory element when said first amount does not need to be adjusted, to said second apparatus through a signal line, wherein said second apparatus comprises, a second controller which updates a third signal corresponding to a third amount of third data that said first apparatus permits of receiving, based on said first signal, a third controller which determines to transmit said first data when said third amount is equal to or larger than said first amount. | 7 |
CROSS REFERENCE TO RELATED APPLICATIONS
Not applicable to this application.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not applicable to this application.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to traffic lights and more specifically it relates to a traffic signal system for utilizing an efficient and simplistic structure to regulate vehicle and pedestrian traffic.
2. Description of the Related Art
Any discussion of the prior art throughout the specification should in no way be considered as an admission that such prior art is widely known or forms part of common general knowledge in the field.
Traffic lights have been in use for years. Typically, traffic lights are used as signaling devices and are positioned at places, such as but not limited to road intersections and pedestrian crossings to indicate whether it is safe to proceed.
Traffic lights are generally comprised of a container holding a plurality of lights. When replacing or performing maintenance on the traffic lights it is generally required to hingedbly open and close the container to gain access to the traffic light. There is generally a wide array of movable parts and wiring associated with the container of the traffic lights, which makes performing maintenance on traffic lights tedious and cumbersome.
Traffic lights are also generally positioned at a high vertical height with a minimal amount of support structures nearby. Because of the lack of support structures, it is generally preferred to spend a minimal amount of time maintaining traffic lights. Traffic lights that include a wide array of parts and complicated container structures generally take longer to perform maintenance on because of the difficulty in accessing the traffic light.
While these devices may be suitable for the particular purpose to which they address, they are not as suitable for utilizing an efficient and simplistic structure to regulate vehicle and pedestrian traffic. Traffic lights with complicated container structures can prove to be tedious in performing maintenance on and also generally have an unnecessarily large amount of parts that are subjectable to being lost over time.
In these respects, the traffic signal system according to the present invention substantially departs from the conventional concepts and designs of the prior art, and in so doing provides an apparatus primarily developed for the purpose of utilizing an efficient and simplistic structure to regulate vehicle and pedestrian traffic.
BRIEF SUMMARY OF THE INVENTION
In view of the foregoing disadvantages inherent in the known types of traffic lights now present in the prior art, the present invention provides a new traffic signal system construction wherein the same can be utilized for utilizing an efficient and simplistic structure to regulate vehicle and pedestrian traffic.
The general purpose of the present invention, which will be described subsequently in greater detail, is to provide a new traffic signal system that has many of the advantages of the traffic lights mentioned heretofore and many novel features that result in a new traffic signal system which is not anticipated, rendered obvious, suggested, or even implied by any of the prior art traffic lights, either alone or in any combination thereof.
To attain this, the present invention generally comprises a support member including at least one receiver member and at least one light module including a plug member extending outwardly from the light module, wherein the plug member is positionable within a cavity of the receiver member.
There has thus been outlined, rather broadly, the more important features of the invention in order that the detailed description thereof may be better understood, and in order that the present contribution to the art may be better appreciated. There are additional features of the invention that will be described hereinafter and that will form the subject matter of the claims appended hereto.
In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of the description and should not be regarded as limiting.
A primary object of the present invention is to provide a traffic signal system that will overcome the shortcomings of the prior art devices.
A second object is to provide a traffic signal system for utilizing an efficient and simplistic structure to regulate vehicle and pedestrian traffic.
Another object is to provide a traffic signal system that does not require the use of tools to interchange traffic lights.
An additional object is to provide a traffic signal system that utilizes a light system comprised of a LED signal module.
A further object is to provide a traffic signal system that easily mountable.
A further object is to provide a traffic signal system that does not have any exposed electrical wiring.
A further object is to provide a traffic signal system that is lightweight.
Other objects and advantages of the present invention will become obvious to the reader and it is intended that these objects and advantages are within the scope of the present invention.
To the accomplishment of the above and related objects, this invention may be embodied in the form illustrated in the accompanying drawings, attention being called to the fact, however, that the drawings are illustrative only, and that changes may be made in the specific construction illustrated and described within the scope of the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Various other objects, features and attendant advantages of the present invention will become fully appreciated as the same becomes better understood when considered in conjunction with the accompanying drawings, in which like reference characters designate the same or similar parts throughout the several views, and wherein:
FIG. 1 is an upper perspective view of the present invention.
FIG. 2 is am exploded upper perspective view of the present invention.
FIG. 3 is a cross-sectional view of the present invention with one light module exploded.
FIG. 4 is a cutaway magnified upper perspective of the present invention.
FIG. 5 is a front magnified view of the present invention with the light module in an initial position.
FIG. 6 is a front magnified view of the present invention with the light module in a locked position.
DETAILED DESCRIPTION OF THE INVENTION
A. Overview
Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIGS. 1 through 6 illustrate a traffic signal system 10 , which comprises a support member 20 including at least one receiver member 24 and at least one light module 50 including a plug member 52 extending outwardly from the light module 50 , wherein the plug member 52 is positionable within a cavity 26 of the receiver member 24 .
B. Support Member
The support member 20 is preferably comprised of a tubular configuration as shown in FIGS. 1 through 3 . The support member 20 is also comprised of an elongated configuration to accommodate a plurality of light modules 50 . The support member 20 is preferably comprised of a metal material to provide added strength to the traffic signal system 10 and also to endure harsh weather conditions; however the support member 20 may be comprised of alternate materials, such as but not limited to plastic.
The support member 20 includes a first end and a second end opposite the first end. The first end and the second end of the support member 20 are preferably comprised of substantially similar configurations. Further, the first end and the second end of the support member 20 are preferably comprised of a threaded configuration as illustrated in FIGS. 2 and 3 .
When the threaded configurations of the first end and the second end are not being utilized a first cap 21 and a second cap 22 are preferably positioned over the first end and the second end as shown in FIGS. 1 through 3 . The first cap 21 and the second cap 22 preferably restrict foreign elements (i.e. dust, rain, etc.) from accessing an interior of the support member 20 .
At least one receiver member 24 extends out from the support member 20 as illustrated in FIGS. 1 through 4 . Further, there are preferably three receiver members 24 extending from the support member 20 to receive three light modules 50 ; however it is appreciated that there may be more than three receiver members 24 utilized with the traffic signal system 10 . The receiver members 24 are preferably comprised of an electrical receptacle configuration. The receiver members 24 are also preferably weatherproof and watertight to withstand harsh weather conditions. The receiver members 24 of the support member 20 are also preferably perpendicularly oriented toward the housing unit 40 .
The receiver members 24 each include a plurality of cavities 26 as shown in FIGS. 2 and 4 . The cavities 26 preferably extend into the receiver member 24 . The cavities 26 are also comprised of an elongated configuration to secure the plug members 52 of the light module 50 . The cavities 26 are preferably positioned around an inner radius of the receiver member 24 as illustrated in FIGS. 2 and 4 .
At least one of the cavities 26 preferably includes a first extending portion 27 . The first extending portion 27 preferably extends perpendicularly inward from at least one of the cavities 26 . It is appreciated that the cavities 26 of the receiver members 24 may be positioned in an alternate configuration rather than the preferred embodiment.
Each of the receiver members 24 preferably include electrically wiring 28 , wherein the electrical wiring 28 travels through a hollow interior of the support member 20 and into a container 29 as shown in FIG. 3 . The electrical wiring 28 of the receiver members 24 preferably terminates inside the container 29 . The container 29 is preferably attached to the support member 20 .
The container 29 is preferably comprised of an electrical junction box configuration. The container 29 serves as an access point to the electrical wiring 28 of the traffic signal system 10 . The electrical wiring 28 preferably transfers a current source to the receiver members 24 . It is appreciated that the receiver members 24 may receive a current source through various other manners rather than the preferred embodiment, such as but not limited to batteries.
C. Attachment Members
The attachment members 30 , 32 preferably extend from the support member 20 to a back of the housing unit 40 as shown in FIGS. 1 through 4 . Further, the attachment members 30 , 32 attach the support member 20 to the housing unit 40 . The attachment members 30 , 32 are comprised of a strong material, such as but not limited to metal. The attachment members 30 , 32 also preferably include a plurality of first attachment members 30 and a plurality of second attachment members 32 .
The first attachment members 30 preferably attach an upper end of the support member 20 to an upper end of the housing unit 40 as shown in FIGS. 1 through 3 . The second attachment members 32 preferably attach a lower end of the support member 20 to a lower end of the housing unit 40 as shown in FIGS. 1 through 4 . The first attachment members 30 and the second attachment members 32 are preferably positioned at an angle to provide added strength to the attachment of the housing unit 40 and the support member 20 . It is appreciated that the traffic signal system 10 may use a plurality of different attachment methods to attach the support member 20 to the housing unit 40 rather than the preferred embodiment.
D. Housing Unit
The housing unit 40 is preferably comprised of a separate structure than the support member 20 ; however it is appreciated that the housing unit 40 may be integrally formed with the support member 20 . The housing unit 40 is also preferably comprised of a metal material to provide added strength to the traffic signal system 10 and also to endure harsh weather conditions; however it is appreciated that the housing unit 40 may be comprised of various materials, such as but not limited to plastic.
The housing unit 40 preferably includes a first plate member 42 as shown in FIGS. 1 through 6 . The first plate member 42 is preferably comprised of a rectangular configuration; however other configurations may be utilized with the first plate member 42 , such as but not limited to a square or circular configuration. The first plate member 42 preferably includes a plurality of vents 43 . The vents 43 are preferably positioned throughout the first plate member 42 , wherein the vents 43 extend through the first plate member 42 . Further, the vents 43 reduce wind resistance upon the traffic signal system 10 .
An interior of the first plate member 42 is also preferably cutout to receive a second plate member 45 as illustrated in FIG. 2 . The first plate member 42 and the second plate member 45 are preferably separate structures; however it is appreciated that the first plate member 42 and the second plate member 45 may be comprised of an integrally formed structure.
The second plate member 45 is preferably comprised of a rectangular configuration and preferably fits slightly over the cutout portion of the first plate member 42 . The second plate member 45 preferably includes at least one opening 46 . The opening 46 is preferably substantially similar in diameter to the diameter of an outer edge of a shell 55 of the light module 50 as illustrated in FIGS. 3 through 6 . Further, the second plate member 45 preferably includes three openings 46 to receive three light modules 50 ; however it is appreciated that there may be more than three openings 46 utilized with the traffic signal system 10 .
The openings 46 are each preferably positioned along the same longitudinal axis of the support member 20 . Each of the centers of the openings 46 preferably align with a center of the receiver member 24 . Further, there preferably exist an equal number of openings 46 in the second plate member 45 as there are receiver members 24 along the support member 20 as shown in FIGS. 1 through 3 .
The second plate member 45 also preferably includes at least one shield member 49 . The shield member 49 preferably extends perpendicularly outward from the outer edge of the openings 46 of second plate member 45 as shown in FIGS. 1 through 4 . The shield members 49 help to reduce the glare of the sun upon the light modules 50 .
The housing unit 40 also preferably includes a first tab 47 and a second tab 48 . The first tab 47 and the second tab 48 are preferably attached substantially near the front outer edge of the openings 46 of the second plate member 45 as illustrated in FIGS. 3 through 6 . The first tab 47 and the second tab 48 are preferably positioned 180 degrees apart from each other around the opening 46 . It is appreciated however that the first tab 47 and the second tab 48 may be positioned at various places around the opening 46 . It is also appreciated that the present invention may include multiple tabs 47 , 48 positioned about the opening 46 . The first tab 47 preferably prevents the light module 50 from moving horizontally outward while positioned within the opening 46 . The second tab 48 preferably prevents the light module 50 from rotating and moving horizontally outward while positioned within the opening 46 .
E. Light Module
The light module 50 is preferably comprised of a traffic light module configuration as illustrated in FIGS. 1 through 4 . It is appreciated that the traffic signal system 10 preferably includes three light modules 50 as shown in FIGS. 1 through 3 ; however it is appreciated that there may be more or less than three light modules 50 utilized with the traffic signal system 10 . The light modules 50 are also preferably comprised of LED signal modules; however it is appreciated that the light modules 50 may be comprised of various configurations rather than the preferred embodiment.
The light modules 50 are preferably comprised of a configuration substantially similar to the openings 46 of the housing unit 40 , wherein the light modules 50 are positioned within the openings 46 . The light modules 50 also preferably include a plurality of plug members 52 as shown in FIGS. 2 through 6 . The plug members 52 preferably fit within the cavities 26 of the receiver member 24 . The plug members 52 and the receiver member 24 are preferably comprised of a twist and lock configuration. Further, the plug members 52 and the receiver member 24 are preferably comprised of an electrical plug and socket configuration, wherein the light module 50 receives power via the plug members 52 .
The plug members 52 are preferably comprised of elongated configurations. The length of the plug members 52 is preferably substantially similar to the depth of the cavities 26 of the receiver member 24 . The plug members 52 preferably extend out from a rear of the light module 50 . Further, the plug members 52 preferably extend out from the light module 50 at a rear center of the light module 50 as shown in FIGS. 5 and 6 . The plug members 52 are also preferably positioned around an inner radius of the light module 50 .
At least one of the plug members 52 preferably includes a second extending portion 53 . The second extending portion 53 preferably extends perpendicularly inward from at least one of the plug members 52 . The second extending portion 53 is received by the first extending portion 27 of the cavities 26 . When the plug members 52 are inserted into the cavities 26 the light module 50 is preferably rotated so the second extending portion 53 locks the light module 50 within the receiver member 24 . It is appreciated that the plug members 52 and the receiver member 24 may be comprised of various electrical plug and socket configurations rather than the preferred embodiment.
The light module 50 also preferably includes a shell 55 surrounding an outer edge of the light module 50 as shown in FIGS. 2 through 4 . An outer diameter of the shell 55 is preferably substantially similar to a diameter of the opening 46 of the housing unit 40 . The shell 55 preferably fits within the opening 46 of the housing unit 40 . A lens 54 is also attached to the outer side of the shell 55 . The lens 54 preferably includes a first slot 56 and a second slot 57 positioned about the outer edge as shown in FIGS. 4 through 6 . It is appreciated however that the first slot 56 and the second slot 57 may be positioned upon the outer edge of the shell 55 . The first slot 56 and the second slot 57 are further preferably positioned 180 degrees apart from each other around the lens 54 . It is appreciated that there are an equal number of slots 56 , 57 positioned about the light module 50 as there are tabs 47 , 48 positioned about the opening 46 .
The first slot 56 and the second slot 57 preferably receive the first tab 47 and the second tab 48 respectively when inserting the light module 50 within the opening 46 . The first slot 56 is further preferably positioned about the top of the light module 50 and the second slot 57 is preferably positioned about the bottom of the light module 50 so the user may easily access the second slot 57 and second tab 48 through the lower gap in the shield members 49 . The radius of the bottom portion of the light module 50 is also preferably slightly greater than the radius of the top portion of the light module 50 as illustrated in FIGS. 3 , 5 and 6 so as to properly secure the second tab 48 within the second slot 57 .
The first slot 56 is preferably comprised of a recessed configuration upon the outer edge of the lens 54 . The first slot 56 receives the first tab 47 when the light module 50 is positioned within the opening 46 . Further, an outer lip of the first tab 47 extends horizontally outward from the first slot 56 , wherein when the light module 50 is rotated the lip of the first tab 47 catches on the outer edge of the light module 50 thus preventing the light module 50 from moving horizontally outward as illustrated in FIGS. 5 and 6 .
The second slot 57 is preferably comprised of a recessed configuration upon the outer edge of the lens 54 . The second slot 57 includes a receiving portion 58 and a locking portion 59 . The outer edges of the locking portion 59 preferably extend slightly downward to catch the horizontal portion of the second tab 48 as illustrated in FIGS. 5 and 6 . The second slot 57 receives the second tab 48 when the light module 50 is positioned within the opening 46 . The horizontal portion of the second tab 48 is initially positioned along an outer edge of the receiving portion 58 , wherein when the light module 50 is rotated the horizontal portion of the second tab 48 is positioned within the locking portion 59 to prevent the light module 50 from rotating further as illustrated in FIGS. 5 and 6 .
Further, an outer lip of the second tab 48 is preferably initially positioned within the receiving portion 58 of the second slot 57 , wherein when the light module 50 is rotated the lip of the second tab 48 is repositioned over the locking portion 59 to prevent the light module 50 from moving horizontally outward as illustrated in FIGS. 5 and 6 . The second tab 48 preferably locks within the locking portion 59 of the second slot 57 at a simultaneous time as the plug members 52 lock into the receiver member 24 when rotating the light module 50 .
The second tab 48 is released from the locking portion 59 and forced into the receiving portion 58 by pushing a dividing member between the receiving portion 58 and the locking portion 59 perpendicularly away from the receiving portion 58 and locking portion 59 . When the second tab 48 is positioned within the receiving portion 58 the light module 50 is preferably able to be removed from the housing unit 40 and the support member 20 .
F. In Use
In use, the support member 20 is first mounted at an adequate position to serve as a traffic signal light. The support member 20 may be mounted via threadably mounting the first end and second end to a support structure. The support member 20 may also be mounted by being clamped against a pole or other structure. It is appreciated that the traffic signal system 10 may be mounted in a plurality of other manners consistent with mounting a traffic light.
After the traffic signal system 10 is securely mounted the electrical wiring 28 may be accessed via the container 29 and subsequently connected to an outside power source. The light modules 50 are now inserted within the openings 46 of the housing unit 40 so the second extending portion 53 of the plug members 52 enters the first extending portion 27 of the cavities 26 and the first tab 47 extends through the first slot 56 and the second tab 48 extends within the second slot 57 , referred to as the initial position. The light modules 50 are now rotated, thus securing the light modules 50 within the housing unit 40 and support member 20 .
When removing a light module 50 from the housing unit 40 and support member 20 the lens 54 is depressed firmly substantially near the slot 57 to disengage the second tab 48 and the light module 50 is pushed slightly inward to disengage the plug members 52 . The light module 50 is now rotated in an opposite direction as the light module 50 was rotated when the light module 50 was attached to the housing unit 40 and the support member 20 . Once the light module 50 reaches the initial position it may be removed by pulling the light module 50 perpendicularly outward from the opening 46 and the receiver member 24 . Another light module 50 may subsequently be replaced within the housing unit 40 and the support member 20 .
What has been described and illustrated herein is a preferred embodiment of the invention along with some of its variations. The terms, descriptions and figures used herein are set forth by way of illustration only and are not meant as limitations. Those skilled in the art will recognize that many variations are possible within the spirit and scope of the invention, which is intended to be defined by the following claims (and their equivalents) in which all terms are meant in their broadest reasonable sense unless otherwise indicated. Any headings utilized within the description are for convenience only and have no legal or limiting effect. | A traffic signal system for utilizing an efficient and simplistic structure to regulate vehicle and pedestrian traffic. The traffic signal system includes a support member including at least one receiver member and at least one light module including a plug member extending outwardly from the light module, wherein the plug member is positionable within a cavity of the receiver member. | 6 |
BACKGROUND OF THE INVENTION
In a principal aspect, the present invention relates to a high efficiency, multistage liquid heating apparatus utilizing combustible fuel as a heat source.
In a liquid heating apparatus, such as a water heater, the liquid to be heated typically is introduced into the lower portion of a tank. As the liquid is heated, it becomes less dense, thereby rising to the top of the tank where it is drawn off.
A heat source for such an apparatus may be a combustible fuel such as natural gas that is burned in a combustion chamber located beneath the tank. The hot gases produced by combustion rise through flues that pass through the tank and serve as a heat exchanger to conduct the heat from the rising hot gas to the liquid inside the tank. Since heat is removed from the hot gas as it moves upward, the temperature of the gas within the flues decreases as it rises. Thus, the temperature difference, and consequently the rate of heat transfer between the hot gas and the liquid to be heated is greatest at the bottom of the tank, and least at the top of the tank.
Historically, multiple staging of liquid apparatae that utilize combustible fuel as a heat source has been commonly employed to increase the theoretical efficiency of heat transfer. In a multiple stage liquid heating apparatus, the coldest liquid enters the uppermost tank and is transferred through successively lower tanks in a serial fashion. This raises the theoretical efficiency of the apparatus because a large temperature difference between the liquid to be heated and the hot gas is maintained throughout the length of the liquid heating apparatus.
A problem associated with a multistage gas fired water heater is that the water vapor formed as a product of combustion condenses in the flues of the upper stages. This is because the cooler rising flue gas contacts the tanks containing the cold water to be heated. The condensate forms water droplets which trickle down the inner walls of the flues. The water eventually trickles down the inner walls of the lower stages. Such condensation not only encourages corrosion of the flue and tank and interrupts the upward movement of hot gases, it also decreases the heat transfer coefficient of the apparatus and thereby reduces its efficiency. The thin film of water that forms on the surface of the flues is responsible for lowering the real heat transfer efficiency of the apparatus.
Another problem associated with multistage liquid apparatae is that the presence of complex flue assemblies interferes with the ability to clean the flues. Since the flues communicate the by-products of combustion from the burner to the exhaust manifold, carbonaceous build-up in the flues is inevitable. Failure to remove this build-up will result in a lower heat transfer efficiency for the apparatus.
The present invention constitutes a multistage liquid heating apparatus that seeks to overcome the problems resulting from water vapor condensation in the upper flues while at the same time providing a simple, easily constructed design that is more easily cleaned.
SUMMARY OF THE INVENTION
Briefly, the present invention comprises a multistage, combustible fuel fired liquid heating apparatus of the type employing heat transfer flues through the liquid tanks and including the improvement of a condensate removal pipe to substantially reduce the presence of water on the inside walls of the flues. The successive tanks of the apparatus are vertically arrayed with substantially linear, vertically aligned flue passages.
Thus, it is an object of the present invention to provide a multistage liquid heating apparatus wherein the presence of water in the flues is substantially reduced, thereby increasing the real heat transfer efficiency of the apparatus.
A further object of the present invention is to provide a multistage liquid heating apparatus that is less susceptible to corrosion.
A further object of the present invention is to provide a multistage liquid heating apparatus that is simple and inexpensive to construct, and does not require elaborate plumbing.
Yet another object of the present invention is to provide a multistage liquid heating apparatus that is easily cleaned.
These and other objects, advantages and features of the present invention will be set forth in the detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWING
In the detailed description which follows, reference will be made to the drawing comprised of the following figures:
FIG. 1 is a side cross-sectional view illustrating a first preferred embodiment of the apparatus;
FIG. 2 is an enlarged side cross-sectional view of the first preferred embodiment illustrating the flue construction of the apparatus;
FIG. 3 is an enlarged side cross-sectional view of the first preferred embodiment similar to FIG. 2 illustrating the flue construction;
FIG. 4 is a top plan cross-sectional view of the first preferred embodiment showing the flue positioning;
FIG. 5 is a side cross-sectional view illustrating a second preferred embodiment of the apparatus;
FIG. 6 is an enlarged side cross-sectional view of the second preferred embodiment illustrating the flue construction of the apparatus; and
FIG. 7 is a top plan cross-sectional view of the second preferred embodiment showing the flue positioning.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
A first preferred, specific embodiment of the present invention is illustrated in FIGS. 1 through 4, and is a two-stage gas fired water heater 10 having a primary stage tank 12 and a secondary stage tank 14. A burner 16 in a combustion chamber 18 is located below the primary stage tank 12. The burner 16 is designed to combust natural gas in the combustion chamber 18 thereby producing a heated gas 20 including water vapor 22. Airflow through the combustion chamber 18 is induced by either natural convection or by use of a forced draft unit 24. The tanks 12, 14 and chamber 18 are surrounded by a layer of insulation 26 and a protective shell 28.
The primary heating tank 12 includes an upper header 30, a lower header 32, and a connecting cylindrical body or shell 34 which are joined together to define a first reservoir 36. The lower header 32 defines the upper limit of the combustion chamber 18.
The secondary tank 14 includes a top header 38, a bottom header 40, and a secondary cylindrical body or shell 42 joined together to define a second reservoir 44. The bottom header 40 of tank 14 is joined to the upper header 30 to define an intermediate manifold 46. Thus, the headers 30, 40 are formed as opposed concave members which are joined about their outer periphery to define the manifold 46.
The top header 38 cooperates with a concave gas collector 48 to define an exhaust manifold 50 at the top of tank 14. A flue outlet 52 is provided in collector 48.
A liquid inlet 54 feeds into the secondary stage tank 14 at the lower portion or bottom of the secondary tank 14. Inlet 54 defines liquid supply means 56 for introducing a liquid 58 to be heated into the lower portion of the secondary stage tank 14.
A secondary liquid outlet 60 located at the upper portion of the secondary cylindrical tank 14 is connected to a conduit 62 which, in turn, is connected to a primary liquid inlet 64 located at the lower portion of the primary stage tank 12. The secondary liquid outlet 60, the conduit 62, and the primary liquid inlet 64 provide a transfer means for transferring the liquid 58 being heated from the upper portion of the secondary stage tank 14 to the lower portion of the primary stage tank 12. It is understood that a multiplicity of secondary liquid outlets 60, conduits 62 and/or primary liquid inlets 64 can be provided.
A primary liquid outlet 66 located at the upper portion of the primary tank 12 defines outlet means for removing the heated liquid 58 from the upper portion of the primary tank 12.
A plurality of primary flues 68 extend between headers 30, 32 through the primary stage tank 12. These primary flues 68 communicate with the combustion chamber 18 and the manifold 46.
A plurality of secondary flues 70 extend between headers 38, 40 through the secondary stage tank 14. These secondary flues 70 communicate with the manifold 46 and the flue gas collector 48. Each of the primary flues 68 operatively associates with one of the secondary flues 70 and is aligned to define a linear, correlative flue passageway 72 having a central axis 74.
Baffles 76 extend through each primary flue 68, the manifold 46, and each secondary flue 70 along central axes 74. The primary flues 68 may have substantially smaller primary diameters than the diameters of the secondary flues 70, as shown in FIGS. 1 and 2.
Each of the primary flues 68 extends upward into the manifold 46 and above the header 30. One of the primary flues 68 is foreshortened relative to the other flues 68 and defines a condensate removal pipe 78. The condensate removal pipe 78 has a bias cut lower end 80 located within the combustion chamber 18. The lower end 80 is biased by effecting an angular cut of the tubing forming the condensate removal pipe 78. This angled cut forms an angle sufficiently acute to allow water to form at the lowermost tip. The lowermost tip 82 of the flue 68 defines a pathway for condensed water 84. Preferably, the tip 82 is adjacent an inner wall of chamber 18 to avoid dripping onto a burner.
A condensate receptacle 86 is located directly below the tapered end 80 of the condensate removal pipe 78. A conduit 88 is located at the bottom of the condensate receptacle 86. The condensate receptacle 86 and the conduit 88 provide drainage means for receiving and discharging water from the condensate removal pipe 78. A collection pan 90 may be directly underneath the conduit 88.
The apparatus operates as follows: liquid 58 to be heated enters the lower portion of the secondary stage tank 14, flows through the tank 14 and is transferred from the upper portion of the secondary stage tank 14 to the lower portion of the primary stage tank 12 by means of one or more conduits 62. The liquid 58 is withdrawn from the upper portion of the primary tank 12.
The fuel is combusted by the burner 16 in the combustion chamber 18 to produce the heated gases 20 which include water vapor 22. The heated gases rise 20 from the combustion chamber 18 through the primary flues 68 and into the intermediate manifold 46, and then through the secondary flues 70, into the concave gas collector 48 and out the flue outlet 52. The heated gases 20 rise, either due to convection or by means of blowing forced draft unit 24. Baffles 76 cause the flow of the heated gas 20 to be substantially turbulent. The water vapor 22 contained in the secondary flues 70 condenses forming water 84. The water 84 trickles down the secondary flues 70 and collects in the manifold 46. After a small amount of water 84 collects in the intermediate manifold 46, it flows down the condensate removal pipe 78, where the water flows off the tapered end 82 of the condensate removal pipe 78, and into the condensate receptacle 86. The water 84 can be removed from the condensate receptacle 86 through conduit 88. The conduit 88 may be directed to collection pan 90 where the water 84 must then be directed to a drain or conduit 88 may be directed directly to a drain.
A second preferred, specific embodiment is illustrated in FIGS. 5 through 7, and is similar to the first preferred embodiment. However, the intermediate manifold 46 of the first preferred embodiment is omitted and replaced with an insulated spacer 92. Moreover, the primary flues 68 and the secondary flues 70 are omitted and replaced by continuous flues 94, each of which has a lower end 96 which is tapered by effecting an angular cut of the tubing.
While there have been shown preferred embodiments, the invention is to be limited only by the following claims and their equivalents. | A multistage gas fired water heater includes a primary heating tank and a secondary tank mounted vertically over the primary tank with a plurality of primary flues located within the primary heating tank aligned with secondary flues located within the secondary tank. One of the primary flues is constructed to operate as a condensate removal pipe for draining water which forms in the secondary flues. The designated condensate removal pipe prevents water from trickling down the other primary flues or collecting in the flue manifold. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to reaction injection molded articles and methods of forming such molded articles, and more particularly it is concerned with a reaction injection molded article formed with threads and a method of forming such molded article.
Heretofore, in the art of producing reaction injection molded articles (hereinafter molded articles), such as foamed urethane molded articles, methods stated as follows have been known for clamping associated parts to the molded articles:
1. Following making of holes in the molded article, tapping and threading of bolts are performed for securing parts.
2. Self-tapping of the molded article is effected for securing parts.
3. Holes are made through the molded article, and parts are secured in place by means of a backing strip and bolts.
4. Following making of holes in the molded article and tapping, helicoils are fitted and bolts are threadably connected to secure parts in place.
Of the aforesaid four methods known in the art, the third method capable of providing a relatively high screw clamping critical torque or a maximum clamping torque capable of clamping the part without damaging the molded article and the threads formed therein is most popular and usually used.
However, this method suffers the disadvantage that when clamping is carried out the backing strip might be forced against the molded article to cause same to buckle and sufficiently high clamping strength could not be obtained. An added trouble is that this method cannot be used for producing containers that must be hermetically closed because of the need to make through holes therein when the molded article is produced.
SUMMARY OF THE INVENTION
This invention has been developed for the purpose of obviating the aforesaid disadvantages of the prior art. Accordingly the invention has as its object the provision of a reaction injection molded article formed with threads having high screw clamping strength and a method of producing such molded article which has its process steps minimized.
One of the outstanding characteristics of the invention is that the reaction injection molded article formed with threads comprises a molded article body, such as a foamed urethane body, formed with holes enclosed by a surface layer of relatively high density, such as a skin layer, and members formed with female threads inserted in the holes and held in place by the surface layer.
Another outstanding characteristic is that the method of molding a reaction injection molded article formed with threads according to the invention is that members formed with threads are positioned in the cavity of a reaction injection mold and a urethane foaming material composed of an A liquid and a B liquid is injected into the cavity. The A liquid contains 100 weight parts of polyether polyol obtained by adding alkylene oxide to various kinds of alcohol and amine, 1-5 weight parts of a reaction promoting agent (catalyst) comprising tertiary amines, tin compounds, etc., 3-50 weight parts of water and a foaming agent, such as low boiling point alkylhalide, 1-5 weight parts of a foaming regulating agent, such as alkylene oxide denatured polydimethl siloxanie and 1-20 weight parts, if necessary, of pigment, dyestuff and filler, such as carbon black, diazo compound, silica, glass fiber, etc., and the B liquid contains 100-200 weight parts of MDI, TDI, crude MDI or crude TDI. The members formed with threads can be formed into a unitary structure with the body of the molded article and securedly held in place by a surface layer of relatively high density (0.7-1.0 g/cm 3 ), such as skin layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of the reaction injection molded article formed with threads comprising one embodiment of the invention;
FIG. 2 is a perspective view, on an enlarged scale with certain parts being shown in section, of the threaded insert used in the embodiment shown in FIG. 1;
FIG. 3 is a graph showing the embodiments of the invention in comparison with the prior art with respect to the screw clamping critical torque;
FIGS. 4a, 4b and 4c are perspective views, with certain parts being shown in section, of modifications of the insert shown in FIG. 2;
FIG. 5 is a sectional view of the mold used for producing the molded article shown in FIG. 1;
FIG. 6 is a sectional view of the molded article comprising another embodiment of the invention;
FIG. 7 is a sectional view, on an enlarged scale, of the helicoil used in the embodiment shown in FIG. 6;
FIG. 8 is a sectional view of the mold used for producing the molded article shown in FIG. 6;
FIG. 9 is a sectional view of the body of the molded article comprising still another embodiment;
FIG. 10 is a sectional view, on an enlarged scale, of the essential portions of the molded article shown in FIG. 9 which is further worked after being molded;
FIG. 11 is a sectional view of the molded article shown in FIG. 10 and an attachment secured to the molded article;
FIG. 12 is a sectional view of the essential portions of the body of the molded article comprising still another embodiment;
FIG. 13 is a sectional view, on an enlarged scale, of the essential portions of the molded article including the body of the molded article shown in FIG. 9 which is further worked;
FIG. 14 is a sectional view of the molded article shown in FIG. 12 and an attachment secured thereto;
FIG. 15 is a graph showing the relation between the density of the skin layer and the hardness of the skin layer;
FIG. 16 is a graph showing the relation between trichclorofluoromethane and the density of the skin layer;
FIG. 17 is a graph showing the relation between the reaction promoting agent and the density of the skin layer;
FIG. 18 is a graph showing the relation between the charging rate and the density of the skin layer;
FIG. 19 is a graph showing the relation between the temperature of the mold or the insert and the density of the skin layer;
FIG. 20 is a graph showing the relation between the density of the skin layer and the screw clamping critical torque; and
FIG. 21 is a graph showing the relation between the shape of the threaded insert and the screw clamping critical torque.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a first embodiment of the invention in which the numeral 1 designates a body of a reaction injection molded article formed with threads, such as a foamed urethane molded article, formed of material (raw material liquid) composed of an A liquid and a B liquid, the A liquid containing 100 weight parts of polyether polyol obtained by adding alkylene oxide to various kinds of amine or alcohol, 1-5 weight parts of a reaction promoting agent (catalyst) comprising tertiary amines, tin compounds, etc., 8-30 weight parts of a foaming agent of low boiling point (30°-70° C. at pressure 1-3 kg/cm 2 ), such as trichlorofluoromethane and 0.5-1.0 weight part of water and the B liquid containing 100-200 weight parts of MDI (methylene dipara-phenylene isocyanate), TDI (toluene diisocyanate), crude MDI or crude TDI. The body 1 of the molded article includes bosses 2, a core 3 and a skin layer 4 of high strength. The numeral 5 designates threaded members or threaded inserts which are embedded in the bosses 2 of the molded article body 1 and securedly attached to the skin layer 4. The mechanism of forming the skin layer 2 will be described. As the A liquid and B liquid are injected into a mold cavity at high pressure (about 200 kg/cm 2 ) while impinging on each other and mixing with each other, they begin to react with each other and the heat of reaction causes the temperature to rise to 70°-150° C., so that the low boiling point foaming agent begins to evaporate to fill the cavity with foamed material. At this time, the foamed material in contact with the mold cavity surface and the insert surface is cooled by the mold and the insert to cause condensation of the vaporized low boiling foaming agent, so that the material becomes almost foamless and constitutes the skin layer 4.
The skin layer 4 has a density of 0.5-1.1 g/cm 3 which is higher than the density 0.05-0.2 g/cm 3 of the core 3 formed by the inwardly disposed material. The higher the density of the skin layer 4, the higher becomes its strength (hardness). FIG. 15 shows the relation between them. The skin layer 4 of high strength can be produced when the proportions of the low boiling foaming agent and the catalyst in the raw material are high and when the charging rate is high and the temperature of the mold and the insert is low. FIGS. 16-19 show these relations.
The threaded inserts 5 are each substantially cylindrical in shape and formed of steel. As shown in FIG. 2, each threaded insert 5 is formed with a female thread on the inside as indicated at 6 and a male thread on the outside.
The reaction, injection molded article formed with threads constructed as aforesaid according to the invention has high bond strength between the threaded inserts 5 and the molded article body 1 because the skin layer 4 of high hardness is formed in the vicinity of the outer side of the threaded inserts 5 and bites into the threaded surfaces of the inserts 5. Thus the molded article according to the invention has a screw clamping critical torque and a thrust (resistance offered by the threaded insert against an axial force when the screw is clamped) higher than those of the prior art.
The embodiment of the invention shown in FIG. 1 has a screw clamping critical torque of 60 kg-cm (M 6 screw used), which compares favorably with those of the prior art, as shown in FIG. 3 which is a graph showing a comparison of the embodiments of the invention with the prior art with respect to the screw clamping critical torque. In FIG. 3, specimens 1-4 are molded articles of the prior art and specimen 5 is the embodiment shown in FIG. 1 while specimen 6 is another embodiment subsequently to be described. In measuring the screw clamping critical torques, Japanese Industrial Standard (JIS) M 6 screws and tapping screws of 6 mm in diameter were used with a torque driver.
As can be clearly seen in the graph of FIG. 3, it will be understood that the screw clamping critical torque exhibited by specimen 5 or the molded article according to the invention is three times as high as that of specimen 3 or the molded article of the prior art which is 20 kg-cm.
Additionally the molded article according to the invention offers the advantage that the process steps to be followed in production can be reduced as compared with those of the prior art because no piercing operation is required following molding. The relation between the screw clamping critical torque and the density of the skin layer secured to the outer periphery of the inserts in the embodiment shown in FIG. 1 is as shown in FIG. 20. As can be seen in the graph of FIG. 20, the higher the density of the skin layer secured to the outer periphery of the inserts, the higher is the screw clamping critical torque. For example, when a screw clamping critical torque of 60 kg-cm or more is required, one has only to obtain the skin layer of over 0.65 g/cm 3 in density. The embodiment shown in FIG. 1 uses the threaded insert 5 shown in FIG. 2. However, the invention is not limited to this specific form of insert and threaded inserts 5A, 5B and 5C shown in FIGS. 4A, 4B and 4C respectively may be used in place of the threaded insert 5 shown in FIG. 2. The inserts 5A, 5B and 5C are all formed of steel. The threaded insert 5A shown in FIG. 4A is formed on the inside with a female thread at 6 while its outside is columnar and knurled. Like the threaded insert 5 shown in FIG. 2, the threaded insert 5A has the effect of increasing the screw clamping critical torque and the thrust. The threaded inserts 5B and 5C shown in FIGS. 4B and 4C respectively are formed on the inside with female threads at 6 while they are polygonal or square and hexagonal respectively on the outside with peripheral (e.g., lateral) grooves 7 being formed thereon. The provision of the polygonal outside enables the threaded insert to resist rotation at the corners to thereby increase the screw clamping critical torque over that of the threaded inserts 5 and 5A, and the provision of the peripheral grooves 7 increases the thrust over that of the threaded inserts 5 and 5A. FIG. 21 shows the relation between the shape of the threaded inserts and the screw clamping critical torque. The threaded inserts 5, 5A, 5B and 5C have been described as being formed of steel. However, the material is not limited to steel and other metal, such as brass, hard aluminum, etc., may be used because of the needs to increase the strength of the thread and to facilitate molding as subsequently to be described.
The method of molding the foamed urethane molded article formed with threads as shown in FIG. 1 will now be described by referring to FIG. 5 in which the numerals 8 and 9 designate an upper mold member and a lower mold member respectively of a reaction injection mold. The lower mold member 9 formed with recesses 9A cooperates with the upper mold member 8 to define therebetween a cavity 10 including boss forming regions 10A. The numeral 11 designates an after mixer through which material for producing a molded article is injected into the cavity 10. The threaded inserts 5 are fixedly placed in the boss forming regions 10A of the cavity 10 as their open ends are inserted in the recesses 9A formed in the lower mold member 9. Thus when the molding material is injected into the cavity 10, the material is prevented from invading the female thread 6 of each threaded insert 5.
Molding material or a mixture of the A liquid and the B liquid is injected through the after mixer 11 into the cavity 10. The molding material is composed of the A liquid containing 100 weight parts of polyether polyol obtained by adding alkylene oxide to various kinds of alcohol or amine, 1-5 weight parts of a reaction promoting agent (catalyst) comprising tertiary amines, tin compounds, etc., 8-30 weight parts of a foaming agent of low boiling point (30°-70° C./1-3 kg/cm 2 ), such as trichlorofluoromethane and 0.5-1.0 weight part of water, and the B liquid containing 100-200 weight parts of MDI, TDI, crude MDI or crude TDI. Upon being injected into the cavity 10, the ingredients of the molding material react with one another in the cavity 10 to foam and set, before being cooled by the upper mold member 8, lower mold member 9 and threaded inserts 5 to produce a foamed urethane molded article formed with threads comprising, as shown in FIG. 1, the core 3 in the interior of the body 1 and the strong skin layer 4 on the surface of the body 1 and at the outer periphery of each threaded insert 5. The strong skin layer 4 can be obtained by increasing the density thereof. It is the reaction promoting agent and the foaming agent of the material composition that exert the greatest influence on the density of the skin layer. FIGS. 16 and 17 show the relation between them. The open end of each threaded insert 5 extends from the boss 3 of the molded article body 1 an amount corresponding to the depth of the recesses 9A formed in the lower mold member 9.
In producing a molded article, the threaded inserts 5 formed of steel having a high thermal conductivity are used. Owing to the temperature difference between the reaction temperature of the resin in the boss forming regions 10A and the temperature of the threaded inserts 5, the material surrounding the periphery of each threaded insert 5 is cooled quickly to enable the skin layer 4 of a small thickness and high strength or hardness to be formed outside each threaded insert 5.
Thus the foamed urethane molded article formed with threads produced as aforesaid has a high screw clamping critical torque and a high thrust.
FIG. 6 shows another embodiment of the reaction injection molded article formed with threads, such as a foamed urethane molded article, in conformity with the invention, in which the body 1A of the molded article is formed with the bosses 2A. The numeral 12 designates members formed with threads or helicoils which are each embedded in the interior of one of the bosses 2A of the body 1A by being securedly held in place by the skin layer 4.
The helicoils 12 formed of steel are bellows-like resilient members which are commercially available with a trade name of HELI-SERT manufactured and sold by Tsugami Corporation of Japan.
The foamed urethane molded article body 1A formed with threads of this embodiment shown in FIG. 6 has high bond strength between each helicoil 12 and the body 1A because the skin layer 4 of high hardness is formed in the vicinity of each helicoil 12 and the resin bites into the outer side (threaded side) of each helicoil 12. The numeral 3 is the core.
As represented by specimen 6 shown in FIG. 3, the embodiment shown in FIG. 6 has a screw clamping critical torque of 40 kg-cm (using M 6 screws) which, although it lags behind that of specimen 5 representing the embodiment shown in FIG. 1, is twice as high as 20 kg-cm of specimen 3 of the prior art.
The molded article shown in FIG. 6 uses helicoils (HELI-SERT, for example) which are commercially available, as members formed with threads. The embodiment shown in FIG. 6 offers the additional advantage of being lower in the number of process steps than the embodiment shown in FIG. 1 which uses the threaded inserts 5 as members with threads.
The method of production of the foamed urethane molded article with threads shown in FIG. 6 will be described. FIG. 8 is a sectional view of one example of the reaction injection mold used in the production of the reaction injection molded article according to the invention. In FIG. 8, parts similar to those shown in FIG. 6 are designated by like reference characters. The helicoils 12 are located in the boss forming regions 10A of the cavity 10 as being threadably fitted over bolts 13 formed of steel each having a head 13A inserted in one of recesses 9B formed in the lower mold member 19.
The method of production of the molded article using the reaction injection mold shown in FIG. 8 is similar to that using the reaction injection mold shown in FIG. 5. By removing the bolts 13 from the body 1A of the molded article, the body 1A of the molded article shown in FIG. 6 is obtained.
In the mold shown in FIG. 8, the bolt 13 is threadably inserted in the helicoil 12, so that the material in the vicinity of the helicoils 12 in the bosses 2A is quickly cooled by the helicoils 12 and bolts 13, to enable the hard and thick skin layer 4 to be formed on the outer side of each of the helicoils 12.
Still another embodiment of the invention will be described by referring to FIG. 9 in which the numeral 21 designates a reaction injection molded article body consisting of a core 22 of the cell construction including bosses 21A each formed with a hole 21B to be threaded later on. The cell construction in the vicinity of the holes 21B of the molded article body 21 has a higher density than the cell construction in the central portion of the body 21 due to the cooling effect of the mold, not shown.
The reaction injection molded article body 21 which is of the cell construction is formed by using a foaming system using water and alkylhalide as foaming agent.
The reaction injection molded article body 21 of this construction can be readily formed with female threads by cutting threads of the helicoil 12 shown in FIG. 7 on the walls of the holes 21B of the body 21 by means of a helicoil tap, not shown, and then threadably fitting the helicoils 12 in the threaded holes 21B as shown in FIG. 10.
An attachment can be attached to the reaction injection molded article by utilizing the female threads formed as aforesaid. As shown in FIG. 11, an attachment 24, such as a steel plate, formed with bolt holes 23 of a predetermined size is brought into contact with the body 21 with the bolt holes 23 being indexed with the holes 21B in the bosses 21A and then bolts 25 are threadably inserted in the helicoils 12 in the holes 21B. The threads of the embodiment shown in FIG. 11 had a screw clamping critical torque of about 20 kg-cm.
Still another embodiment of the invention will be described by referring to FIGS. 12-14. In these figures, parts similar to those shown in FIGS. 10 and 11 are designated by like reference characters.
The reaction injection molded article body 31 shown in FIG. 12 comprises a skin layer 34 of high density formed on its underside 31A with holes 31B to be subsequently threaded located at the outside, and a core 32 of the cell constriction of low density located in the interior.
The reaction injection molded article body 31A of the dual layer structure comprising the skin layer 31A on the outside and the core 32 of the cell construction in the interior is formed by using a foaming system consisting of a foaming agent, such as low boiling alkylhalide, for example.
Then threads are cut on the wall of the hole 31B of the skin layer 34 of high density of the molded article body 31 as shown in FIG. 13 by means of a helicoil tap, not shown, and helicoils 12 as shown in FIG. 7 are threadably inserted in the holes 31B. Thus the reaction injection molded article body 31A can be readily formed with female threads.
An attachment can be attached to the reaction injection molded article by utilizing the female threads formed as aforesaid. As shown in FIG. 14, the attachment 24 formed with the bolt holes 23 of a predetermined size made as of steel plate is brought into contact with the body 31 with the bolt holes 23 being indexed with the heles 31B on the underside 31A of the reaction injection molded article body 31. Then the bolts 25 are threadably inserted in the helicoils 12 in the holes 31B, to thereby secure the attachment 24 to the reaction injection molded article.
In the embodiment shown and described hereinabove, the helicoils 12 are threadably inserted in the holes 31B formed in the skin layer 34. Thus the threads of this embodiment have a higher screw clamping critical torque than those of the embodiments shown and described previously which was about 30 kg-cm. It has been found that when a three-component system comprising 4, 4'-diaminodiphenylmethane added with propylene oxide (40 weight parts), glycerine added with propylene oxide and ethylene oxide (10 weight parts) and monoethanol amine added with propylene oxide (50 weight parts) is used as the polyol of the urethane foaming material, the foamed body obtained has its mechanical strength increased by about 20-30% and its thermal resistance also increases by 30-50%. It has also been found that crude MDI used as the B liquid has increased reactivity with polyol and raises no problem with regard to safety.
In all the embodiments shown and described hereinabove, the threaded inserts and the helicoils have been described as being made of steel. However it is to be understood that other metal or nonferrous metal and plastics of high toughness, such as ABS, may be used. The reaction injection molded article has been described by referring to a foamed urethane molded article. However, the invention is not limited to the foamed urethane molded article and it can have application in other reaction injection molded articles. | A reaction injection molded article formed with threads and a method of molding same, wherein threaded members, such as threaded inserts, helicoils, etc., are positioned in the cavity of a reaction injection mold, and molding material is injected into the cavity to form the threaded members into a unitary structure with a body of the reaction injection molded article. The threaded members are securedly held in place by a surface layer of relatively high density. The molding material is a mixture of an A liquid and a B liquid, the A liquid containing 100 weight parts of polyether polyol obtained by adding alkylene oxide to various kinds of alcohol or amine, 1-5 weight parts of a reaction promoting agent (catalyst) comprising tertiary amines, tin compounds, etc., 3-50 weight parts of water and a foaming agent, such as low boiling point alkylhalide, 1-5 weight parts of a foaming regulating agent, such as alkylene oxide denatured polydimethyl siloxane and 1-20 weight parts, if necessary, of pigment, dyestuff and filler, such as carbon black, diazo compound, silica, glass fiber, etc., and the B liquid containing 100-200 weight parts of MDI, TDI, crude MDI or crude TDI. | 8 |
BACKGROUND OF THE INVENTION
This invention relates to cleaning devices, and, more particularly, to an attachment for water closets which can be used as a bidet, as a cleansing device for babies, their soiled diapers, and a device for clearing clogged toilets and drains.
The advantages of bidet bathroom fixtures and sitz baths are well recognized in the art of therapeutic hygienic cleaning. Generally, bidet fixtures are mounted separately from toilet bathroom fixtures and require separate plumbing for proper operation. The disadvantage of such a separate fixture is that it necessarily occupies a space in an often limited confines of a modern bathroom and, in many cases, becomes cost prohibitive. To solve the problem, numerous patents have been issued for attachments for water closets which could serve as bidet, or personal cleaning devices, or which can be doubled as a sitz bath, when necessary. Examples of such attachments can be found in a number of U.S. patents, some of which are listed below:
U.S. Pat Nos. 1,818,388; 2,036,985; 4,000,742; 4,287,618; 4,326,308; 4,510,630; 4,596,058; 4,622,704; 4,764,997; 5,023,961; 5,295,274; 5,384,919; 5,419,363.
Some of these devices disclose the use of hand-held showerheads mounted on a handle which also carries an actuating control valve. Others suggest the use of a showerhead with a rigid handle which is connected to a conventional faucet to allow delivery of water to the showerhead and facilitate personal cleansing of a person seated on a toilet. Still others suggest the use of specially adapted toilet seats to accommodate a showerhead with a nozzle that is supported under the toilet seat to direct the water upwardly. However, none of the above mentioned devices provides for the use of a hygienic device that can be also used to facilitate clearing of drainage clogs or a device that can be used during diaper changes of a baby.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a personal hygienic device which can be connected to conventional water plumbing fixtures and utilized for cleansing of an infant.
It is another object of the present invention to provide a device which can be used for clearing drain clogs in a toilet or in bathroom drains.
It is a further object of the present invention to provide a hand-held personal hygienic device which can be easily connected to commercial bathroom fixtures without requiring expensive separately standing structures.
These and other objects of the present invention are achieved through a provision of a cleaning device which comprises an elongated flexible tubing, one end of which is adapted for connection to a source of water supply. A fluid control valve is secured to one end of the tubing to regulate the flow of water through the tubing. A rigid hollow handle is secured to an outlet of the flow control valve, the handle carrying a vented spray nozzle at its free end, with the spray nozzle provided with a plurality of openings. A curved connecting member retains the spray nozzle at an acute angle in relationship to a longitudinal axis of the handle so as to direct a flow of water exiting through the openings upwardly when the cleaning device is in use.
The handle is long enough to extend from an outside confines of a toilet bowl to a location immediately above the toilet bowl. When the device is in use, the control valve appears on the outside of the toilet bowl, in front of the user seated on the toilet bowl.
An open front or optional modified toilet seat is provided with a curved cutout in its top upper surface to accommodate the handle which rests in the cutout or opening when the device is in use. A sealing gasket is secured to the underside of the toilet seat to seal the parameter of the toilet seat and close the area between the top rim of the toilet bowl and the underside of the toilet seat, thereby preventing escape of water from the toilet bowl.
An alternative embodiment of the cleaning device in accordance with the present invention provides for the use of a cleaning attachment suitable for clearing clogged drain outlets. This attachment unit comprises a length of flexible tubing made from for example plastic or rubber so as to bring an open free end of the tubing to an immediate proximity of the clogged opening and deliver a stream of water through the drain outlet to thereby facilitate clearing of the toilet or drain pipe.
A further alternative embodiment of the cleaning device in accordance with the present invention provides for the use of a secondary cleaning unit suitable for cleaning a diaper area of an infant. The secondary unit provides for the use of an elongated hose independently connected to a source of water supply and provided with a spray nozzle on the free end of the hose. A spring operated manual depressible lever regulates the flow of water exiting the openings in the sprayer to clean the infant and rinse the soiled diaper.
An optional open top housing in the form of a basket with openings or slots is provided for use with the secondary unit. The housing, or basket, is dimensioned to be seated over the toilet bowl and engage with its rim the inside parameter of the toilet seat or the top rim of a toilet bowl. The user positions an infant into the basket and, while holding the infant with one hand, directs the spray of water through the hand-held sprayhead onto the diaper area and afterward onto the diaper which is rinsed in the basket.
The cleaning device in accordance with the present invention provides and inexpensive, versatile alternative to cumbersome bathroom fixtures currently known in the industry.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference will now be made to the drawings, wherein like parts are designated by like numerals and wherein:
FIG. 1 is a perspective view of the device in accordance with the present invention mounted a tank of a water closet.
FIG. 2 is a perspective, partially cross sectional view of a flow control valve of the device in accordance with the present invention.
FIG. 3 is a front view of a modified toilet seat designed to accommodate a hand-held spray nozzle of the device in accordance with the present invention.
FIG. 4 is a detail view of a support bracket suitable for mounting the device on a water closet tank
FIG. 5 is an alternative embodiment of the hygienic device in accordance with the present invention provided with a sprayhead nozzle suitable for use during diaper changes.
FIG. 6 is a detail view showing a support bracket for the sprayhead suitable for use during diaper changes.
FIG. 7 is a perspective view of a basket suitable for accommodating an infant during a diaper change.
FIG. 8 is a perspective view of a third embodiment of the device in accordance with the present invention utilizing an attachment for clearing drainage clogs.
FIG. 9 is a perspective detailed view of the shower sprayhead for use in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings in more detail, numeral 10 designates the cleaning device in accordance with the present invention. The device 10 comprises a hand-held personal hygiene attachment unit 12 which is connected to a dual outlet water supply valve 14 by a flexible elongated tubing 16. The tubing 16 can be made from plastic or spiral metal hose. The tubing 16 is made from a heat transferable material, such as metal. It is preferred that a collar 17 is placed over at least a portion of the tubing 16 so as to minimize discomfort of contact with cold metal part by the body of the user. The collar 17 is shown schematically in FIGS. 1, 5, and 8. The unit 12 is comprised of an elongated tubular rigid hollow handle 18 having an inlet portion, connected to an outlet 20 of a control valve 22, and an outlet portion, provided with a standard annular fitting connector 24. Detachably connected to the fitting 24 is a shower sprayhead 26 which is secured to the fitting 24 by a curved elbow joint 28 which allows to retain the shower sprayhead 26 at an acute angle in relationship to a longitudinal axis of the handle 18.
Mounted in a surrounding relationship over at least a part of the handle 18 is a grip portion 30 made from a resilient flexible material, for example rubber, to facilitate convenient frictional engagement of the handle by the user.
As can be seen in FIGS. 1 and 4, the valve body 32 of the control valve 22 is removably supported on a J-shaped bracket 40 which is comprised of an elongated narrow plate 42 provided with transverse extensions 44 and 46. Extension 46 is unitarily attached to the upper end of the plate 42, while the extension 44 is unitarily attached to the lower end of the plate 42. The length of the extension 46 is slightly greater than the thickness of a conventional toilet tank wall to allow positioning of the extension 46 on the top edge of the toilet tank, such that the underside of the extension 46 contacts the upper edge of the tank wall.
A downwardly extending lip 48 is oriented at a right angle to the extension 46 and descends inside the toilet tank 50 to prevent disengagement of the bracket 40 from the tank 50. The length of the extension 44 is sufficient to support a bottom wall 52 of the flow control valve 22 when the unit 12 is positioned in the bracket 40. Securely connected to the extension 44 is a second vertical plate 54 which is oriented in a substantially parallel relationship to the first vertical plate 42 and prevents sliding of the unit 12 from the extension 44 when the unit 12 is supported by the bracket 40.
In such cases where the toilet tank has a flushing handle on a side of at toilet tank, it is preferred that the bracket 40 be mounted on a wall adjacent the toilet tank so as not to interfere with the normal operation of the lavatory. In that case, it is possible to have extension 46 rest on some outwardly projecting member associated with the wall mount and be disengageable therefrom when required.
As can be further seen in FIG. 1, the conventional dual outlet water supply valve 14 is provided with a second outlet 60 which receives a water flow from the inlet end 62 of the valve 14. A flexible tubing 64 is connected to the outlet 60 at one of its ends and to an inlet 66 of the toilet tank 50. A control handle 68 allows to control the water flow from a municipal water supply through the valve 14 to the device 10 and to the toilet tank 50.
Turning now to FIG. 2, the flow control valve 22 in accordance with the present invention is shown to comprise the valve body 32 provided with an outlet orifice 20 and an inlet orifice 70. Both the inlet and outlet orifices are provided with conventional externally threaded annular connectors 72 and 74, respectively, to allow connection of matchingly threaded tubing connectors to the inlet and outlet of the valve 22. Of course the connectors 72 and 74 can be made as female members or a combination of one male and one female member. An internal conduit 75 is formed inside the body 32 in fluid communication between the inlet orifice 70 and the outlet orifice 20. The conduit 75 is formed as an L-shaped channel within which a shaft 76 moves in a sliding reciprocating relationship.
A plug 78 is carried by one end of the shaft 76. The plug 78 is shaped and sized to seat against a conical seat 80 within the conduit 75 and block the passageway connecting the inlet 70 and the outlet 20. The plug 78 is formed with matchingly tapered exterior wall to snugly fit against the seat 80 and terminate the fluid flow from the inlet 70 to the outlet 20 when the valve is closed.
The sliding shaft 76 is threadably engaged, such as by threads 82, within an internally threaded annular bushing 84 which is carried by the valve body 32. The shaft 76 extends through an opening 86 formed in the side of the valve body 32 opposite the inlet orifice 70. A handle 88 is carried by a free end 90 of the shaft 76, the handle 88 allowing to regulate the amount of flow traveling from the inlet 70 to the outlet 20. As the handle 88 is secured in close proximity to the handle 18 of the unit 12, the user can conveniently regulate the flow of water traveling through the spray nozzle 26 during operation of the device 10.
If desired, the spray nozzle head 26 can be provided with a suitable vent 27, as well as a keyed fitting to prevent the elbow joint 28 from turning out of its set position during operation of the device.
Turning now to FIG. 3, the modified toilet seat to be used with the cleaning device 10 is illustrated. The toilet seat 100 is provided with an indentation 102 in its front top surface to accommodate the handle 18 when it is positioned above the toilet bowl (not shown) before operation of the device. A peripheral gasket 104 is secured about the periphery of the underside of the seat 100 to close the gap between the seat 100 and the top rim of a toilet bowl. One or more air vents 106 are formed in the gasket 104 as can be better seen in FIG. 3. The gasket 104 can be made from a flexible resilient material, such as plastic or rubber, and can be glued to the bottom of an existing toilet seat or manufactured as part of a modified toilet seat shown in FIG. 3. The gasket 104 prevents water from escaping the confines of the toilet bowl during operation of the device.
During use, the device 10 is removed from its position on the bracket 40 and the handle 18 is inserted in the indentation 102 on the seat 100 of a toilet bowl. The spray head 26 is oriented with its opening 108 in such a manner that the water flow is directed upwardly when the control valve 22 is in an open position. Since the control valve 22 will extend directly in front of the user when he or she is seated on the toilet seat 100, the regulation of the flow of water can be easily accomplished. The unit 12 will serve as a personal hygienic cleaning device or as a bidet for the user when the spray nozzle attachment 26 is engaged with the handle 18.
When it becomes necessary to use the cleaning device 10 for cleansing a baby during a diaper change, the device 10 provides for the use of an alternative embodiment shown in FIG. 5. In this embodiment, a T-connector 110 is secured to one of the outlets 112 of the outlet valve 14. The connector 110 connects a second flexible hose 114 to the outlet 112, while another tubing 16 is connected to its second outlet. The remaining open outlet allows connection of a hose to supply water to the toilet tank. The hose 114 carries a hand-held sprayhead, or attachment 116 which is comprised of an elbow-shaped sprayhead formed with a plurality of spray openings 118 formed in one end of the sprayhead 116. A spring operated lever 120 is carried by the sprayhead 116 to allow for precise regulation of the amount of water delivered through the openings 118 when the attachment 116 is in use.
A separate bracket 130 is provided for supporting the attachment 116 on the toilet tank 50. The bracket 130, similar to the bracket 40, is comprised of an elongated narrow plate 132 having a transverse extension 134 which is designed to rest on the top rim of the toilet tank 50. A downwardly extending plate 136 prevents disengagement of the bracket 130 from the tank 50. A second horizontal extension 138 is provided with an irregularly-shaped opening 140 which is designed to accommodate the sprayhead 116 and retain it in a secure position within the bracket 130 when the unit 116 is not in use.
In order to safely hold the infant above the toilet bowl, the present invention contemplates provision of an optional infant basket 142 which has an upper rim 144 extending transversely to the body 146 of the basket 142. The rim 144 is of a diameter greater than the opening 148 in the toilet seat 100 so as to allow retention of the basket 142 above the toilet bowl when an infant is placed in the basket 142. A pair of handles 150 are secured on opposite sides of the basket body 146 to facilitate positioning and removal of the basket 142, when in use.
In operation, the user places the baby into the chamber 152 which is defined by the interior wall of the basket body 146. It is preferred that the body 146 be formed with slots or openings to allow escape of water and debris from the interior chamber 152 during use of the basket 142. Holding the infant with one hand, the user picks up the unit 122 from the bracket 130. While holding the sprayhead 116, the user pushes on the lever 120 to allow water to escape through the openings 118 and cleanse the diaper area of the infant. After the infant has been attended to, the soiled diaper and the basket 152 can be rinsed of debris using the unit 122.
Turning now to FIG. 8, the third embodiment of the device in accordance with the present invention is illustrated. The third embodiment provides for the use of a detachable, flexible extension tubing 160 which can be secured to the attachment ring 24 at one of its ends as a substitute for the spray nozzle assembly 26. The tubing 160 has an open free end 162 which delivers a flow of water from the handle 18 when the valve 22 is in an open position. It is preferred that the tubing 160 be made from a flexible, bendable material to allow directing of a water flow in a narrow, strong flow to a drain opening of a sink, toilet, bathtub, or shower. The flow of water, being directed to the immediate proximity of the drain opening facilitates breaking of the debris accumulated in that area and clearing of the drainage opening.
It is envisioned that the hose 16 can be manufactured as a spiral hose, and that other flexible tubing can be made from a similar material so as to minimize clutter in the limited confines of a modem bathroom. The cleaning device 10 can be easily connected/disconnected either by hand or by using standard plumbing instruments, and can be sold as a unit with different attachments, or with one attachment, as desired.
The length and shape of the handle 18 can be easily modified either by the manufacturer or the user to accommodate requirements of the user.
Many changes and modifications can be made in the design of the present invention without departing from the spirit thereof. I, therefore, pray that my rights to the present invention be limited only by the scope of the appended claims. | A cleaning device which can be used as a personal hygienic unit, as a unit for cleaning a diaper area of an infant, and rinsing soiled diapers, or as a cleaning unit for clearing clogs in a toilet or drain pipe. There is included a flexible hose which is connected to a water supply and to an inlet of a flow control valve. An outlet of the flow control valve is connected to a rigid hollow handle for delivery of water through the handle to a sprayhead secured at an acute angle in relation to a longitudinal axis of the handle so as to deliver water upwardly from the spray head openings when the device is in use. A secondary unit is independently connected to a water supply for delivery of water to a hand-held spray nozzle to allow cleaning of a diaper area of an infant and rinsing soiled diapers. As an alternative to the sprayhead, there is provided a flexible, bendable pipe having a free open end, through which a stream of water can be delivered to an immediate proximity of a clogged toilet or drain. | 3 |
BACKGROUND OF THE INVENTION
The invention relates to a floor panel in the form of a rectangular plastic plate according to the introductory portion of claim 1 .
A floor panel in the form of a rectangular plastic plate with tongue and groove profiling at least at two mutually opposite edges is known from the British patent 1,430,423. In comparison to a conventional tongue and groove connection, the tongue and groove profiling used has the special feature that the tongue and groove can be locked to one another so that adjacent plates can be prevented from drifting apart in the plane in which they are laid. In the present context, a connection of this type is to be referred to as a lockable tongue and groove connection.
Recently, tongue and groove connections have been employed widely in the course of the success of the so-called laminated floor panels. In practice, because of the possibility of locking adjacent panels together in a springy fashion, click connections are also mentioned in practice. The known, relevant patents include the EP 843,763 A1, the EP 1,024,234 A1, the EP 1,036,341 A1 and the EP 698,126 A1.
The known floor panels generally consist of a chipboard core (such as an MDF or an HDF core), which is covered (laminated) with a décor layer and a use surface or a finishing layer.
Laminated floors have proven to be optically appealing, advantageously priced, relatively light and flooring material, which can also be laid by lay persons. Furthermore, they are correspondingly widely spread.
Because of the high proportion of wood material in the laminated panels, it has not been possible until now to appreciably reduce the relatively high impact noise, which emanates from laminated floors.
On the other hand, plastic floor coverings are also known, which generally consist predominantly or completely of PVC and are supplied in the form of individual tiles or panels. These individual tiles or panels are glued to a solid substrate. Admittedly, these plastic floor coverings have advantages in relation to the transfer of impact noise. However, laying the individual panels by gluing them to the substrate continues to be time-consuming and labor intensive. Since dispersion adhesives are generally used for this purpose, bubbles may be formed in the floor covering because of the diffusion of vapors through the adhesive layer or also due to moisture from the substrate.
SUMMARY OF THE INVENTION
It is therefore an object of the invention, to create a floor panel of the type mentioned above, which, while retaining the advantageous impact noise properties, can be laid rapidly, simply and without problems.
This objective is accomplished by means of a wall or floor panel with the distinguishing features of claim 1 .
An inventive floor panel is in the form of a multilayer rectangular laminate, which has a soft core of plastic, especially of PVC, on the upper side of which there is a décor film. A transparent finishing layer and, on the latter, a transparent lacquer layer are applied on the décor film. On the back of the panel, there is a counteracting layer. At least two mutually opposite edges are provided with a lockable tongue and groove profile.
The inventive floor panels can be laid in the same way as conventional floor panels of MDF and HDF. Because of its relatively soft core of plastic, especially of PVC or polyurethane, the material has a high degree of impact noise dampening.
An inventive floor panel is completely water-resistant and can therefore also be used for rooms, which are exposed to water and other liquids and moisture. The material does not swell after it comes into contact with a liquid.
A particularly high increase in impact noise damping can be achieved by affixing an impact noise mat to the back of the panels.
At the present time, PVC comes into consideration first of all as a material for the core and the various other layers of the inventive panel. However, the use of other plastics, such as polyurethane and polyolefin, would also be possible.
The individual layers are connected to one another by a hot laminating process. Only the UV-cured lacquer layer is applied subsequently in a separate step.
The inventive panel should be thicker than the conventional elastic floor panels. The thickness should be 4 to 8 mm. The weight should be 1.5 to 2.0 kg per mm and per m 2 .
Connecting panels with a lockable tongue and groove profile have the advantage that an area can be laid so as to float. Moisture below the floor can be diverted to the side.
It is particularly significant that it is not necessary to glue the panels. The previously customary gluing was always associated with much contamination of the material and of the premises as well as of the personnel. It takes some time for the adhesive to dry. The evaporation during the drying generally is perceived as unpleasant. These disadvantages do not arise in the case of the inventive laying system without gluing.
After the panels are laid, the floor can be used immediately. In the case of renovations, downtimes are reduced appreciably.
PVC raw material has the negative property that, during the aging process, there is migration of the plasticizer and, with that, shrinkage. In the case of conventional, glued connections, this can lead to the formation of gaps. Since the inventive floor can be laid so as to float, any shrinkage occurring can be compensated for by the floating arrangement and the locking of the panels.
Just like previous laminated floors, an inventive floor can be taken up and used once again, making it suitable for exhibitions and stores, for presentation areas in sales spaces, in furniture stores, etc.
The inventive floor panels can be produced especially in different dimensions of conventional floor panels, for example, in sizes staggered by 10 cm from 30×30 cm to 60×60 cm. They can also be offered in strip formations ranging in length from 90 to 120 cm and in width from 7 to 22 cm.
The inventive floor panels accordingly correspond in structure essentially to the conventional laminates with an HDF or MDF core. However, they consist entirely of plastic. A plastic laminate of this type has a series of positive properties, which clearly make up for the possibly somewhat higher price, especially for certain purposes.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, preferred examples are explained in greater detail by means of the attached drawings, in which
FIG. 1 shows a diagrammatic, partial section to illustrate the inner construction of the inventive floor panel and
FIGS. 2 a - 2 e show different diagrammatic partial sectional representations to explain lockable edge profiles, which can be used pursuant to the invention.
DETAILED DESCRIPTION
To begin with, reference is made to FIG. 1 . The center of the inventive floor panel is a core 10 of a relatively highly filled, but still elastic plastic, especially PVC or polyurethane. On the core, there is a décor layer 12 , such as a printed PVC film, which may be a décor of any type, for example a wood décor or also a stone décor and also any décor imaginable. The décor layer 12 is covered by a use surface or a finishing layer 14 , which has a high abrasion resistance. Finally, there is a UV curable layer 16 on the surface. Curing by UV light has the particular advantage that the manufacturing process is accelerated. On the back of the panel, there is a counteracting layer, which prevents curvature of the panel during expansion and shrinkage.
At the underside of the panel, a damping layer 19 may be provided, which additionally contributes to damping the sound of steps and/or of room noise. The layer 18 of FIG. 1 may, in addition, carry out the function of a back pull and, at the same time, be a damping layer. It is, however, possible to divide the functions of a back pull layer and of a damping layer and have them carried out by two separate layers. The damping layer may be a foam layer, for example, of polyurethane. Fillers, especially mineral fillers, such as sand, chalk or the like may be present in the damping layer. These fillers increase weight and, with that, contribute to the damping. There may also be suitable fillers in the core 10 .
FIG. 2 shows different examples of the edge profile, which is to be used and enables adjacent panels to be locked.
FIG. 2 a shows two adjacent tiles 20 - 22 with a lockable tongue and groove connection. At the right side of the panel in FIG. 2 a , the groove 24 has a straight flank 26 , which extends parallel to the plane of the panel. The other flank 28 approaches the opposite flank 26 in the direction of the depth of the groove 24 and, at its open end, has a protrusion 30 , which is directed inward in the direction of the opposite flank 26 . Accordingly, this type of tongue and groove connection is partly undercut. However, it may be pressed together with a click effect, particularly since the material, as a whole, is relatively elastic and therefore deforms adequately, when two panels are to be connected with one another. The profile of FIG. 2 a is a typical locking profile.
The embodiments of FIGS. 2 b , 2 c and 2 d are similar to one another. Once again, they have a slightly undercut groove 32 , which, on the whole, has a direction, rising into the interior of the material of the panels 20 , 22 , as well as an expanded head region at the base of the groove. Tongue and groove connections of this type can be caused to “interact” with one another, when two panels are to be connected with one another. In the case of profiles of this type, it is customary to speak of “single angle profiles”. To begin with, a new panel, which is to be added, is bent slightly and, after the tongue, which is not labeled, is pressed into the groove of the new panel, lowered into the flat position. In this way, adjacent panels, overcoming the undercuts of the tongue and groove connections, can be installed relatively easily and with little expenditure of force.
The tongue includes a head having a greatest dimension measured in a transverse direction of the floor panel, and a connecting portion that connects the tongue to the core of plastic. The connecting portion has a constricted dimension in said transverse direction which is less than said greatest transverse dimension of the head to define a narrow connecting neck. The groove is provided for receiving the tongue. The groove has an open end with an inwardly directed protrusion thereat which defines a constricted opening to the groove, with the protrusion engaging the connecting portion when the tongue is inserted fully into the groove. The groove has an expanded head portion for receiving the head of the tongue and which has a greatest dimension measured in said transverse direction, and said constricted opening has a constricted dimension in said transverse direction which is less than said greatest dimension of said expanded head portion.
FIG. 2 e shows a further locking profile, namely, an embodiment with a groove 34 and a tongue 36 , which are close to one another in a tongue and groove connection, but have an expanded head region 38 , 40 . In view of the expansion of the head region, adjacent panels must be assembled with a certain pressure. The elastic material of the panels permits the tongues to be locked easily in the grooves. | The invention relates to a floor panel in the form of a multilayer, rectangular laminate with a soft core ( 10 ) of plastic, a décor film ( 12 ) on the upper side of the core ( 10 ), a transparent finishing layer ( 14 ) and a transparent lacquer layer ( 16 ) applied on the finishing layer ( 16 ), as well as a back-pull layer ( 18 ) on the back of the core ( 10 ), with a lockable tongue and groove connection at least at two mutually opposite edges of the panel ( 20, 22 ). | 8 |
FIELD AND BACKGROUND OF THE INVENTION
[0001] The present invention relates generally to the field of quilts and quilted or quilt fabrics (collectively called quilts here), and in particular to a new and useful process for giving a whole cloth quilt and whole cloth quilt fabrics a vintage or antique appearance, and to the new and useful quilt product itself.
[0002] Whole cloth quilts are defined as single panels of fabric or fabrics that have been seamed to produce the effect of a single panel on both the top and bottom surfaces of the quilt, and an intermediate layer of batting fabric between the two panels. The stitching of the quilt can be hand-done or machine-made with the effect of forming a sculptured outline of designs caused by the stitching pattern and the puffing of the batting underneath the fabric as it is confined to the spaces between the stitches.
[0003] There is a long history of whole cloth quilting in America, as it was one of the first quilting styles brought to this country. The original fabrics used in the 18 th century were wool for everyday or white cotton and white linen for more formal use. There was a renewal of interest in whole cloth quilts in the early twentieth century due to the growth in popularity of the sewing machine during that time period, and cotton sateen fabric was often used.
[0004] Excellent short articles on whole cloth history can be found on the Internet at:
www.womenfolk.com/quilting_history/wholecloth.htm and www.quilthistory.com/dating_quilts.htm.
[0007] Today, whole cloth quilts are stitched by hand or machine using cotton, linen, silk, wool, polyester or blends of any of these fibers. Many of these quilts are marketed with the puffed, sculptured effect of the stitch patterns as the primary appearance feature. Some of the quilts, after they are sewn, also undergo a finishing method to achieve a vintage look. The most popular method is for quilts using 100% cotton batting to be machine washed and dried. This method achieves a puckering of the fabric. The puckering is primarily due to the shrinkage of the cotton batting within the sewn space. With this process, the original smooth and sculptured effect is modified with a puckering giving a different appearance to the quilted fabric. Therefore, there are two different types of whole cloth quilt appearances with each look having its own proponents—the puffed, sculptured effect vs. the puckered effect.
[0008] An example of a whole cloth quilted sculptured look modified by the puckered effect in quilts can be seen in FIG. 1 which is a partial and schematic illustration of a pattern for a whole cloth quilt that can be antiqued according to the present invention.
[0009] Patents that are relevant to the present invention include U.S. Pat. No. 4,690,084 for Production of Puffed Embroidered Design Fabrics, U.S. Pat. No. 4,688,502 for Puffed Embroidered Design Fabrics, U.S. Pat. No. 6,702,861 for a Process for Antiquing Fabric, U.S. Published Patent Application 2003/0196276 for a Process for Antiquing Fabric, U.S. Published Patent Application 2002/0133261 for a Method and System for Producing Garments Having a Vintage Appearance, and U.S. Pat. No. 5,759,210 to Potter, et al. for a Lyocell Fabric Treatment to Reduce Fibrillation Tendency.
SUMMARY OF THE INVENTION
[0010] It is an object of the present invention to provide a process for antiquing a quilt which artificially makes the quilt appear faded and worn, and the quilt itself. The term “quilt,” as used here is meant to include quilt fabrics and quilted fabrics that may be used alone or combination with other quilt or quilted fabrics to make a completed quilt. Also within the meaning of the term “quilt,” as used here, are any and all quilted fabrics that can be used to make other products such as jackets, shirts, pants, skirts, robes, dresses, hats, and other types of apparel that utilize textile fabrics that can be sewn into a finished garment, handbags, tote bags, luggage, overnight bags, duvet covers, comforters, shams, bed skirts, fitted and unfitted furniture covers for all types of furniture, tablecloths, placemats, napkins, window treatments, decorative throws, decorative pillows, toys, stuffed toys, laundry bags, diaper bags, laptop bags, cosmetic bags, soft furniture, and scarves.
[0011] Accordingly the process includes providing a first fabric panel comprising a first selected fiber, a second fabric panel comprising a second selected fiber and a batting panel comprising a third selected fiber. At least the first fabric panel is colored, e.g. piece dyed, yarn dyed, printed or otherwise pigmented in solid color or pattern and/or has some pigment applied in a finishing process as opposed to being in a griege goods state and/or the color was applied to the yarn prior to weaving, and at least the first selected fiber is susceptible to damage, e.g. fading and/or wear, by some aspect of washing, such as wetting and/or abrasion and/or heating. The selection of such a fiber which normally should not be washed, in a quilt which is washed, unexpectedly produces the useful result of the invention, namely the antique effect.
[0012] The process includes layering the three panels and stitching them along a stitch pattern to form a whole cloth quilt which is then washed in a wet bath and with heat and agitation to cause at least the first fabric panel to wear and fade and then drying the quilted fabric to form a quilt and/or quilted fabric with antique appearance.
[0013] The inventive process may also include the first and second selected fibers being susceptible to damage by wetting, wherein the first selected fiber includes cellulosic material, preferably rayon, lyocell or blends thereof.
[0014] The inventive process may also include providing the third selected fiber of the batting to be of a type which shrinks when heated and the washing step including heating the quilt sufficiently to shrink the batting and cause the pattern to contain puckers.
[0015] The inventive process may also include a washing step including heating the quilt to about 100 to 190 degrees Fahrenheit and agitating the quilt so that surfaces of at least the first fabric panel are rubbed against each other at least 50 times.
[0016] The antiquing effect of the present invention can be applied to any and all of the puffed sculpted or the puckered or the sculpted and puckered looks. The invention gives an antique appearance of worn and faded fabric to the sculptured look while retaining the puffed, sculptured features. This can be achieved, as will be explained in greater detail later in this disclosure, when polyester batting is used as there is no batting shrinkage forming puckering although there can be minor puckering due to the occasional shifting of the polyester batting within the stitch lines but this is much less puckering than with cotton batting and the whole cloth quilt fabric still retains the puffed, sculptured appearance. The antiquing effect of the present invention can also be applied to the current vintage process achieved by puckering, to improve and enhance the vintage qualities by adding the worn and faded features to the puckered effect.
[0017] The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects attained by its uses, reference is made to the accompanying drawings and descriptive matter in which a preferred embodiment of the invention is illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] In the drawings:
[0019] FIG. 1 is a schematic plan view of part of a whole cloth quilt of the invention that has been subjected to the process of the invention;
[0020] FIG. 2 is a flow chart illustrating the process of the present invention;
[0021] FIG. 3 is a representation of part of a whole cloth quilt of the present invention which better illustrates the puckering effect;
[0022] FIG. 4 is a representation of part of a whole cloth quilt of the present invention which better illustrates the sculpturing effect; and
[0023] FIG. 5 is a composite representation of a control fabric next to a treated fabric according to the present invention, in actual size at the top and in two magnifications at the center and bottom, to illustrate the advantageous effects of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0024] Referring to the drawings, FIG. 1 shows part of a whole cloth quilt 10 , having a top fabric panel 12 meant generally to be viewed more often, a bottom fabric panel 14 generally meant to be viewed less than the top panel, intermediate batting 16 , and a pattern of stitches 18 forming sculptured effects 22 and for connecting the three layers to each other. Special care is taken at the out edge 28 of the quilt 10 to insure that the surface panels 12 and 14 are directly engaged with each other along the outer edge to prevent any batting being visible at the edge, and to insure that the batting panel 16 is also secured to both surface panels.
[0025] Scale 20 having one inch increments shown, appears on quilt 10 in FIG. 1 to indicate the scale of the stitch pattern 18 .
[0026] Top fabric panel 12 at least, and perhaps bottom fabric panel 14 also, is dyed, printed, pigmented or otherwise colored containing or carrying in a solid color or in a print or pattern. This characteristic of one or both surface fabrics, here simply called colored, can be vivid or bright or pale and has been applied to the griege goods or applied to the yarns before weaving and/or printed on a dyed or prepared-for-print fabric, before the quilt is washed, but is artificially faded by the inventive process as will be explained later.
[0027] The purpose of the invention is to achieve an antiqued finish on such whole cloth quilt fabrics. The antiqued effect is a worn and/or faded appearance of the top surface fabric 12 or of both surface fabrics 12 and 14 of the quilt.
[0028] With references to FIG. 2 , the process is as follows.
[0029] Step 1 : The three panels 12 , 16 and 14 are layered on each other, with the batting layer 16 between the top and bottom surface fabrics 12 , 14 as shown in box 24 in FIG. 2 .
[0030] Consideration 1—Fiber content of surface fabrics 12 and 14 :
[0031] The following table gives the colorfastness, wet strength, abrasion resistance and dimensional stability properties of certain fibers subjected to commercial wash/dry cycles. Research by the inventor shows that the present invention works best with rayon and rayon blends that exhibit the damage properties to a satisfactory extent, namely they have very low wet strength and low abrasion resistance (causing wear) and largely due to the nature of the fiber and the dyes attraction to the fiber, the abrasion on the surface and the loss of the finish-sizing, among others, they are subject to fading during the laundering process. The types of dyes, the dye application methods and print methods that are used will also effect the loss of color. Although a high degree of shrinkage for the batting may also be useful to achieve puckering, the shrinkage property is not always needed or significant, depending on the type of appearance desired. In addition to rayon and rayon blends, lyocell, also a cellulosic fiber, and lyocell blends exhibit the faded and worn qualities. The lyocell fiber fibrillates when it is washed and agitated. This splintering of the fiber on random areas of the surface causes a faded and worn effect. The desired effect is most prevalent in lyocell fabrics that have not been chemically treated to prevent or reduce fibrillation.
TABLE 1 Fiber Properties related to this Invention Abrasion Dimensional Colorfastness* Wet Strength** Resistance*** Stability**** NATURAL Cellulosic Cotton Moderate High Moderate Moderate Linen Moderate High Moderate Moderate Protein-based Silk Moderate Low Moderate Low Wool Moderate Low Moderate Low Cellulosic ManMade Viscose Rayon Moderate Low Low Low Lyocell Moderate Moderate Low Moderate Acetate Moderate Moderate Moderate Moderate SYNTHETIC Polyester Moderate High High High Nylon Moderate High High High Acrylic High High Moderate High Definition of Properties- Colorfastness* The resistance of a dyed and/or printed fabric to fading, in this case during commercial laundering. Wet Strength** The strength of a fabric when it is saturated with water, in this case during commercial laundering. Abrasion Resistance*** The ability of a fiber or fabric to withstand surface wear and rubbing, in this case during commercial laundering. Dimensional Stability**** The ability of a fabric to maintain its original width and length and configuration in this case during commercial laundering.
[0032]
TABLE 2
These results were obtained after 1 time through the commercial
wash/dry process described in the application. Although the effects increase after
each time processed, the change is much less significant after the first time. The
process of the invention can achieve the desired results through up to 10 wash/dry
cycles while prior art quilts and methods achieve some antiquing effect only after 20
or more wash/dry cycles.
QUILTED FABRIC TEST
RESULTS
Quilt
Quilt
Quilt
Top
Average
Quilt
Quilt
Quilt top
Quilt top
Top
Top
Surface
Water
Quilt Top
Bottom
Batting
Length
Width
Fade
Wear
Dimension
Smp
Temp
Fiber
Fiber
Fiber
Shrinkage %
Shrinkage %
Grade
Grade
Grade
1
140
Rayon
Rayon
Cotton
−6.98
−13.95
2
3
4
2
140
Rayon
60S/40R
Cotton
−6.98
−11.63
2
3
3-4
3
140
Rayon
Linen
Cotton
−4.65
−6.98
2
3
4
4
140
Rayon
Rayon
Poly
−4.65
−6.98
2
3
2
5
140
Bemberg
Bemberg
Cotton
−4.65
−6.98
2
4
4
6
140
Bemberg
Bemberg
Poly
−4.65
−6.98
2
4
1
7
140
Rayon
50R/50L
Cotton
−6.98
−9.30
3
3
4
8
140
50R/50L
Rayon
Cotton
−9.30
−9.30
3
4
5
9
140
Rayon
85L/15R
Cotton
−6.98
−13.95
2
3
4
10
140
85L/5R
Rayon
Cotton
−4.65
−13.95
2
4
4
11
140
50R/50L
50R/50L
Poly
−11.63
−2.33
4
4
2
12
140
Rayon
Silk
Cotton
−6.98
−4.65
2
4
4
13
140
Rayon
Silk
Cotton
−9.30
−6.98
2
2
4
14
140
Rayon
52C/48R
Poly
−4.65
−11.63
2
3
1
15
140
Linen
Rayon
Cotton
−6.98
−6.98
1
2
3-4
16
140
Cotton
Rayon
Cotton
−4.65
−4.65
1
1
4
17
140
Cotton
Cotton
Cotton
−4.65
−6.98
1
1
4
18
140
Linen
Linen
Cotton
−6.98
−4.65
2
2
5
19
140
Silk
Rayon
Cotton
−6.98
−9.30
1
1
4
20
140
60S/40R
60S/40R
Poly
−4.65
−4.65
2
2
1
21
140
60S/40R
60S/40R
Cotton
−4.65
−6.98
2
2
4
22
140
85R/15L
50R/50P
Cotton
−4.65
−4.65
3
3
2
23
140
50R/50P
85R/15L
Cotton
−2.33
−2.33
2
4
4
24
140
Silk
Silk
Cotton
−6.98
−13.95
1
2
4
25
140
Silk
Silk
Cotton
−9.30
−6.98
1
1
4
26
140
Silk
Rayon
Cotton
−6.98
−11.63
1
2
3
27
140
85C/15R
Cotton
Cotton
−4.65
−6.98
2
3
4
28
140
Cotton
85C/15R
Cotton
−4.65
−6.98
1
1
4
29
140
50R/50P
50R/50P
Poly
−6.98
−11.63
2
3
1
30
140
50R/50P
50R/50P
Cotton
−9.30
−11.63
2
3
3
31
140
85C/15R
Rayon
Cotton
−6.98
−11.63
2
4
4
32
140
52C/48R
Cotton
Cotton
−4.65
−6.98
2
2
4
33
140
52C/48R
Rayon
Poly
−4.65
−11.63
2
4
1
34
140
52C/48R
Rayon
Cotton
−4.65
−11.63
2
4
4
35
140
70S/30R
Rayon
Cotton
−6.98
−11.63
2
3
3
36
140
80R/20W
80R/20W
Cotton
−6.98
−6.98
2
4
4
37
140
80R/20W
80R/20W
Poly
−6.98
−6.98
2
4
2
38
140
Wool
Wool
Cotton
−11.63
−6.98
1
2
4
39
140
Wool
Wool
Poly
−11.63
−6.98
1
2
1
40
140
Acetate
Acetate
Cotton
−6.98
−2.33
2
1
3
41
140
Acetate
Acetate
Poly
−2.33
−2.33
2
1
2
42
140
Lyocell
Lyocell
Cotton
−2.33
0
2
3
4
43
140
Lyocell
Lyocell
Poly
−2.33
−2.33
2
3
2
44
140
Acrylic
Acrylic
Cotton
−2.33
−2.33
1
2
4
45
140
Acrylic
Acrylic
Poly
0
0
1
2
2
46
140
Lyocell
Lyocell
Cotton
−2.33
−2.33
2
3
4
47
140
Lyocell
Lyocell
Cotton
−2.33
−2.33
2
3
4
48
140
60L/40R
60L/40R
Cotton
−4.65
−4.65
2
3
4
[0033] Tests were conducted to determine the fading, wear and surface dimension of quilted fabrics. The AATCC-American Association of Textile Chemists and Colorists test methods were used as guidelines for conducting these tests to obtain accurate and reliable results, specifically, AATCC Test Method 61-2003.
[0034] Colorfastness to Laundering, Home and Commercial: Accelerated and AATCC Test Method 96-2001 Dimensional Changes in Commercial Laundering of Woven and Knitted Fabrics except Wool. These AATCC tests are not meant to be used for quilted fabrics and the Colorfastness test is an accelerated test. They have been used as guidelines only, to provide the best possible procedures considering the differences in their usage with this test.
[0035] The quilted samples were sewn 8 ″×8″ consisting of a top fabric, bottom fabric and inner layer of batting. The squares were sewn in a grid quilt pattern using ½″, 1″ and 1½″ spacing of the quilt lines to provide variation in distances between the quilt lines. Bench mark lines made with a template were drawn with a marking pen on each side of the quilted sample to be later used for measuring quilt shrinkage.
[0036] Samples were laundered in a commercial washer on Cotton/Sturdy cycle at a temperature of about 140 degrees F. The samples were washed together at one time so that the load weighed about 3 lbs to provide sufficient friction of fabrics against each other. A detergent was used in an amount indicated for normal washing that is similar in content to the AATCC Standard Reference Detergent—Without Optical Brighteners—so that it would not interfere with the color change. The total running time of the washing was about 30 minutes including wash cycle and fill time.
[0037] The quilted samples were dried in a commercial dryer—Tumble Dry—Cotton/Sturdy cycle at about 160 degrees F. for about 30 minutes until all samples were completely dry, with the cotton batting samples taking longer than the polyester batting samples to dry.
[0038] The samples were then graded on a 1-5 scale compared to the control samples that were not laundered.
[0039] Grading System:
[0040] Fade—Degree of Color Change
1—No change in color 2—Minimal change in color 3—Moderate change in color 4—Heavy change in color 5—Very Heavy change in color.
[0046] Wear—Surface Attributes—One or More of: short fiber ends, hairy, uneven thinning, irregular texture, scoffed, and stippled
1—No change in surface fibers 2—Minimal change in surface fibers 3—Moderate change in surface fibers 4—Heavy change in surface fibers 5—Very Heavy change in surface fibers.
[0052] Surface Dimension—Contours of the surface fabrics
1—Full, puffed surface 2—Slight puffed surface 3—Moderately flat surface 4—Moderate dense, rippled surface 5—High dense, rippled surface.
[0058] The natural fibers of cotton and linen in their pure form (not blended with rayon) have high wet strength and therefore are not susceptible to fade or wear during the washing process. Pure silk, although it has low wet strength, has medium or moderate abrasion resistance in most of its forms and will show almost no fading or wear during the washing process. The wool tested showed little wear or fading.
[0059] Fabrics with blends of the natural fibers and rayon or lyocell, all showed a degree of wear and fading to be included in this invention. The same holds for the synthetic fibers. In their pure form, polyester, nylon and acrylic have a high wet strength and therefore cannot be included in this invention. When they are blended with rayon or lyocell, they exhibit degrees of wear and fading on the surface. The minimum amount of rayon or lyocell that needed to be part of the blend for all the fabrics, both natural and synthetic, was 15%, or from 10% to 100% by weight, as a preferred range. In addition, it did not matter if the blended fabric was made from blended yarns or if the fabric was made from a pure fiber warp or weft woven in combination with a pure rayon or lyocell warp or weft.
[0060] Also, within the designated fiber types, rayon and rayon blends, the degree of wear and fading was related to the way the fibers were spun into yarn, the type of weave and the finishing of the fabrics. Staple fibers, looser weaves, jacquard weaves and minimal finishing resulted in more wear and fading than longer filament yarns, tight weaves, plain weaves, and heavy finishing processes. However, all rayon and rayon blended fabrics showed wear and fading within the grade ranges specified in Table 2.
[0061] The surface dimension was strongly related to the batting fiber. The cotton batting produced a rippled surface and the polyester batting a smoother, puffed surface. The type of batting did not effect the wear or fading of the surface fabrics.
[0062] Since the rippled surface is often viewed as a vintage look, this invention will improve and enhance that process. In addition, this invention will also provide a method for antiquing for those who Want to retain the puffed, sculptured look that can be caused by polyester batting stitched in whole cloth quilted fabric.
[0063] Other cellulosic fibers in addition to rayon and lyocell may also work to achieve the desired extent of antiquing.
[0064] Rayon is a manufactured but non-synthetic fiber.
[0065] There are three different types of rayon for apparel and home textiles. The most dominant form, with the largest market share, is called “regular rayon” or “viscose.” It is the regular or viscose rayon that is produced in the most widespread production process that has the properties most applicable to the present invention. The main reasons are that when wet, the rayon fibers are very weak and can break down at the surface when abrasion is applied during the washing process. Also, the fabric loses its luster, sheen and a degree of color, usually from the loss of the sizing that is used in the finishing of the fabric, the nature of the fibers and the effect of abrasion on the surface. Also, the low dimensional stability during washing can contribute to an irregular texture on the fabric surface which has a distressed effect.
[0066] The two other types of rayon are produced in relatively much smaller quantities—HWM and Cupramonium rayon. HWM can be machine washed and dried and has high wet strength. It is frequently called “polynosic.” Cupramonium rayon has similar properties to regular, viscose rayon, and can be included in this invention. Cupramonium rayon is often referred to under the trademark name of “Bemberg”. 100% Bemberg rayon was included in the test and showed comparable results to the regular, viscose rayon.
[0067] The object in any case is to select a fabric which contains at least some fiber that is susceptible to damage by some aspect of washing such as wetting and/or agitation, so that the fiber fades or appears worn after washing. The fiber selected thus is of a type which, counter-intuitively, should not be washed, but which the inventor has discovered produces a new, advantageous and unexpected result, namely an attractive vintage or antiqued appearance.
[0068] According to the present invention the word “damage” means fading or wear or other distress caused by some aspect of washing, such as but not limited to wetting and agitation.
[0069] Consideration 2—Fiber content of batting:
[0070] 100% Cotton and 100% polyester batting was tested.
[0071] Weight of the cotton batting was 200 grams per square meter with batting shrinkage of 3-5%. Cotton batting for this invention will have an average range from about 150-270 grams per square meter but it can be lighter or heavier. The polyester used in the testing was low loft. Both high loft and low loft polyester and any loft of polyester can be used for this invention. Polyester does not shrink and generally causes a lightweight, smooth, puffy surface. The polyester retains the sculptured effect of the quilt pattern of the whole cloth quilted fabric. Although much rarer, wool batting can be used, and the wool batting that is resin bonded can be machine washed and dried without shrinkage, causing a similar appearance to the polyester. The wool batting provides warmth and is lightweight. Wool batting can be used in whole cloth quilted fabric in this invention. Also, silk or rayon or lyocell batting can be used for this invention. Blended fibers such as cotton and polyester blended can be used as batting in addition to any combination of the aforementioned batting fibers.
[0072] The choice of batting for a quilt or quilted fabric is generally determined by these factors: use of the quilt or quilted fabric, whether it is needed for warmth, desired fiber-natural or synthetic, whether done by machine or hand, distance of stitch lines, and appearance. The type of batting fiber and how it is processed affects its performance during and after the quilting process. Most quilt batting is made with a bonding or a needle-punched process, and either process will produce the desired effect. Batting that is plain or garneted will require the quilt lines stitching in any pattern to be closer together, generally ¼ to 1 inch apart, to prevent bunching or shifting. This applies to all quilts not only to whole cloth quilts or whole cloth quilts with the antiquing process of the present invention.
[0073] Based on the inventor's research, both cotton batting and polyester batting work for the invention. The surface effects are different but both can be antiqued to the desired appearance. If a “rippled effect” or puckering is also desired in addition to the antiquing, then batting susceptible to shrinkage (meaning cotton or the like, and not polyester) is used. Also, wool, silk, rayon, lyocell and any combination of the fibers can be used.
[0074] Step 2 : The three layers are stitched together by hand or machine with stitching across the surface of the fabrics, illustrated by box 26 in FIG. 2 .
[0075] The edges of the quilt at 28 in FIG. 1 , must be finished so that the top and bottom panels 12 , 14 are joined together with batting also attached but enclosed between the top and bottom layers so that no batting is visible at the edge.
[0076] Consideration 1—Length of the stitches:
[0077] Not less than 6 stitches per inch should be used. An average number of stitches is 10 to 14 stitches per inch and generally 6 to 21 can work with the invention or a higher number based on machine used. The maximum amount must be less than would cause gathering of fabric around the stitch line. If machine stitched, tension must be adjusted so that stitching 18 is smooth.
[0078] Consideration 2—Fiber content of the thread used for stitching:
[0079] Cotton thread was used for the test because in general, the thread type should match the fiber content and cotton thread is generally used with cottons, linens, rayons as they are cellulosic and even silks, when silk thread is not available. However, polyester thread can be used in this invention with no anticipated problems, but is not advisable due to the above.
[0080] Consideration 3—Distance between the patterns being stitched:
[0081] The closer together the stitch lines 18 in any pattern, the more defined the pattern on the surface fabric 12 as the batting 16 is in a more confined space. Therefore, the stitch lines can be next to each other or apart from each other with the average distance ¼ to 2 inches. Going beyond 4 square inches of space without stitching will diminish the fullness of the sculptured effect because the batting has more space between stitch lines but is still a viable part of this patent application. The distance between the stitch lines in any pattern does not affect the wear or fading of the fabric.
[0082] Step 3 : Washing of the quilt, at 30 in FIG. 2 .
[0083] The quilt is washed in a commercial washer or can be washed by hand in a temperature ranging from 100 to 190 degrees Fahrenheit. The machine washing cycle is heavy or the longer wash cycle with the most agitation—with the agitator causing abrasion on the wet fabric. If washed by hand, the surface of the fabric must be rubbed against itself a minimum of 50 times. This amount of agitation automatically takes place for machine washing.
[0084] Testing has confirmed the water temperature and best range.
[0085] Step 4 : Drying of the quilt, at 32 in FIG. 2 .
[0086] The quilt is machine dried in a commercial dryer on the warm/hot setting.
ADVANTAGES OF THE INVENTION
[0087] The antique or vintage look has gained in popularity as consumers desire items that have a nostalgic feeling. The yearning for products that appear aged by time is a trend that many say will only grow, particularly as the Baby Boomer generation continues to mature. In addition, decorating with antiques and distressed furniture has also increased in popularity and this invention fits and enhances that decorating style and can be a useful product for consumers with that decorating preference. The worn, faded and rippled surface on a whole cloth quilt offers a vintage appeal to a product that has a long history in the United States. It provides a much more authentic vintage look over current processes. The current process provides a puckered look, but the fabric itself can still look new. This invention is an improvement over that process because it also gives an antique appearance to the fabric which makes the item appear more authentically vintage. The invention also allows for different types of surface effects—including the original sculptured, outlined look, depending on the fiber content of and the batting.
[0088] FIG. 3 illustrates the puckering effect of a whole cloth quilt of the present invention and FIG. 4 illustrates the puffed, sculptured effect. FIG. 5 , upper left section is an actual size image of a quilt of the present invention before it has been subjected to the treatment according to the present invention. The upper right section of FIG. 5 is an actual size image of the quilt after treatment to show the antiqued effect. The middle left and right sections show the same respective control and treated quilts at three times magnification (×3) while the bottom left and right sections show the control and treated quilt images at six times magnification (×6).
[0089] While a specific embodiment of the invention has been shown and described in detail to illustrate the application of the principles of the invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | Process for antiquing a quilt and resulting product includes providing a first fabric panel containing at least some of a first selected fiber, a second fabric panel containing at least some of a second selected fiber and a batting panel containing at least some of a third selected fiber. At least the first panel and its fiber is colored and susceptible to damage by washing. The three panels are layered and stitched together using thread of a fourth selected fiber and along a pattern to form a whole cloth quilt or fabric therefore can be used as is or as material for another product. Washing the quilt in a wet bath and with heat and agitation causes at least the first fabric panel to wear and fade and the quilt is then dried and has the antiqued appearance. | 3 |
TECHNICAL FIELD
[0001] This invention relates to refining non-ferrous metal using oxygen to oxidize impurities in the molten metal.
BACKGROUND ART
[0002] A problem which arises in the refining of non-ferrous metal using oxygen to oxidize impurities in the molten metal is the formation of accretions on the surface of the lance from which the oxygen is injected into the refining vessel. These accretions comprise solidified material from the headspace of the refining vessel which solidify on the face of the lance due to the relatively cold temperature of the lance which results from water-cooling and the oxygen passing through the lance. These accretions disturb the flow of oxygen from the lance causing some of the oxygen to be deflected away from the bath. This has three very detrimental effects. First a significant portion of the oxygen is not delivered to the target area of the molten metal bath resulting in inefficient oxygen usage. Second, some of the oxygen is deflected to such a degree that it impacts the vessel wall thus reducing the life of the refractory lining of the wall. Third, the lance must undergo more frequent maintenance and replacement. All of these problems increase the cost of the refining process.
SUMMARY OF THE INVENTION
[0003] A method for refining non-ferrous metal comprising:
[0004] (A) providing a refining vessel containing a bath of non-ferrous metal and having a headspace above the bath of non-ferrous metal;
[0005] (B) passing a stream of oxygen containing gas from a lance at a velocity of not more than 3 Mach into the headspace, and passing the oxygen containing gas stream through the headspace from the lance to the non-ferrous metal bath;
[0006] (C) providing a flame envelope around the oxygen containing gas stream for a portion of the distance from the lance to the bath; and
[0007] (D) reacting oxygen from the oxygen containing gas stream with material in the bath to oxidize said material.
[0008] As used herein the term “oxygen containing gas” means a gaseous fluid having an oxygen concentration of at least 25 mole percent.
[0009] As used herein the term “flame envelope” means a combusting flow around and along one or more gas streams.
[0010] As used herein the term “coherent jet” means a gas stream which has little or no increase in diameter in its flow direction.
BRIEF DESCRIPTION OF THE DRAWING
[0011] The sole Figure is a cross-sectional end view of a non-ferrous metal refining vessel in operation with one preferred embodiment of the refining method of this invention.
DETAILED DESCRIPTION
[0012] In the practice of this invention oxygen containing gas is passed from a lance into the headspace of the refining vessel at a velocity which may be subsonic, sonic or supersonic but is not more than 3 Mach, preferably not more than 1.5 Mach and is most preferably within the range of from 0.835 Mach to 1.13 Mach.
[0013] In addition, in the practice of the method of this invention which enables oxygen refining practice of non-ferrous metal with reduced accretion formation, there is employed a flame envelope around the gas stream proximate the lance face. The flame envelope serves to melt solidified material and/or to keep material from solidifying on the lance face and thus aids in the attainment of the beneficial results of this invention, i.e. avoidance of detrimental effects of solidified material buildup on the oxygen lance in oxygen refining practice. The flame envelope is formed preferably by providing fuel, such as natural gas or other hydrogen containing fuel, and oxidant, such as oxygen containing gas, from the lance into the vessel headspace. Most preferably the fuel and oxidant are provided respectively from two concentric rings of ports on the lance face around the central nozzle from which the refining oxygen containing gas is provided into the headspace, wherein the fuel is provided from the inner ring with respect to the nozzle and the oxidant is provided from the outer ring. A single ring design may also be used.
[0014] In addition to contributing to the attainment of the beneficial result of reduced accretion formation, the flame envelope provides for a second beneficial effect. The flame envelope forms a barrier around and along the oxygen containing gas stream for a portion of the oxygen containing gas stream from the lance to the bath. This barrier keeps refining vessel gases in the headspace from passing into the oxygen containing gas stream. Thus the oxygen containing gas stream forms a coherent jet for at least a portion of the distance from the lance to the top surface of the molten metal bath. This enables the oxygen containing gas to impact the bath with greater force and purity than would otherwise be the case and this results in improved contact of the oxygen containing gas with the bath which in turn enables more efficient oxygen reaction with the bath constituents and better overall refining results. In addition, the application of the flame envelope or flame shroud can allow the oxygen lance to be operated at greater lance to bath distances than would otherwise be the case.
[0015] The method of this invention may be employed to refine many non-ferrous or base metals among which are copper, nickel, lead, zinc and tin. It is understood that there may be small amounts of ferrous metal in the bath of non-ferrous metal refined in the method of this invention.
[0016] The invention is particularly useful for the refining of copper wherein oxygen is employed to react with sulfur in the molten copper to produce sulfur dioxide which is then removed from the copper. It is in conjunction with this particularly preferred application and also with reference to the Drawing that the invention will be further described in detail.
[0017] Referring now to the Figure there is shown refining vessel 1 which has a refractory lining 4 and which contains a bath 2 of copper and has a headspace 3 above the bath.
[0018] At least one oxygen lance 10 is employed to provide oxygen containing gas into the headspace. Oxygen containing gas within the requisite velocity range is passed out of the lance into headspace 3 to form oxygen containing gas stream 12 . A flame envelope, as illustrated by flame envelope 13 , surrounds each oxygen containing gas stream for a portion of the distance from the lance to the top surface of bath 2 . The oxygen from the oxygen containing gas stream reacts with material in the bath to oxidize that material. In particular, the oxygen reacts with sulfur in the molten copper bath to form sulfur dioxide which then bubbles out from the bath and is removed from the refining vessel.
[0019] Preferably, such as is illustrated in the Figure, the molten bath is agitated through the injection of a gas 15 from below the surface of the bath through one or more injection devices 14 . Among the suitable gases which may be employed as mixing gas 15 one can name oxygen, nitrogen, argon, steam and mixtures thereof. The injection device 14 may be any suitable injection device such as a tuyere or a porous plug. The inert gas flows upward from the injection device in a bubble plume 16 and serves to mix the molten metal bath to counteract stratification and to enhance the efficiency of the refining operation.
[0020] The mixing gas which rises through the molten metal bath may form a continuous eye of freshly exposed bath material composed of solidified or semi-solidified material 17 on the surface of the bath above the injection device from which the mixing gas was provided into the bath. In a particularly preferred embodiment of the invention such as is illustrated in the Figure, one or more oxygen containing gas lances are positioned such that the oxygen containing gas stream from that lance is directed toward and impacts the agitated area of the bath such as at the eye. As a result of the bottom injected mixing gas, the coherent jet of oxygen containing gas is not required to penetrate deeply into the bath for improved contact and reaction with the bath and therefore can operate efficiently at low Mach number supply conditions.
[0021] Although the invention has been described in detail with reference to a certain preferred embodiment, those skilled in the art will recognize that there are other embodiments of the invention within the spirit and the scope of the claims. | A method for refining non-ferrous metal wherein a stream of oxygen containing gas is provided from a lance into the headspace of a refining vessel for passage to the molten metal bath within the refining vessel, and a flame envelope is provided around and along the oxygen containing gas stream for a portion of its length, wherein the flame envelope simultaneously serves to keep accretions from forming on the lance face and serves to maintain the oxygen-containing gas stream coherent. | 2 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates to a mount for a display screen. In particular the invention relates to a switch for operating a display screen mounted in a seat back and especially for use in automobile seat backs.
BACKGROUND TO THE INVENTION
[0002] It is known to mount display screens, such as audio visual display screens and touch screen displays to the rear of vehicle seats. These display screens can be mounted directly to the backrest, or headrest, of a vehicle seat, in a fixed fashion or in which a user (viewer) may adjust the viewing angle of the display by pushing or pulling the display screen about a rotational axis. In some vehicles, such as aircraft and other passenger carrying vehicles, it is known to mount a display screen to an interior surface of the vehicle such as the interior roof surface, and the display screen may be in a fixed position, or mounted such that it may be electrically stowed and rotated from the stowed position into a viewable position as and when required.
[0003] In certain vehicles, such as automobiles, it is preferred to mount the screen in a housing in the back of the seat, such that it is out of sight and protected by the housing. A particularly advantageous arrangement has the screen housed flat against the back of the seat, in a housing, from which it extends axially (upwards) out of the housing, into a viewing position. Especially, but not exclusively, in automobiles, where the position and orientation of the seat in which the screen is displayed is adjustable, it is useful to be able to adjust the viewing angle of the screen. US2009/0085383 discloses an example of such a mount, in which the display extends axially from a mount to a deployed position and is pivotally mounted from its top to the top of the support, so that the plane of the display is movable relative to the plane of the display support.
[0004] However, this example, whilst effective, suffers certain drawbacks, in particular; the necessity to push the display screen back into position flush with the support before retracting it; and the potential for the display screen to change its position in relation to the pivot and to shake or rattle. Furthermore, although a motorised mechanism is suggested for adjusting the viewing angles, no details are given concerning how this motorisation might work.
[0005] Embodiments of the present invention have been made in consideration of these problems, with a view to mitigating or alleviating them.
SUMMARY OF THE INVENTION
[0006] According to a first aspect of the invention, there is provided an electrically adjustable display screen mount, comprising a control mechanism operable by a user to select between a first automatic operation for stowing and deployment of the display screen, and a second, user adjustable operation for user adjustment of the deployed position of the display screen; wherein the first automatic deployment operation effects movement between the stowed position and the last used deployment position.
[0007] This can allow the initial deployment to be carried out at the press of a button, without holding on, whilst the fine adjustment of the angle can be carried out separately and movement to the last used deployment position is particularly convenient.
[0008] The control mechanism may be a switch mechanism, the switch having a deployment memory position in which activation of the switch activates the first automatic operation to effect movement between the stowed position and a last used deployment position.
[0009] The switch may have an adjustment mode position which activates the second user adjustable operation so that a user may adjust the deployment position of the display screen.
[0010] The adjustment mode position may include two separate functions, one which enables a user to adjust the deployment position of the screen in one direction and another in the opposite direction.
[0011] The deployment memory position may include two functions, one which is activated to deploy the display screen in a last used deployment position and the other which is activated to move the display screen to the stowed position.
[0012] The switch may comprise a stowing position, a detent corresponding to the adjustment mode position, and a deployment memory position.
[0013] The switch may be moved through the detent position into to the deployment memory position in order to deploy the display screen.
[0014] The switch may be moved to the detent position in order for a user to adjust the required deployment position of the display screen by way of the second user adjustable operation.
[0015] The detent may have two functions, a first function in which the detent position effects movement towards the display screen stowing position, and a second function in which the detent effects movement towards the deployment memory position.
[0016] The switch may be moveable in at least two directions, and the stowing position and deployment memory position of the switch may be effected by opposite movement of the switch.
[0017] The, user adjustable operation may enable rotation of the display screen up to 15°.
[0018] The switch may further comprise a neutral position, to which the switch is urged in absence of any user input.
[0019] The first automatic operation may cause the screen to move faster than the second user adjustable operation (to allow for fine adjustment).
[0020] A seat may be provided, comprising an electrically adjustable display screen mount as set out above, wherein user adjustment of the deployed position of the screen changes the viewing angle such that the base of a display screen mounted on the display screen mount moves longitudinally away from the back of the seat and/or the top of a display screen mounted on the display screen support moves longitudinally towards a headrest.
[0021] Movement of the base longitudinally away from the back of the seat, and/or movement of the top longitudinally towards a headrest may occur simultaneously with axial movement in the deployment direction. This means that in adjusting the angle, upward movement of the screen is accompanied by tilting of the screen such that the base moves towards the user and/or the top moves away from the user—this is particularly useful because when a seat is tilted backwards, its top will be lower and its angle will be towards the user of the screen. Accordingly, extension of the display screen mount results in angling the screen away from the user and lifting it higher, thereby compensating both for the angle and the height of the screen.
[0022] Movement of the adjustable display screen mount in the retraction direction may be associated with a corresponding movement of the base of the screen towards the back of the seat, and/or movement of the top of the screen away from the headrest.
[0023] The present invention also provides a seat comprising a display screen mount as set out above, mounted in the seat back, for viewing by a passenger in the seat behind. A vehicle comprising such a seat is also provided. The vehicle may be an automobile.
DETAILED DESCRIPTION OF THE INVENTION
[0024] In order that the invention may be more clearly understood, embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, of which:
[0025] FIG. 1 shows a cross sectional view of a seat including a display screen mounted on a display screen mount according to the invention, in a stowed position;
[0026] FIG. 2 shows a cross sectional view of the seat of FIG. 1 with the display screen mount in a deployed position, set at a forward tilt;
[0027] FIG. 3 shows a cross sectional view of the seat of FIGS. 1 and 2 with the display screen mount in a deployed position, set at a neutral tilt;
[0028] FIG. 4 shows a cross sectional view of the seat of FIGS. 1 to 3 with the display screen mount in a deployed position, set at a backward tilt;
[0029] FIG. 5 shows a cross sectional view of the seat of FIGS. 1 to 4 with the display screen mount in the deployed position showing backward, forward and neutral tilts;
[0030] FIG. 6 shows a rear view of the display screen of attached to the screen mount of FIGS. 1-5 ;
[0031] FIG. 7A illustrates a side view of a switch mechanism for the display screen mount of FIGS. 1-6 , in a neutral position;
[0032] FIG. 7B illustrates the switch mechanism in a deployment memory position;
[0033] FIG. 7C illustrates the switch mechanism in a reclining adjustment position; and FIG. 7D illustrates the switch in an inclining adjustment position.
[0034] With reference to FIGS. 1 to 5 , a seat 1 of an automobile (not shown) has a main body portion 2 , a headrest 3 and a housing 4 at the rear. The housing 4 has a slot 5 in its upper surface, through which a display screen 6 can move between a stowed position (shown in FIG. 1 ), within the housing 4 , to a deployed position outside the housing 4 (shown in FIGS. 2-5 ).
[0035] As shown in FIG. 6 , the display screen 6 is attached to a display screen support 7 e.g. by fastenings 8 , e.g. nuts/bolts. The display screen support 7 is pivotally mounted to a first slide 201 , via a hinge 9 and fixedly attached to a second slide 202 .
[0036] Referring once again to FIGS. 1-5 , the first slide 201 is slidably mounted at its lower end to a first track 203 e.g. by wheels (not shown), although with suitable materials/lubrication wheels may not be necessary. The first track 203 is linear and extends generally along the axis of the body of the seat 1 , parallel to the main plane of the housing 4 which defines the seat back.
[0037] The first slide 201 is drivably mounted, for example by a rack and pinion mechanism, or a spindle drive. Indeed, in an alternative embodiment, the first slide 201 could include a rack mechanism, or the spindle and the separate track 203 could be eliminated. Accordingly, when the first slide 201 is driven, it follows the linear path defined by the first track 203 . The first slide 201 could even, for example, be the rod of an (e.g. hydraulic) actuator (such as a ram), with the cylinder defining the first track 203 .
[0038] The second slide 202 is also slidably mounted (e.g. by wheels) at its lower end, this time to a second track 204 . The second track 204 is non-linear and is shaped to guide the display screen support 7 as it moves between the deployed and stowed positions. In its lower region, the non-linear second track 204 has a linear portion 205 . The linear portion 205 runs parallel to the linear path defined by the first track 203 .
[0039] In an upper region, best seen in FIGS. 2-4 , the second track 204 has a non-linear portion 206 , which deviates from the linear path defined by the linear portion 205 in the lower region; the non-linear portion 206 curves away from axis of the linear path, longitudinally, towards the housing 4 and away from the axis of the body 2 of the seat 1 . The non-linear portion 206 then straightens up to continue to define a straight path 207 , which will be followed by the slide 102 , upwards and away from the body 2 of the seat 1 . Although it is straight, the path 207 is considered to be non-linear as it does not continue the linear path defined by the linear portion 205 of the second track 204 in its lower region.
[0040] In use, to deploy the display screen 6 from the stowed position shown in FIG. 1 , an electric switch 60 (shown in FIGS. 7A to 7D ) is actuated. This causes the first slide 201 to be driven along the linear path defined by the first track 203 . The non-driven second slide 202 is thus caused to follow a linear path along the linear portion 205 of the non-linear second track 204 . This linear path is followed as the display screen 6 emerges from the slot 5 in the housing 4 .
[0041] Then, when the display screen 6 has almost entirely emerged from the slot, 5 the lower end of the second slide 202 , which is slidably connected to the second track 204 reaches the non-linear portion 206 . The first slide 201 continues to follow a linear motion, driving the display 6 upwards. However, the lower end of the second slide 202 follows a non-linear path, curving away from the axis of the body 2 of the seat 1 . Because the display support 7 is pivotally mounted to the first slide 201 and fixedly mounted to the second slide 202 , this movement causes the support 7 to it pivots about the hinge 9 , with the result that the base of the display support 7 (and the display 6 ) moves longitudinally away from the axis of the body 2 of the seat 1 . Correspondingly, the top of the display tilts towards the axis of the body 2 , and towards the headrest.
[0042] FIG. 2 shows the configuration of the display screen 6 and its mount when this tilting action has just begun, with the lower end having travelled round the curved region of the non-linear portion 206 onto the start of the straight path 207 . In this position, where the second slide has not travelled far along the straight path 207 making up part of the non-linear portion 206 , the display screen is almost parallel with the axis of the linear first track 203 . Since the axis of the body 2 of the seat 1 is leaning backwards, the top of the screen is tilted backwards with respect to the seat 1 , or at a forward tilt, with respect to the user.
[0043] As the first slide 201 is driven along the linear path defined by the first track 203 , the lower end of the second slide 202 continues up the straight path 207 in the non-linear portion 206 of the second track 204 , it eventually reaches the end of the path 207 at its uppermost and longitudinally furthest from the body 2 of the seat 1 (closest to the housing 4 ) as shown in FIG. 4 . At this point, the second slide 202 is at its greatest angle with respect to the first slide 201 and therefore, the display 6 is angled backward, with its top closest to the headrest and its base further from the axis of the body 2 of the seat 1 , towards the user.
[0044] In between the forward tilt shown in FIG. 2 and the backward tilt shown in FIG. 4 , when the first slide 201 is not fully extended, the second slide is positioned between the curved portion of the non-linear region 206 and the end of the straight path 207 . Accordingly, a neutral position can be defined, e.g. halfway along the straight path, in which the angle of the display is roughly in line with the axis of the headrest, and most likely to be at a suitable viewing angle to an average sized rear-seat passenger, if the seat 1 is occupied by an average sized occupant in an ordinary position (e.g. height and orientation of the seat body.
[0045] Backrests of seats are normally rotatably mounted at their base. Accordingly, leaning back the seat body 2 lowers the height of the slot 5 through which the display screen 6 exits the housing 4 . On the other hand, leaning forward towards a straight upright position raises the height of the slot.
[0046] The display screen 6 exits the slot in a plane parallel to the axis of the seat body 2 . Therefore, it too is leant backward with respect to the seat i.e. tilted forward with respect to the viewer. Accordingly, when the seat 1 is leant back, the user (viewer) is likely to wish to tilt the display screen 6 backwards (that is to say, to lean the top of the screen in the direction of the back of the screen, away from the viewer). This is achieved by extending the first slide 201 as far as possible, which also raises the height, therefore both bringing about the correct angle and adjusting towards a better height.
[0047] In use, a user wishing to deploy the screen 6 from the stowed position as shown in FIG. 1 , to a deployed position as shown in FIGS. 2 to 5 may manipulate a switch 60 as shown in FIGS. 7A-7D in order to activate the electric drive. At this point, the first slide 201 is driven upwards along the linear path defined by the first track 203 , which causes the second slide 202 to be driven along the second track 204 . As the slides 102 , 202 are moved along the tracks 203 , 205 , the display screen 6 is moved upwards and follows the path described above, as the second slide 202 reaches the non-linear portion of the second track 204 .
[0048] In a new installation of a seat 1 and display screen 6 in a vehicle, for example, the support 7 and hence display screen 6 may be provided with a default deployment memory position, this may be the neutral position as shown in FIG. 3 , in which it is expected that the seat 1 is upright and the height of the passenger behind the seat is such that the screen is at eye level. The position of the display screen 6 may not be optimal, especially if the body 2 of the seat 1 is moved to a different position, e.g an especially upright, or unusually laid back position, in which case, for an average height viewer, the orientation of the display screen 6 would need to be reclined towards the “forward tilt” and inclined towards the “backward tilt” positions shown in FIGS. 2 and 4 respectively.
[0049] As shown in FIGS. 7A-7D , the seat 1 , or another part of the vehicle (not shown), e.g. an armrest (not shown) is provided with a switch 60 which enables adjustment of the deployment position of the display 6 by a user. The switch 60 is a rocker switch having five positions 66 a , 66 b , 66 c , 66 d , 66 e , corresponding to the stowing position 66 a , a inclining detent 66 b , a neutral position 66 c , a reclining detent 66 d and a deployment memory position 66 e . The switch 60 is manipulated by a user, who can move the switch between all of the positions. In use the switch 60 is urged to the neutral position 66 c shown in FIG. 7A , unless a user manipulates the switch 60 . A user may move the switch 60 in one direction, through the reclining detent 66 d to the deployment memory position 66 e as shown in FIG. 7B . A user may also move the switch 60 through the inclining detent 66 b to the stowing position 66 a in the opposite direction. A user may also move the switch 60 to the reclining detent 66 d , as shown in FIG. 7C , in order to adjust the deployment position of the display 6 in one direction, and to the inclining detent 60 b , to move the display position in the opposite direction as shown in FIG. 7D . The deployment memory position 66 e , when activated, effects the default position of the deployment of display 6 as shown in FIG. 3 , and the stowing position 66 a when activated, effects the stowed position of display 6 as shown in FIG. 1 , the display being entirely situated beneath the slot 5 in the housing 4 of the seat 1 .
[0050] The inclining and reclining detents 66 b , 66 d between the stowing position and deployment memory position have respective functions, the reclining detent 66 d enables the user to adjust the position of the display 6 in a forward (and downward) direction towards user in the position shown in FIG. 2 , and the inclining detent 66 b enables a user to adjust the position of the display in a backward (and upward) direction towards the position shown in FIG. 4 away from the user. In use, a user may activate either detent 66 b , 66 d of the switch 60 , which activates the electric drive to drive the first slide 201 in the required direction, in order to adjust the position of the display screen 6 relative to the seat 9 and the user. When the required position has been achieved, a user may release the switch 60 which moves back to the neutral position 66 c , so that the display screen 6 remains in the desired position. At this point, suitable electronic means may store the data of the new display screen deployment position, and seat position as the new default deployment memory position. A user may then stow the display screen 6 when required, by moving the switch 60 to the stowing position 66 a . When the user next utilises the display screen 6 , moving the switch 60 to the deployment memory position 66 e will automatically move the display screen 6 to the last known deployment memory position and user may adjust the display screen 6 again as necessary.
[0051] When the switch is moved to the deployment memory position 66 e , or the stowing position 66 a , the display screen 6 is caused to move at a first, relatively fast, speed, on the other hand, when the switch is moved to the inclining detent 66 b , or the reclining detent 66 d , the display screen 6 is caused to move at a second, relatively slow, speed, in order to achieve fine adjustment.
[0052] The above embodiment is/embodiments are described by way of example only. Many variations are possible without departing from the scope of the invention as defined in the appended claims. | A switch mechanism actuates an electrically adjustable screen mount. The switch mechanism allows a user to select between a first automatic operation for stowing and deployment of the display screen ( 6 ), and a second, user adjustable operation for adjustment of the deployed position of the display screen ( 6 ), in order to tilt the screen back and forth. The adjustment back and forth may be accompanied by a movement upward or downward, with an upward movement when the top of the screen tilts away from the user, and downward movement when the top of the screen tilts towards the user. This can compensate for tilting of the surface to which the screen mount is attached, such as a seat-back. | 5 |
This application claims the benefit of and the priority of U.S. Provisional Application Serial No. 60/146,104, filed on Jul. 29, 1999, and is a continuing application of International application PCT/EP00/01892, with an international filing date of Mar. 3, 2000.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to novel microorganisms and to a novel biotechnological process for preparing or enriching N-acetylmannosamine using these microorganisms.
2. Background Art
N-Acetylmannosamine (hereinbelow referred to as NAM) is an important intermediate in the preparation of N-acetylneuraminic acid (hereinbelow referred to as NANA), which in turn is an important starting material for therapeutic agents (European Published Patent Application No. 0701623).
To date, a plurality of biotechnological process for preparing or enriching NAM are known. Spivak C. T. & Roseman S. (JACS, Volume 81, 1959, pp. 2403 to 2404) describe the enrichment of NAM using washed microorganisms of the species E. coli , which have been adapted such that they can grow using N-acetylglucosamine (hereinbelow referred to as NAG) as the sole carbon source. This process has the disadvantages that it is not feasible industrially, and that NAM is obtained in only moderate yield.
Kuboki et al., (Tetrahedron, Vol. 53, 1997, pp. 2387 to 2400), describes a process for enriching NAM using washed microorganisms of the species Rhodococcus rhodochrous, where NAM is enriched starting from a mixture comprising NAM and NAG in a ratio of 4.5:1 (82:18). In this process, too, NAM is enriched in an uneconomical, not industrially feasible, manner.
BRIEF DESCRIPTION OF THE INVENTION
The object of the present invention is to provide a microorganism and a biotechnological process for preparing or enriching NAM, where the desired product is enriched rapidly in a simple manner. This object is achieved with microorganisms which are in accordance with the present invention obtainable by selecting microorganisms using N-Ac-Glc rapidly as sole carbon source for growth and are stable and can metabolize N-Ac-Glc rapidly in the presence of N-Ac-Man and with a process employing said microorganisms for preparing N-Ac-Man by the microorganism of the invention and the process of the invention.
The microorganisms according to the invention can be isolated from soil samples, mud or wastewater with the aid of customary microbiological techniques. According to the invention, the microorganisms are isolated in such a manner that they are cultivated in a customary manner in a medium comprising NAG as the sole carbon source, and with a suitable nitrogen source. From the culture obtained by cultivation, those are selected which are stable and have the property to metabolize NAG rapidly in the presence of NAM.
The invention includes biologically pure cultures of the microorganisms of the invention.
Advantageously, the microorganisms selected in such a manner metabolize NAG in a concentration of 60 g/l in less than 30 hours.
A suitable nitrogen source which can be used by the microorganisms is, for example, ammonium.
The selection medium used can be the mineral salt media customarily used by persons skilled in the art, such as, the medium described in Table 1, the mineral salt medium according to Kulla et al., Arch. Microbiol. (1983), 135, 1 to 7, or buffers of low molarity comprising mineral salts/trace elements. Preference is given to using the medium described in Table 1 of Kulla et al, ibid. The buffer of low molarity used can, for example, be a phosphate buffer of low molarity.
The selection is generally carried out at a temperature of from 15° to 60° C., advantageously from 25° to 45° C., and at a pH between pH 4 and pH 9, advantageously between pH 6 and pH 8.
Preferred microorganisms are microorganisms of the genus Klebsiella, advantageously of the species Klebsiella pneumoniae having the designation KHA (DSM 12702) and KHA1 (DSM 12703) or their “functionally equivalent variants”. The microorganisms having the designation DSM 12702 and DSM 12703 were deposited with the Deutsche Sammiung von Mikroorganismen und Zellkultur GmbH, Mascheroderweg 1b, D-38124 Brunswick, in accordance with the Budapest Treaty, on Feb. 23, 1999.
DETAILED DESCRIPTION OF THE INVENTION
“Functionally equivalent variants” are to be understood as microorganisms which essentially have the same properties and functions as the original microorganisms. Such variants can be formed arbitrarily, for example, by UV irradiation or other mutagenesis techniques known to a person skilled in the art.
Taxonomic description of Klebsiella pneumoniae
with the name KHA (DSM 12702)
Cell form
Rods
Width, μm
0.8-1.0
Length, μm
1.2-2.5
Motility
−
Gram reaction
−
Lysis by 3% KOH
+
Aminopeptidase (Cerny)
+
Oxidase
−
Formation of acid from:
D-Glucose
+
D-Xylose
+
Erythritol
−
Adonitol
−
D-Mannose
+
Rhamnose
+
Inositol
+
Sucrose
+
α-Methyl-D-glucose
+
Inulin
−
Cellobiose
+
Maltose
+
Lactose
+
5-Ketogluconate
+
L-Sorbose
+
Dulcitol
+
β-Galactosidase
+
ADH (alcohol dehydrogenase)
−
LDC (lactate decarboxylase)
−
ODC (ornithine decarboxylase)
−
Voges Proskauer
+
Indol
−
Malonate utilization
+
H 2 S formation
−
Citrate utilization (Simmons)
+
Phenylalanine desaminase
−
Urease (3 d)
Hydrolysis of:
Gelatin
−
DNA
−
Tween 80
Taxonomic description of Klebsiella pneumoniae
with the name KHA 1 (DSM 12703)
Cell form
Rods
Width μm
0.8-1.0
Length μm
1.2-2.5
Motility
−
Gram reaction
−
Lysis by 3% KOH
+
Aminopeptidase (Cerny)
+
Oxidase
−
Catalase
+
Formation of acid from:
D-Glucose
+
D-Xylose
+
Erythritol
−
Adonitol
−
D-Mannose
+
Rhamnose
+
Inositol
+
Sucrose
+
α-Methyl-d-glucose
+
Inulin
+
Cellobiose
+
Maltose
+
Lactose
+
5-Ketogluconate
+
L-Sorbose
+
Dulcitol
−
β-Galactosidase
+
ADH (alcohol dehydrogenase)
−
LDC (lactate decarboxylase)
w
ODC (ornithine decarboxylase)
−
Voges Proskauer
+
Indol
−
Malonate utilization
+
H 2 S formation
−
Citrate utilization (Simmons)
+
Phenylalanine desaminase
−
Urease (3 d)
+
Hydrolysis of:
Gelatin
−
DNA
−
Tween 80
−
The process of according to the invention for preparing or enriching NAM is carried out such that, starting from an NAG/NAM mixture, NAG is metabolized by fermentation using the microorganisms according to the invention, NAM being enriched.
Advantageously, NAG is employed as a mixture comprising NAG and NAM in a ratio by weight of 1:1. This mixing ratio is preferably, according to R. Kuhn & G. Barschang (Liebigs Ann., 659, 1962, pp. 156 to 163), obtained by epimerizing the NAG, which was hydrolyzed from chitin, in a basic medium, resulting in a thermodynamical equilibrium of NAG to NAM of 4:1 parts by weight. This mixture is then enriched in accordance with the literature reference described above by selective removal of NAG, for example, by crystallization, so that a mixing ratio of NAM:NAG of 1:1 results.
In principle, the further enrichment according to the invention of NAM is possible using any NAG-metabolizing microorganisms which can be obtained by the selection method already described. In particular, the enrichment is carried out using the microorganisms of the genus Klebsiella, more preferably of the species Klebsiella pneumoniae. In a most preferred embodiment, the invention is carried out using strains of Klebsiella pneumoniae having the designation KHA (DSM 12702) or KHA1 (DSM 12703) or their “functionally equivalent variants”.
The enrichment of NAM is advantageously carried out directly by fermentation of the selected microorganisms on the NAG/NAM mixture (i.e., with growing cells under aerobic conditions), without removing and washing the microorganisms beforehand, for example, by centrifugation.
Suitable for use as fermentation media are the same media as those described above used for the selection, using the NAG/NAM mixture instead of NAG as the carbon source.
Advantageously, the metabolization of NAG is carried out such that the concentration is below 20 percent by weight, preferably below 10 percent by weight. In particular, the appropriate NAG/NAM mixture is added once, batch-wise (in a plurality of portions) or continuously. The pH of the medium can be in the range of from 5 to 9, preferably from 6 to 8. The metabolization is advantageously carried out at a temperature of from 20° to 50° C., preferably from 25 to 40° C.
After customary metabolization of less than 30 hours, the NAM enriched in this manner can be isolated by customary work-up methods, such as, by electrodialysis, filtration techniques and crystallization
EXAMPLE 1
Enrichment of Microorganisms Which Grow Using NAG
100 ml of mineral salt medium (cf. Table 1 below) containing 2 g/l of NAG was inoculated with 2 g of moist clarifier sludge and incubated in a 500 ml Erlenmeyer flask fitted with flow spoilers at 30° C. on a shaker table. 5 ml of this suspension was used to inoculate a further flask containing 100 ml of mineral salt medium and 2 g/l of NAG, and cultivation was carried out at 30° C. on a shaker table. After 3 days, a further passage was carried out. Individual colonies were obtained by plating out a dilution series and streaking out for purification purposes on agar plates of the enrichment medium described above (cultivated at 30° C.). In this manner, inter alia, the two strains KHA (DSM 12702) and KHA1 (DSM 12703) were isolated.
EXAMPLE 2
Selection of Microorganisms Which Grow Using NAG but not NAM as Sole Carbon Source
Microorganisms which grow using NAG as sole carbon source (for example from the enrichment according to Example 1) were spread out on agar plates containing mineral salt medium (cf. Table 1 below) and 5 g/l of NAG and mineral salt medium (cf. Table 1 below) and 5 g/l of NAM, respectively, and cultivated at 30° C. The microorganisms which grew rapidly on NAG plates but only very slowly, if at all, on NAM plates were selected. In this manner, inter alia, the two strains KHA (DSM 12702) and KHA1 (DSM 12703) were selected.
EXAMPLE 3
Selection for Rapid Growth in the Presence of Elevated NAG Concentrations
100 ml of mineral salt medium (cf. Table 1 below) containing 5 g/l, 10 g/l, 20 g/l and 40 g/l of NAG was inoculated from the agar plate (containing NAG in accordance with Ex. 2) and cultivated in a 500 ml Erlenmeyer flask fitted with flow spoilers at 30° C. on a shaker table. By monitoring the optical density, it was possible to examine the growth rate under the different conditions. Strains which grew very rapidly and in the presence of elevated NAG concentrations were selected.
Strain KHA
OD (650) after 18 h
OD (650) after 42 h
5 g/l NAG
4.2
4.5
10 g/l NAG
6.5
8.5
20 g/l NAG
8.2
13.8
40 g/l NAG
9.1
14.7
EXAMPLE 4
Preparation of an NAG/NAM Mixture in the Ratio 1:1
1 kg of NAG was dissolved in 3 1 of water, the pH was adjusted to >11 using 30 percent strength aqueous sodium hydroxide solution and the mixture was allowed to stand at 20° to 40° C. for 1 to 2 days until an NAG/NAM ratio of about 4:1 had been reached. The solution was neutralized using sulfuric acid and concentrated under reduced pressure to about 30 percent. 0.6 kg of NAG crystallized out and was filtered off and was able to be recycled into the same reaction. The filtrate (0.8-1 1) contained 0.4 kg of NAG/NAM in a ratio of 1:1 (according to GC analysis).
EXAMPLE 5
Selection for Rapid Growth in the Presence of Elevated NAM Concentrations or Simple Batch Process
2 l of the mineral salt medium (cf. Table 1 below) containing 40 g/l of an NAG/NAM mixture (1:1) was inoculated with 80 ml of a preculture of the strain KHA or KHA1 (grown overnight on mineral medium containing 5 g/l of NAG; OD>4) and fermented at pH 7, 30° C., with aeration and stirring. After 16 hours, the OD (650 nm) was 13.7 (strain KHA) and 15.5 (strain KHA1), respectively, and only traces of NAG, if any at all, were found in the medium, which did however contain NAM (GC analysis; NAG:NAM <5:95). Strains such as Klebsiella pneumoniae KHA (DSM 12702) and KHA1 (DSM 12703), which grew rapidly and selectively on NAG in the presence of NAM were selected.
EXAMPLE 6
Fed Batch Process
1.5 l of mineral salt medium (cf. Table 1 below) containing 40 g/l of an NAG/NAM mixture (1:1) was inoculated with 100 ml of a preculture of the strain KHA (grown overnight on mineral medium containing 10 g/l of NAH; OD>4) and fermented at pH 7, 30° C., with aeration (1.5 l of air/min) and stirring (500 rpm). After 14 hours, 360 ml of a 46 percent strength solution of NAG/NAM mixture (1:1) (total: 113 g of NAG, 113 g of NAM; corresponding in each case to 57 g/l) was added. After 29.5 hours, the OD (650 nm) was 38.5, and only traces of NAG, if any at all, were found in the medium, which did however contain NAM (GC analysis; NAG;NAM <5:95).
EXAMPLE 7
Fed Batch Process, NAG/NAM Mixture (2:1)
1.5 1 of mineral salt medium (cf. Table 1 below) containing 40 g/l of an NAG/NAM mixture (2:1) were inoculated with 100 ml of a preculture of the strain KHA1 (grown overnight on mineral medium containing 10 g/l of NAG; OD 0.4) and fermented at pH 7, 30° C., with aeration (1.5 1 of air/min) and stirring (500 rpm). After 16 hours, 240 ml of a 46 percent strength solution of an NAG/NAM mixture (2:1) was added (total: 114 g of NAG=60 g/l, 57 g of NAM=30 g/1). After 22.5 hours, the OD (650 nm) was 43.4, and only traces of NAG, if any at all, were found in the medium, which did however contain NAM (GC analysis; NAG:NAM<5:95).
TABLE 1
Mineral salt medium (pH 7.0)
2.0 g/l (NH 4 ) 2 SO 4 ,
2.0 g/l Na 2 HPO 4 ,
1.0 g/l KH 2 PO 4 ,
2.0 g/l NaCl,
0.4 g/l MgCl 2 × 6H 2 O,
14.5 mg/l CaCl 2 × 2H 2 O,
0.8 mg/l FeCl 3 × 6H 2 O,
0.1 mg/l ZnSO 4 × 7H 2 O,
0.09 mg/l MnCl 2 × 4H 2 O,
0.3 mg/l H 3 BO 4 ,
0.2 mg/l CoCl 2 × 6H 2 O,
0.01 mg/l CuCl 2 × 2H 2 O,
0.02 mg/l NiCl 2 × 6H 2 O,
0.03 mg/l NaMoO 4 × 2H 2 O,
5.0 mg/l EDTA × 2Na × 2H 2 O,
2.0 mg/l FeSO 4 × 7H 2 O. | Novel microorganisms, which can be obtained by the following selection method:
(a) microorganisms which grow using N-acetylglucosamine as the sole carbon source are cultivated in a customary manner,
(b) from the resulting culture, these microorganisms are then selected which are stable and have the property to metabolize N-acetylglucosamine rapidly in the presence of N-Acetylmannosamine.
Furthermore, a novel process for preparing NAM starting from a mixture of NAM and NAG. | 2 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. provisional application No. 62/280,159, filed 19 Jan. 2016, which is hereby incorporated by reference as though fully set forth herein.
BACKGROUND
[0002] The instant disclosure relates to catheters for use in medical procedures, such as electrophysiology studies. In particular, the instant disclosure relates to an atraumatic coupling that can be used to join two shafts of unequal size.
[0003] Catheters are used for an ever-growing number of procedures, such as diagnostic, therapeutic, and ablative procedures, to name just a few examples. Typically, the catheter is manipulated through the patient's vasculature and to the intended site, for example, a site within the patient's heart.
[0004] A typical electrophysiology catheter includes an elongate shaft and one or more electrodes on the distal end of the shaft. The electrodes may be used for ablation, diagnosis, or the like. Oftentimes, these electrodes are ring electrodes that extend about the entire circumference of the catheter shaft.
[0005] One specific use of an electrophysiology catheter is to map the atrial regions of the heart, and in particular the pulmonary veins, which are often origination points or foci of atrial fibrillation. Such electrophysiology mapping catheters typically have at least a partial loop shape at their distal end, oriented in a plane generally orthogonal to the longitudinal axis of the catheter shaft, which allows the loop to surround the pulmonary vein ostia.
[0006] Further, the more proximal and elongate region of the shaft often has a larger diameter than the more distal region (e.g., the portion formed into at least a partial loop). Thus, there is a need to transition from the larger diameter proximal shaft to the smaller diameter distal shaft.
BRIEF SUMMARY
[0007] Disclosed herein is a catheter including: a proximal shaft having a first diameter; a distal shaft having a second diameter different from the first diameter; and a coupling joining the proximal shaft to the distal shaft, the coupling having a hollow interior and including a distal portion and a proximal portion, wherein a proximal portion of the distal shaft is inserted into the hollow interior of the coupling through a distal end of the coupling and the proximal portion of the coupling is inserted into the proximal shaft through a distal end of the proximal shaft.
[0008] In embodiments, the catheter also includes a sensor having a hollow core disposed within a distal portion of the proximal shaft, wherein the proximal portion of the coupling is inserted into the hollow core of the sensor and the distal portion of the proximal shaft. The proximal portion of the coupling can include a first sub-portion having an outer diameter small enough to allow insertion into the hollow core of the sensor; and a second sub-portion having an outer diameter small enough for insertion into the distal portion of the proximal shaft, but too large for insertion into the hollow core of the sensor, wherein the second sub-portion is positioned distally of the first sub-portion.
[0009] According to aspects of the disclosure, an outer diameter of the coupling is smaller at the distal end of the coupling than at a point adjacent the distal end of the proximal shaft. For example, the distal portion of the coupling comprises can include dome shaped portion and/or a frustoconical portion.
[0010] According to other aspects of the disclosure, a maximum outer diameter of the proximal portion of the coupling is less than a maximum outer diameter of the distal portion of the coupling.
[0011] The hollow interior of the coupling can include an abutment surface for the proximal portion of the distal shaft, which stops the advancement of the distal shaft into the coupling at a desired depth. It is also contemplated that the coupling can cause the distal shaft to be positioned coaxially within the proximal shaft.
[0012] In embodiments, an exterior surface of the coupling includes a plurality of ribs. The coupling can also be made out of a clear polymeric material, for example to facilitate visualization of the distal shaft within the coupling.
[0013] The distal shaft can be formed into at least a partial loop. The radius of curvature of the loop can be fixed or variable.
[0014] Also disclosed herein is a method of manufacturing a catheter, including: providing a proximal shaft having a first diameter, a distal shaft having a second diameter different from the first diameter, and a coupling having a hollow interior; inserting a proximal portion of the distal shaft into the hollow interior of the coupling through a distal end of the coupling; inserting a proximal portion of the coupling into the proximal shaft through a distal end of the proximal shaft; securing the distal shaft to the coupling; and securing the proximal shaft to the coupling.
[0015] The hollow interior of the coupling can include an inner abutment surface, such that inserting a proximal portion of the distal shaft into the hollow interior of the coupling through a distal end of the coupling can include advancing the proximal portion of the distal shaft into the hollow interior of the coupling until a proximal end of the distal shaft abuts the inner abutment surface. Similarly, an exterior surface of the coupling can include an outer abutment surface, such that inserting a proximal portion of the coupling into the proximal shaft through a distal end of the proximal shaft can include advancing the proximal portion of the coupling into the proximal shaft until the distal end of the proximal shaft abuts the outer abutment surface.
[0016] According to aspects of the disclosure, the manufacturing method also includes: providing a sensor having a hollow core; inserting the proximal portion of the coupling into the hollow core of the sensor; and inserting the proximal portion of the coupling and the sensor into the proximal shaft through the distal end of the proximal shaft.
[0017] The distal shaft, coupling, and proximal shaft can be secured to each other, for example, using an ultraviolet curing adhesive.
[0018] In another aspect, the present disclosure provides an atraumatic coupling for securing a first shaft segment to a second shaft segment having a different outer diameter from the first shaft segment. The coupling includes: a proximal portion having an exterior surface, the exterior surface of the proximal portion including a plurality of ribs, and wherein an outer diameter of the proximal portion is not greater than an inner diameter of the first shaft segment; and a distal portion, the distal portion having an exterior surface that tapers from a point at which the proximal portion meets the distal portion to a distal tip of the distal portion, and wherein an outer diameter of the distal portion at the point at which the proximal portion meets the distal portion is about equal to an outer diameter of the first shaft segment, wherein at least the distal portion defines an interior cavity of the coupling, and wherein a diameter of the interior cavity of the coupling is not smaller than an outer diameter of the second shaft segment. It is contemplated that the coupling can include a clear polymeric material.
[0019] The foregoing and other aspects, features, details, utilities, and advantages of the present invention will be apparent from reading the following description and claims, and from reviewing the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIGS. 1 and 2 illustrate exemplary electrophysiology catheters.
[0021] FIG. 3 is a close up of a portion of an electrophysiology catheter according to some embodiments of the instant disclosure.
[0022] FIG. 4 depicts the assembly of a distal shaft, a proximal shaft, a coupling, and a sensor according to aspects of the disclosure.
[0023] FIG. 5A is a perspective view of an embodiment of a coupling as disclosed herein.
[0024] FIG. 5B is a cross-sectional view of the coupling of FIG. 5A .
[0025] FIG. 6 is a simplified cross-sectional assembly drawing of a distal shaft, a proximal shaft, a coupling, and a sensor as disclosed herein.
[0026] FIG. 7 is a cross-sectional view of another embodiment of a coupling as disclosed herein.
[0027] FIG. 8 is a perspective view of still another embodiment of a coupling as disclosed herein.
DETAILED DESCRIPTION
[0028] For the sake of illustration, certain embodiments of the disclosure will be explained herein with reference to an electrophysiology catheter utilized in cardiac electrophysiology studies. It should be understood, however, that the present teachings may be applied to good advantage in other contexts as well.
[0029] Referring now to the figures, FIGS. 1 and 2 depict two embodiments of an electrophysiology (“EP”) catheter 10 according to aspects of the present disclosure. EP catheter 10 includes catheter body 12 , which in turn includes a proximal shaft 14 , a distal shaft 16 , and a coupling 18 that joins proximal shaft 14 and distal shaft 16 as discussed herein. In some embodiments, catheter body 12 is tubular (e.g., it defines at least one lumen therethrough). It should also be understood that the relative lengths of proximal shaft 14 , distal shaft 16 , and coupling 18 as depicted in FIGS. 1 and 2 are merely illustrative and may vary without departing from the spirit and scope of the instant disclosure. Of course, the overall length of catheter body 12 should be long enough to reach the intended destination within the patient's body.
[0030] Catheter body 12 will typically be made of a biocompatible polymeric material, such as polytetrafluoroethylene (PTFE) tubing (e.g., TEFLON® brand tubing). Of course, other polymeric materials, such as fluorinated ethylene-propylene copolymer (FEP), perfluoroalkoxyethylene (PFA), poly(vinylidene fluoride), poly(ethylene-co-tetrafluoroethylene), and other fluoropolymers, may be utilized. Additional suitable materials for catheter body 12 include, without limitation, polyamide-based thermoplastic elastomers (namely poly(ether-block-amide), such as PEBAX®), polyester-based thermoplastic elastomers (e.g., HYTREL®), thermoplastic polyurethanes (e.g., PELLETHANE®, ESTANE®), ionic thermoplastic elastomers, functionalized thermoplastic olefins, and any combinations thereof. In general, suitable materials for catheter body 12 may also be selected from various thermoplastics, including, without limitation, polyamides, polyurethanes, polyesters, functionalized polyolefins, polycarbonate, polysulfones, polyimides, polyketones, liquid crystal polymers and any combination thereof. It is also contemplated that the durometer of catheter body 12 may vary along its length. In general, the basic construction of catheter body 12 will be familiar to those of ordinary skill in the art, and thus will not be discussed in further detail herein except to the extent necessary to understand the instant disclosure.
[0031] As seen in FIG. 3 , distal shaft 16 can be predisposed into at least a partial loop. This loop shape allows distal shaft 16 to conform to the shape, for example, of a pulmonary vein ostium. The partial loop may take a number of configurations, depending on the intended or desired use of EP catheter 10 , consistent with the present teachings. Therefore, it should be understood that the loop configuration depicted in FIG. 3 is merely illustrative.
[0032] FIG. 3 also illustrates that distal region 16 can include a plurality of electrodes 20 disposed thereon. Electrodes 20 may be ring electrodes or any other electrodes suitable for a particular application of EP catheter 10 . For example, where EP catheter 10 is intended for use in a contactless electrophysiology study, electrodes 20 may be configured as described in U.S. application Ser. No. 12/496,855, filed 2 Jul. 2009, which is hereby incorporated by reference as though fully set forth herein. Of course, in addition to serving sensing purposes (e.g., cardiac mapping and/or diagnosis), electrodes 20 may be employed for therapeutic purposes (e.g., cardiac ablation and/or pacing).
[0033] FIG. 3 further illustrates that the outer diameter of proximal shaft 14 differs from the outer diameter of distal shaft 16 . For example, the outer diameter of proximal shaft 14 can be 8 French (0.104 inches), while the outer diameter of distal shaft 16 can be 4 French (0.052 inches). Thus, coupling 18 secures proximal shaft 14 to distal shaft 16 while providing an atraumatic transition from the outer diameter of one to the outer diameter of the other as discussed in further detail below. This is also illustrated to good advantage in FIG. 4 .
[0034] Referring again to FIGS. 1 and 2 , a handle 22 is coupled to catheter body 12 . Handle 22 includes suitable actuators (e.g., actuator 24 a in FIG. 1 ; actuator 24 b in FIG. 2 ) to control the deflection of catheter body 12 , for example as described in U.S. Pat. No. 8,369,923, which is hereby incorporated by reference as though fully set forth herein. Various handles and their associated actuators for use in connection with electrophysiology catheters are known, and thus handle 22 will not be described in further detail herein.
[0035] Although in some embodiments, the radius of curvature of the loop of distal shaft 16 may be fixed, it is also contemplated that it may be adjustable, for example to conform to the varying sizes of pulmonary vein ostia of patients of different ages. This additional control may be provided, for example, via the use of an activation wire that is adapted to alter the radius of curvature of the loop of distal shaft 16 . One suitable material for such an activation wire is stainless steel, though other materials can be employed without departing from the spirit and scope of the instant disclosure.
[0036] In some embodiments, one end (e.g., the distal end) of the activation wire may be coupled to the tip of catheter body 12 (e.g., coupled to a distal-most tip electrode of electrodes 20 ), while the other end (e.g., the proximal end) of the activation wire may be coupled to an actuator (e.g., a thumb slider) on handle 22 . Thus, for example, sliding the thumb slider proximally can place the activation wire in tension, thereby altering the radius of curvature of the loop of distal shaft 16 .
[0037] Another exemplary mechanism for varying the radius of curvature of the loop of distal shaft 16 is described in U.S. Pat. No. 7,606,609, which is hereby incorporated by reference as though fully set forth herein.
[0038] A first embodiment of coupling 18 is depicted in perspective view in FIG. 5A and in cross-section in FIG. 5B . As shown in FIGS. 5A and 5B , coupling 18 includes a hollow interior 28 . As used herein, the term “hollow interior” means that there is at least one cavity within the interior; the term “hollow core” is used synonymously in this disclosure. Although this cavity is depicted in FIGS. 5A and 5B as extending throughout the entire length of coupling 18 with a substantially constant diameter, the term “hollow” is not intended to be so limited. Thus, the diameter of the cavity can vary along the length of coupling 18 and still be considered “hollow” within the meaning of the instant disclosure.
[0039] Coupling 18 includes a distal portion 30 and a proximal portion 32 . As shown in the simplified assembly drawing of FIG. 6 , distal portion 30 of coupling 18 receives distal shaft 16 (e.g., the proximal portion 34 of distal shaft 16 is inserted into hollow interior 28 of coupling 18 through the distal end 36 of coupling 18 ). Similarly, proximal portion 32 of coupling 18 is received into proximal shaft 14 (e.g., proximal portion 32 of coupling 18 is inserted into proximal shaft 14 through the distal end 38 of proximal shaft 14 ).
[0040] FIGS. 5A, 5B, and 6 also illustrate that the outer diameter of coupling 18 changes along its length. In particular, the outer diameter of coupling 18 is narrower at its distal end 36 than it is at a point adjacent distal end 38 of proximal shaft 14 . That is, distal portion 30 of coupling 18 tapers towards its distal end 36 and can, in embodiments, include a dome-shape as shown in FIGS. 5A, 5B, and 6 . In other embodiments, such as shown in FIG. 7 , distal portion 30 of coupling 18 can include a frustoconical shape.
[0041] According to aspects of the disclosure, the maximum outer diameter of proximal portion 32 of coupling 18 is less than the maximum outer diameter of distal portion 30 of coupling 18 . It is further contemplated that the outer diameter of the distal portion 30 of coupling 18 where distal portion 30 meets proximal portion 32 (e.g., a point adjacent distal end 38 of proximal shaft 14 when catheter 10 is assembled) is about equal to the outer diameter of proximal shaft 14 in order to facilitate a smooth transition to proximal shaft 14 . Thus, for example, if proximal shaft 14 has an 8 French outer diameter, then the outer diameter of coupling 18 where distal portion 30 thereof transitions to proximal portion thereof can also be about 8 French. There can, however, be about an 8% difference in these outer diameters without adversely affecting the smooth and atraumatic transition provided by the combination of the tapering shape of distal portion 30 and the relative diameters of distal portion 30 , proximal portion 32 , and proximal shaft 14 (e.g., as shown in FIG. 4 ).
[0042] As shown in FIGS. 6 and 7 , proximal portion 32 of coupling 18 can include an abutment surface 40 . Abutment surface 40 stops the advancement of distal shaft 16 into hollow interior 28 of coupling 18 . That is, distal shaft 16 is advanced into hollow interior 28 of coupling 18 until the proximal portion 34 of distal shaft 16 abuts the abutment surface 40 (see FIG. 6 ).
[0043] The exterior surface of proximal portion 32 of coupling 18 can also include one or more ribs 42 . Ribs 42 can increase the bondability between coupling 18 and proximal shaft 14 , for example by creating a mechanical lock with the adhesive used to attach coupling 18 to proximal shaft 14 .
[0044] FIG. 8 depicts an additional embodiment of coupling 18 that is configured to facilitate the positioning of an additional sensor 44 (shown in FIGS. 4 and 6 ) along catheter body 12 . In the embodiment of coupling 18 depicted in FIG. 8 , proximal portion 32 of coupling 18 includes a first sub-portion 46 and a second sub-portion 48 . First sub-portion 46 has an outer diameter small enough for insertion into a hollow core of sensor 44 such that, for example, sensor 44 is advanced until it abuts surface 50 at the transition between first and second sub-portions 46 , 48 (which can be the opposite side of abutment surface 40 against which distal shaft 16 abuts).
[0045] Second sub-portion 48 , which is distal of first sub-portion 46 , has an outer diameter small enough for insertion into proximal shaft 14 , but too large for insertion into the hollow core of sensor 44 . Second sub-portion 48 (and thus proximal portion 32 ) ends at surface 52 , which restricts the advancement of coupling 18 into proximal shaft 14 during assembly.
[0046] Alternatively, coupling 18 can also serve as a datum for positioning one or more sensors 44 without having coupling 18 inserted therein.
[0047] In embodiments, coupling 18 can be made of a clear polymeric material. The use of a clear polymeric material enables the use of an ultraviolet curing adhesive to join coupling 18 to distal shaft 16 . It also facilitates visual confirmation that distal shaft 16 is properly positioned within coupling 18 . Of course, in other embodiments, coupling 18 can be translucent or opaque.
[0048] Assembly of catheter body 12 can be understood with reference to FIG. 6 . Distal shaft 16 is inserted into hollow interior 28 of coupling 18 through the distal end 36 of coupling 18 until proximal portion 34 of distal shaft 16 reaches the abutment surface 40 within proximal portion 32 of coupling 18 .
[0049] Optionally, a hollow core sensor 44 can be fit over first sub-portion 46 of proximal portion 32 of coupling 18 , for example until sensor 44 abuts surface 50 . Proximal portion 32 of coupling 18 (and sensor 44 , if present) can then be inserted into proximal shaft 14 through distal end 38 of proximal shaft 14 , for example until distal end 38 of proximal shaft 14 abuts surface 52 .
[0050] Advantageously, coupling 18 facilitates coaxial alignment between proximal shaft 14 , sensor 44 (if present), and distal shaft 16 . Once the desired alignment is achieved, the various components can be secured to one another, for example via the use of an ultraviolet curing adhesive.
[0051] Although several embodiments of this invention have been described above with a certain degree of particularity, those skilled in the art could make numerous alterations to the disclosed embodiments without departing from the spirit or scope of this invention.
[0052] For example, although certain exemplary embodiments have been described above with reference to a unitary coupling 18 , it is contemplated that coupling 18 can also include multiple constituent parts that are mated together during assembly of catheter 10 .
[0053] All directional references (e.g., upper, lower, upward, downward, left, right, leftward, rightward, top, bottom, above, below, vertical, horizontal, clockwise, and counterclockwise) are only used for identification purposes to aid the reader's understanding of the present invention, and do not create limitations, particularly as to the position, orientation, or use of the invention. Joinder references (e.g., attached, coupled, connected, and the like) are to be construed broadly and may include intermediate members between a connection of elements and relative movement between elements. As such, joinder references do not necessarily infer that two elements are directly connected and in fixed relation to each other.
[0054] It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not limiting. Changes in detail or structure may be made without departing from the spirit of the invention as defined in the appended claims. | A catheter includes a proximal shaft and a distal shaft having differing diameters; often, the distal shaft will have a smaller diameter than the proximal shaft. A coupling joins the distal shaft to the proximal shaft. For example, a proximal portion of the distal shaft can be inserted into the coupling through its distal end, while the proximal portion of the coupling can be inserted into the proximal shaft through its distal end. To provide an atraumatic transition from the distal shaft to the proximal shaft, coupling can taper towards its distal end, for example by using a dome- or frustoconical-shape for the distal portion of the coupling. The exterior of the coupling can be ribbed to facilitate bonding to the proximal shaft. The distal shaft can be formed into at least a partial loop having a fixed or variable radius of curvature. | 0 |
BACKGROUND OF THE INVENTION
The invention relates to supports for elevated floors, and in particular to adjustable pedestal supports for such floors.
PRIOR ART
Elevated floors are widely used in commercial building applications where utilities, communication lines, air ducts, and like services are extensive and frequently altered, supplemented, or repaired. In practice, it is usually difficult and prohibitively expensive to construct a subfloor which is exactly level. It has heretofore become customary to support individual panels, collectively making up the elevated floor, with pedestals separately adjustable in length so that each pedestal may be adjusted to accommodate any variations in the actual level of a local area of a subfloor from a nominal level.
A prevalent general type of pedestal design operates on the principle of a screw jack by employing an externally threaded bar or tube telescoped within an outer tube, and an internally threaded nut on or abutting an end of the outer tube. Examples of this type of pedestal are represented in U.S. Pat. Nos. 3,279,134; 3,616,584; and 3,811,237. The forming of threads on the elements of such prior art devices represents a significant portion of their cost and, consequently, limits potential cost reductions. Initial assembly of the threaded pedestal elements, further, involves manipulative steps of alignment, registration, and relative turning of various elements, each step requiring labor. Moreover, where height adjustments through a substantial range must be made during set-up in the field, manipulation of the threaded elements may be both time consuming and tedious.
SUMMARY OF THE INVENTION
The invention provides an adjustable pedestal for supporting elevated floors which employs a movable wedge element for selective height adjustment. The horizontal position of the wedge element determines the height of an upper platform of the pedestal above its base. As disclosed, the wedge vertically supports the platform and is automatically locked in a selected position in response to a downward force as applied on it by the platform. The self-locking action of the pedestal assembly is developed by confining a lower area of the wedge in a locking taper zone formed by elements of the pedestal base. The locking taper zone generates gripping forces, which are generally transverse to the plane of the wedge and which are capable of resisting forces tending to cam the wedge away from its selected position. The gripping action of the locking taper is augmented by a knurled or toothed surface integrally formed on the base, which is adapted to bite or cut into the body of the wedge and lock against slippage.
The pedestal assembly, constructed in accordance with the invention, owing to reductions in the number and complexity of parts, is significantly more economical to manufacture than are known prior art devices. Since a floor installation ordinarily requires a substantial number of pedestals, unit cost savings in manufacture is multiplied and results in a relatively low-per-square-foot installation cost.
The disclosed pedestal unit is readily assembled with few and simple manipulative steps. Adjustment in the field to suit local floor conditions is accomplished in a straightforward and time-saving manner requiring manual positioning of the wedge by simply sliding it over the base along a straight line.
These and other features and advantages of the invention will be apparent from the following disclosure of a preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, schematic view of an area of an elevated floor employing a plurality of pedestals embodying the principles of the invention;
FIG. 2 is an elevational, exploded view of the pedestal of the invention;
FIG. 3 is a plan view of the pedestal assembly, with portions of an upper platform thereof broken away to reveal constructional details of its base;
FIG. 4 is an elevational view of the pedestal in assembled condition, partially in section, and indicating variations of height adjustment in phantom;
FIG. 5 is a cross sectional view of the pedestal assembly taken along the line 5--5 of FIG. 4; and
FIG. 6 is an enlarged fragmentary view of an area of contact between wedge and base elements of the pedestal.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawing, there is illustrated in FIG. 1 the corner area of an elevated floor installation 10 comprising a plurality of abutting square or rectangular panels 11 vertically supported at their corners by a plurality of pedestal assemblies 12. As shown, the pedestals 12 are arranged on a base or subfloor 13 in a rectangular matrix or gridlike pattern along joint lines 14 between the panels 11. In accordance with conventional practice, with the exception of pedestals immediately adjacent vertical walls 15, each pedestal 12 supports the corners of four panels 11.
An individual pedestal 12 comprises a base 18, a platform 19, and a wedge 20, each preferably fabricated of steel. The base 18 includes a generally square or rectangular lower plate 21 and an upstanding, round tube 22, perpendicular to the base plate. The base plate 21 is a generally planar body stamped from sheet metal stock, with embossed peripheral stiffening ribs 23 and diagonal ribs 24 and 25. The upper surface of one diagonal rib 24, which is continuous from one corner of the plate to an opposite corner, is provided with a series of discontinuities or teeth 27, like that of a knurl. The teeth or discontinuities 24, each formed crosswise of the longitudinal direction of the ribs, are provided along the full length of the rib. Each of the ribs 23 through 25, including the knurled rib 24, has an arcuate or U-shaped cross section. The rib 25 perpendicular to the knurled rib 24 is interrupted adjacent the center of the plate 21 so as not to interfere with the tube 22. The base tube 22 is projection welded or otherwise fixed to the base plate 21 substantially at its geometric center. A pair of slots 31 in the lower end of the tube 22 extend upwardly from a lower end face of the tube. The slots 31 are of substantially the same width and length and are aligned along the diagonal knurled rib 24.
The platform 19 includes a carrier plate 36 and a depending round tube 27. As shown, the carrier plate 36 includes a set of four coplanar surface areas 38. The surface areas 38 are separated and stiffened by generally flat depressions 39 embossed in the plate 36 in the form of a cross. Tapped holes 41 are provided for attachment of stringers (not shown) between pedestals, when desired, in accordance with conventional practice. Projections 42 stamped in the plate 36 are indexable with recesses in the underside of the panels 11 at their respective corners.
An upper end face 43 of the tube is projection-welded or otherwise fixed to the underside of the carrier plate 36 substantially at its geometric center. The diameter of this upper depending tube 37 is slightly smaller than the minimum inside diameter of the lower base tube 22, allowing it to telescope therein and vertically align the carrier plate 36 to the base 18. At a lower end face 44, the upper tube 37 is formed with diametrally opposite notches or slots 46 and 47 of unequal lengths corresponding to the profile of the wedge 20. The notches 46 and 47 are oriented diagonally with respect to the carrier plate 36 so that when aligned with the slots 31 of the lower tube 22, the carrier plate, as viewed from above, is in angular registration with the base plate 21.
The illustrated wedge 20 is stamped or otherwise fabricated of sheet metal stock into a body having a generally triangular profile and a U-shaped or channel-like cross section comprised of spaced, parallel sidewalls 48 and a rounded camming edge 49. The major length of the camming edge 49 is inclined in the illustrated example at an angle of approximately 20° with respect to the lower, normally horizontal sidewall edges 51. As shown, the upper tube notches 46 and 47 are rounded at their inner or base areas in a manner complementary to the camming edge 49 to distribute contact forces between these areas.
As is self-evident from the above description, assembly of the pedestal 12 simply requires the upper tube 37 to be telescoped into the base tube 22, with the respective slots 31, 46, and 47 aligned with one another. The wedge 20 is first inserted into the lower base tube 22 from the side associated with the relatively longer notch 46 of the upper tube. As suggested in FIG. 4, simple horizontal positioning of the wedge 20 on the base 18 along the diagonal knurled rib 24 determines the height of the carrier plate 36 above the base plate 21. More specifically, as the wedge 20 is moved to the left a relatively higher portion of the camming edge or surface 49 is effective to support the upper platform tube 37. By adjusting the length of an individual pedestal 12 in this suggested manner, variations in the grade of local areas of the subfloor 13 are eliminated in the level of the elevated panels 11.
Once the desired position of the wedge 20, and therefore the carrier plate 36, has been selected, these elements are self-locking in their position. With particular reference to FIG. 6, the lower sidewall edges 51 of the wedge 20 are confined and gripped in tapered zones defined at each wedge sidewall 48 by the lower side areas of the tube slots 31 and adjacent opposed areas of the knurled rib 24. As shown, these areas each decrease in width in a downward direction to a dimension somewhat less than the width of the sidewalls 48. A downward force imposed on the wedge 20 by the platform through the upper tube 37 causes the wedge to be frictionally locked at its selected position by contact reaction forces directed laterally against the sidewalls 48, i.e., in a direction generally perpendicular to the line of movement which the wedge 20 might otherwise take along the knurled rib 24. Frictional locking of the wedge 20 is augmented by provision of the knurl or teeth 27 along the rib 24. Preferably, these teeth 27 are relatively sharp and the hardness of the wedge edges 51 are somewhat softer than the teeth, so that the edges are adapted to be cut or otherwise permanently locally deformed by the teeth, whereby these areas are mechanically interlocked against relative movement along the rib.
While the invention has been described in connection with specific embodiments 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 pedestal assembly for supporting elevated floors having means for adjusting its height in the form of a generally triangular wedge. The wedge is horizontally displaceable on the assembly to cam an upper carrier element of the assembly into a desired elevation. The assembly is provided with self-locking means to maintain the wedge and carrier elements in their selected positions. The self-locking means comprises a taper lock and supplementary locking teeth operative on the wedge in response to loading applied thereto through the carrier element. | 4 |
BACKGROUND OF THE INVENTION
a. The Field of the Invention
This invention relates to an apparatus for washing fabrics and more particularly to an apparatus for continuously, uniformly and thoroughly washing continuous pieces of fabrics, particularly knitted fabrics and the like, which are lengthwise admitted into a plurality of washing tanks while being maintained transversally spread for its full width. The apparatus washes the fabric by maintaining it in a completely immersed and tensionless or "relaxed" condition in a washing liquid bath.
B. The prior Art
This art is a known and well worked one. An apparatus which has been proven to provide satisfactory washing and treatment of continuous pieces of fabric has been described in the U.S. Pat. No. 3,646,785, corresponding to the British Pat. Specification No. 1,317,938. This prior art apparatus is provided with a plurality of washing tanks in which the continuous fabric is sequentially guided by progressed by means of pluralities of rollers including washing rollers and fabric widening rollers. The washing rollers are hollow and apertured for issuing washing liquid through their outer surfaces for full impregnation with the fabric. The widening rollers each have a helically ribbed surface so arranged that opposite sideward pulls are applied to the fabric when rotated adjacently thereto.
As set forth in the above-mentioned patent disclosures, the characteristic texture of a knitted fabric, such as those widely mass-produced by circular knitting machines and widely made use of, for example, for ladies' garments, is such that it is not adapted to resist tensions. It is subject to elongation in any direction in which a pull is exerted thereon. Additionally, such knitted fabrics are subject to curl or roll-up, particularly when wet, from the edges towards the center portion of the piece of fabric. On the other hand, such fabrics can be, and generally are, ornamented by printing processes and require a very careful final treatment, principally a so-called "finishing" treatment including a plurality of preliminary and of forced final immersion washing steps. The combined action of the washing and widening rollers of the prior art apparatus described above which are positioned beneath the level of the liquid baths that are maintained and recycled into washing tanks, has been proven capable of ensuring a generally satisfactory treatment for the fabtric, especially when the same was maintained well open and fully spread and slightly tensioned in the longitudinal and/or transversal directions.
It has, however, been found that a more satisfactory washing will occur if the washing treatment includes at least one step in which the fabric is maintained immersed in a completely tensionless condition, the condition being generally termed in the art as a "relaxed condition". Such a relaxed condition has heretofore been believed to be unfeasible in the operation of a continuously-run apparatus which has roller means that are designed for continuously pulling the fabric along and through the apparatus.
Further, it has been found that after a length of fabric, in particular a knitted fabric, is immersed into and progressed along a liquid path in a tensionless condition that the proper alignment of the fabric along the predetermined path lying in the longitudinal vertical plane of symmetry of the apparatus will be seriously affected by unpredictable and uncontrollable sideward displacements of relaxed portions of the length of the fabric.
It is, therefore, a principal object of this invention to provide a new and improved apparatus for the final immersion washing of continuous lengths of fabrics, including certain new and advantageous means and devices, and combinations and arrangements of said means and devices, as set forth hereinbelow, by which a proper and efficient washing treatment can be performed in the apparatus, the treatment including the washing of the fabric in relaxed condition and the re-alignment of the fabric in its proper path, if and when a misalignment occurs.
SUMMARY OF THE INVENTION
According to the invention, there is provided an immersion washing apparatus including a plurality of sequentially arranged washing tanks and roller means for continuously and guidingly progressing a continuous length of fabric from one to the others of said tanks, said roller means including widening rollers means having helical ribs capable of exerting oppositely sidewardly-directed pulls on either side portion of the fabric contacting said roller. The apparatus comprises at least one of said washing tanks, a rotary drum having vanes extending radially thereof and forming therebetween spaces wherein successive portions of the fabric length can be entrapped, maintained in relaxed condition and immersed into and carried out of the liquid bath in said tank in said relaxed condition. The widening rollers means includes at least a composite widening roller, located downstream of said one tank, including co-axially symmetrically helically-ribbed half roller side parts each individually connected to separately controlled sources of rotary motion. Moreover, sensor means are positioned to sense the actual position of the fabric relative to the predetermined plane of symmetry of the apparatus, said sensor means providing and applying a signal to said sources of rotary motion for selectively accelerating the roller side part toward which an extra lateral pull is to be exerted on the fabric for counteracting a misalignment detected by said sensor means relative to said plane of symmetry.
These and other features and advantages of the invention will be best apparent from the following detailed description of a preferred embodiment thereof, taken in conjunction with the accompanying drawings, wherein the essential components of the new apparatus have been diagrammatically illustrated. The various structural details and complemental means and devices which individually are known in the art have been omitted for simplicity.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a broken-away sectional view of the apparatus, taken in its longitudinal vertical plane of symmetry;
FIG. 2 is a broken-away view which illustrates in enlarged scale and in somewhat greater detail a part of a tank wherein the fabric is immersion washed in tensionless condition;
FIG. 3 is a fragmentary view of a fabric lateral misalignment sensing and correcting device, as seen on a plane containing the progressing fabric;
FIG. 4 is a sectional vertical view of a complete washing unit wherein the fabric is immersion washed in relaxed condition;
FIGS. 5A and 5B are fragmentary transversal sectional views, with some components in side view, of the unit of FIG. 4; and
FIG. 6 is a transversal vertical sectional view of a final drying unit, also illustrated in FIG. 1, with which the apparatus is advantageously complemented.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1, there is shown the critical minimal combination of units which are necesssary for performing a complete final treatment of the kind considered above, in an apparatus according to the invention, for immersion washing of continuous lengths of fabrics. Such units comprise at least one preliminary washing unit 10; at least one unit 12 for immersion washing the fabric in relaxed condition, wherein the fabric can be considered as relatively "stationary" in the liquid bath (it will be understood that the fabric is not stationary in unit 12, but is described as relatively stationary in consideration of the relatively long amount of time that the fabric is present in the bath due to the very slow advancement of the fabric in the unit 12); at least one unit 14 of "forced" washing, wherein the liquid is forced through the fabric; and a drying unit or plant 16. Downstream of each washing unit, such as units 10, 12 and 14, a fabric progressing mechanism 18', is provided. Such mechanisms 18', comprise, according to the current art, pairs of fabric driving rollers, squeezing rollers and suitable means for transferring the fabric from the upstream to the downstream unit.
Of course, in the actual manufacture of the apparatus, and according to the specific requirements of the processing of the fabrics, the apparatus can well include two or more of the above-described series of units 10-18.
According to the invention, at least one progressing mechanism 18, including the mechanism indicated at 18' downstream of the unit 12 where the fabric is washed in relaxed condition (that is, in a condition where the fabric is most subject to misalignment since it is not being retained by tension-applying means), is provided with a misalignment-correcting device, which will be described below in detail with reference to FIG. 3.
The preliminary washing unit (or units) 10 is preferably provided with three rotary drums 20 conventionally provided with a wire net cylindrical surface through which pressurized water can be outwardly sprayed by suitable spray-nozzles (not shown).
The unit (or units) 12 enbody a substantial improvement over the prior art. As shown in FIGS. 1, 2, 4, 5A and 5B, the unit 12 comprises a tank 22 wherein the washing bath liquid is maintained at a level such as indicated at L. A drum 24 is rotatably supported in the tank 22 and is about half-way immersed in the liquid. A plurality of radial vanes 26 are secured to and radially extend from said drum. Toothed wheels 28 are co-axially secured at both axial ends of the drum 24, and the diameter of said wheels is slightly greater than that defined by the outer edges of the vanes 26. Sprocket chains 30 engage the lower half of toothed wheels 28 and are arranged to revolve in U-shaped closed loops by pinions 32 (FIGS. 2 and 4) which are well above the level L. Vanes or planks 34 are secured to said chains 30 in a predetermined spacing and phase relationship along the elongation thereof so that, when such chains remove about the wheels 28, said planks will assume a plurality of end-to-end adjacent and co-planar positions with the radial vanes 26. As shown in FIGS. 2 and 4, the vanes 26, when rotated to a horizontal position, cooperate and register with the respectively adjacent and co-planar planks 34 in order to form a planar horizontal support surface. Similarly, the pairs of co-planar vanes 26 and planks 34 form, about the lower half of the drum 24, essentially closed spaces even while the drum 24 continues to rotate.
As shown in FIG. 1, the fabric is fed from above upon one of such formed support surfaces and laid thereover in lapping fashion, by means of a conventional lapping device 36 (or by means of a pair of rollers 50, FIG. 4, mechanically reciprocated in the directions indicated by the illustrated small arrows), until a proper amount 38 of the fabric is folded and collected. The drum 24 is inter-mittently driven by a suitable source of power (not shown and easily conceivable by those skilled in the art) so that the successively formed amounts 38 of fabric are first immersed below the level L, and then slowly and in steps carried below the drum where it is thus immersion washed in a completely tensionless condition. Consequently, the fabric is maintained immersed in the bath for an extended holding time, neither pressed nor tensioned, thereby resulting in a proper and continuous immersion washing.
The washing liquid is preferably continuously re-cycled by means such as those shown in FIG. 5A. Apertured tubes 40, located within the drum 24, which is also apertured or formed by a wire network, are connected by a duct 46 to the inlet of a pump 42 that is driven by a motor 44. The outlet of the pump 42 is connected by a duct 48 to apertured pairs of pipes 50 and 52 (FIG. 4) so that the re-cycled liquid falls on the incoming and the outgoing delivered fabric. The pair of pipes 50 can form the reciprocating-folding or distributing pair of rollers or a stationary pair of rollers for overlapping the fabric being fed into the unit.
As the fabric exits from any washing unit, it is squeezed between conventional pairs of squeezing rollers (diagrammatically shown in FIG. 1). The squeezed-off liquid is collected by hopper means, one of which is indicated at 54 in FIGS. 4, 5A and 5B.
The relatively long holding or washing time in tensionless condition of the fabric in the unit 12 leads to a somewhat lateral displacement and disorder of the fabric. Therefore, at least the mechanism 18' downstream of unit 12 is provided with the device shown in FIGS. 2 and 3. A widening roller, such as the roller engaging the fabric T issuing from below, consists of two co-axial half-rollers 60 and 62 having oppositely coiled helical ribs (the operation of such widening rollers having been described in the above-described prior U.S. and British patent publications), each adapted to exert a transverse pull on the fabric. The half rollers are individually driven by separate motors 64 and 66 respectively. Assuming that these half rollers are concurrently driven at the same speed, they will jointly act to operate as a widening roller.
At a proper location, such as downstream of a pair of squeezing rollers 56 and of a tensioning dancer roller 58 (such devices are known and therefore are not described in detail herein) sensor means 68 and 70 are each located on opposite sides of one of the edges of the fabric T. In FIG. 3, the sensor means 68 and 70 have their opposing sensor positions on the right side of the fabric although they can equivalently be provided on the left side of the fabric. Each sensor means can comprise, for example, a photocell sensor portion and a source of light sensor portion which is adapted for exciting the photocell, such as is diagrammatically illustrated at 68' and 68" in FIG. 2. The sensor means are so positioned, that when the fabric T is properly aligned in the apparatus, the sensor 70 "feels" the fabric while the sensor 68 does not.
As shown in FIG. 3, if the fabric were misaligned towards the right, the sensor 68 will sense the presence of the fabric, while a leftward misalignment will cause the sensor 70 to no longer sense the presence of the fabric. The sensor means 67, 70 are connected by suitable conventional circuitries the power sources of motors 64 and 66 so that a signal provided by such means, indicating the occurrence of a misalignment, will cause the half roller 60 or 62, which applies the transverse pull to the fabric T, in the direction necessary to compensate such misalignment, to accelerate and thus to center the fabric. This action will be discontined as soon as the sensors will sense the proper normal position of the fabric. Of course, such sensor means can be of other different types of constructions. For example, a pair of rollers may be used to contact the opposite sides of the fabric, or a pair of pneumatic sensors including a nozzle which issues a jet of air against the fabric may be utilized. The signal, in both cases, is provided by the difference of pressure resulting from the fact that the roller or jet impinges or not upon the fabric, and so on. The sensor means, as before, generate the signals in order to actuate the proper motor.
The apparatus is preferably complemented by a drying unit such as generally indicated at 16 in FIG. 1, some details of which are shown in FIG. 6. Such a drying unit comprises a plurality of drums 72 about which the fabric is carried while being dried. The fabric is admitted into the unit 16 over a bed of rollers 74 and is driven by a progressing roller 76, from which it is laid in tensionless condition over a conveyor belt 78 in the upper portion of the chamber 80 of the dryer. The drums 72 are nearly completely encased within shaped boxes 82 and 84 which are connected to suction fans 86 and 88. A further fan 90 is connected to the top of chamber 80.
It is evident that the invention might be subjected to several modifications as to its details without departing from the spirit and scope thereof. | An apparatus for the continuous immersion washing of uninterrupted pieces of fabrics, particularly of knitted fabrics, progresses the length of fabric through a series of washing stations including immersion washing tanks and progressing mechanisms including fabric widening rollers. At least one immersion washing tank has an intermittently driven rotary member partially immersed therein and having circumferentially distributed first projections which form a platform with second projections distributed along endless sprocket chams which drive the rotary member. Portions of the fabric are fed and loosely folded in relaxed tensionless condition onto the platform. A pair of axially-aligned, independently-driven and controlled half rollers exert transverse pulls on the fabric to counteract and correct misalignments detected and signalled by sensor means located downstream of the immersion washing tank. | 3 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 60/806,810, filed Jul. 10, 2006, the disclosure of which is incorporated by reference herein in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to image segmentation, and more particularly, to a method for automatic separation of segmented tubular and circular objects.
[0004] 2. Discussion of the Related Art
[0005] In general, segmentations of branching or multiple tubular objects in close proximity to each other relative to the resolution of an imaging device result in the fusing together of originally distinct structures, Image noise, partial volume artifacts, and other factors can also contribute to the fusing together of such structures. An example of the fusing together of originally distinct structures involves the segmentation of the vessels within the lungs. Here, the arteries and veins are frequently segmented together as a single component. Similar situations are also found within arteries and veins throughout the body. As a result, the goal of many researchers is to get a segmentation that illustrates the arteries and/or veins separately.
[0006] The ability to create separate segmentations for the arteries and veins can allow for improvements in visualization and Computer Aided Detection (CAD) by eliminating unneeded data. For example, pulmonary embolism (PE) is a condition where a clot occurs within the arteries of the lungs. An examination to determine if a PE exists does not require a physician to search within the veins. Hence, if only the arteries were identified and the veins eliminated, the search would be simplified.
[0007] Approaches to artery-vein segmentation can involve physical methods for discrimination. These methods depend on differences in the direction of flow, differences in the uptake of contrast agents, or measurements of blood oxygen levels. However, these approaches require specific contrast agents, complex acquisitions, or limit the imaging modality that can be used. Recently, image processing approaches have been offered that allow for more generalized application with less of these physical limitations. However, manual user interaction requirements and limited applicability can be issues for these methods.
[0008] For example, the method presented in T. Lei, J. K. Udupa, P. K. Saha, and D. Odhner, “Artery-Vein Separation via MRA—An Image Processing Approach,” IEEE TMI, Vol. 20., No. 8, August 2001, makes use of fuzzy connectivity to define arteries and veins within Magnetic Resonance Angiography (MRA) image data. Here, the user must specify several points within the image to delineate the arteries and veins. These points are then used to compete against each other within the segmentation. No notion of a tubular bifurcating structure is used in this method. Another approach involving MRA image data that makes use of level set techniques is described in C. M. van Bemmel, L. J. Spreeuwers, M. A. Viergever, and W. J. Niessen, “Level-Set-Based Artery-Vein Separation in Blood Pool Agent CE-M JR Angiograms,” IEEE TMI, Vol. 22, No. 10, October 2003. This method makes use of a vessel-like model though level sets and uses a line-filter for segmentation. However, the user must specify paths within both the arterial and venous trees. These requirements of manual interaction limit the possibilities for applications such as CAD or even in cases where further processing is required once manual input is obtained.
[0009] An automatic approach for artery-vein segmentation within the lungs of computed tomography (CT) images was presented in T. Bulow, R. Wiemaker, T. Blaffert, C. Lorenz, and S. Renisch, “Automatic Extraction of the Pulmonary Artery Tree from Multi-Slice CT Data,” SPIE Medical Imaging 2005: Physiology, Function, and Structure from Medical Images, pp. 730-740, 2005. This method makes use of the airways to help isolate arteries from the veins. Here, a tree model of the segmented vessels is evaluated at each point to determine if nearby airways follow these vessels. Vessels with a higher measure of likely airways are determined to be arteries and all descendants are classified as such. This method, however, is limited to the lungs.
[0010] A generalized approach for tree separation in segmented structures was presented in S. R. Aylward and E. Bullitt, “Initialization, Noise, Singularities, and Scale in Height Ridge Transversal for Tubular Object Centerline Extraction,” IEEE TMI, Vol. 21, No. 2, February 2002 and U.S. Patent Application Publication No. 2006/0056685, “Method and Apparatus for Embolism Analysis”, filed Aug. 12, 2005. In the method disclosed in U.S. Patent Application Publication No. 2006/0056685, a tree model was fitted to a segmentation and intersecting branches from other tree structures were detected and eliminated based upon expected normal branch angles. This method was applied to a sub-tree of an entire tree structure that was manually chosen by a user. Although this method is promising, a fully automatic approach is desired for some applications, since applying this method to an entire tree structure may be time consuming given the complexity of the tree structure.
SUMMARY OF THE INVENTION
[0011] In an exemplary embodiment of the present invention a method for labeling connected tubular objects within segmented image data, comprises: receiving segmented image data; and labeling the segmented image data to identify a plurality of components in the segmented image data, wherein the labeling includes: processing the segmented image data to create a processed image that represents centerline and radii estimates of the connected tubular components; determining seed point candidates in the processed image that are within a band of radii; grouping the candidates based on their physical distance from each other and their radii estimates; partitioning the segmented image data in accordance with the grouped candidates; and assigning a separate color label to each of the plurality of components that are different from each other.
[0012] Determining seed point candidates and grouping the candidates are repeated by using other bands of radii until a minimum or maximum number of grouped candidates is found.
[0013] The segmented image data is partitioned by performing a competitive region growing on the processed image, a fuzzy connectedness segmentation on the processed image, a level-set segmentation on the processed image, a fast-marching segmentation on the processed image or a watershed segmentation on the processed image.
[0014] The method further comprises receiving original image data corresponding to the segmented image data, wherein the processing is applied to the original image data in addition to the segmented image data to create the processed image.
[0015] After labeling the segmented image data, the method further comprises for each labeled component, determining if the component is to be further separated by: fitting a tree model to the component; dividing the component into at least two components if the tree model indicates that there are at least two trees present for the component; and re-labeling the divided component.
[0016] After labeling the segmented image data, the method further comprises for each labeled component, reconnecting the component to another component and assigning a single label to the reconnected components if they have a physical proximity to each other within a first threshold, a contact surface area within a second threshold and a directional heading within a third threshold.
[0017] The method further comprises receiving original image data corresponding to the segmented image data, wherein gray-level values of the original image data are used to determine if the contact surface area between the two components is within the second threshold.
[0018] The segmented image data is received from a multi-dimensional imaging modality.
[0019] The labeled components are connected tubular objects.
[0020] In an exemplary embodiment of the present invention, a system for labeling connected tubular objects within segmented image data, comprises: a memory device for storing a program; a processor in communication with the memory device, the processor operative with the program to: receive segmented image data; and label the segmented image data to identify a plurality of components in the segmented image data, wherein the processor is further operative with the program when labeling to: process the segmented image data to create a processed image that represents centerline and radii estimates of the connected tubular components; determine seed point candidates in the processed image that are within a band of radii; group the candidates based on their physical distance from each other and their radii estimates; partition the segmented image data in accordance with the grouped candidates; and assign a separate color label to each of the plurality of components that are different from each other.
[0021] The seed point candidates are determined and the candidates are grouped by using other bands of radii until a minimum or maximum number of grouped candidates is found.
[0022] The segmented image data is partitioned by performing a competitive region growing on the processed image, a fuzzy connectedness segmentation on the processed image, a level-set segmentation on the processed image, a fast-marching segmentation on the processed image or a watershed segmentation on the processed image.
[0023] The processor is further operative with the program after labeling the segmented image data to: for each labeled component, determine if the component is to be further separated, wherein the processor is further operative with the program when determining if the component is to be further separated to: fit a tree model to the component; divide the component into at least two components if the tree model indicates that there are at least two trees present for the component; and relabel the divided component.
[0024] The processor is further operative with the program after labeling the segmented image data to: for each labeled component, reconnect the component to another component and assign a single label to the reconnected components if they have a physical proximity to each other within a first threshold, a contact surface area within a second threshold and a directional heading within a third threshold.
[0025] The processor is further operative with the program to receive original image data corresponding to the segmented image data, wherein gray-level values of the original image data are used to determine if the contact surface area between the two components is within the second threshold.
[0026] The segmented image data is received from a multi-dimensional imaging device.
[0027] The processor is further operative with the program to display the labeled segmented image data.
[0028] The labeled components are connected tubular objects.
[0029] In an exemplary embodiment of the present invention, a method for separating components within segmented medical image data, comprises: receiving the segmented medical image data, wherein the components are arteries, veins and extraneous structures; separately labeling the components in the segmented medical image data, wherein the labeling includes: applying a distance transform to the segmented medical image data by labeling each segmented point in the segmented medical image data based on its distance to a surface of the segmentation to create distance labeled image data; determining seed point candidates in the distance labeled image data that are within a band of radii; grouping the candidates to each other if their physical distance to each other is less than a minimum or maximum of their radii estimates; performing a competitive region growing on each of the groups of candidates in the distance labeled image data to partition the segmented medical image data into the components; and assigning a different color label to each of the components; for each of the components, determining if they are to be further separated by: fitting a tree model to the component; dividing the component into at least two components if the tree model indicates that there are at least two trees present for the component; and re-labeling the divided component; and for each of the labeled components, reconnecting the component to another component and assigning a single label to the reconnected components if they have a physical proximity to each other within a first threshold, a contact surface area within a second threshold and a directional heading within a third threshold.
[0030] Determining seed point candidates and grouping the candidates are repeated by using other bands of radii until a minimum or maximum number of grouped candidates is found.
[0031] The segmented medical image data is received from a multi-dimensional medical imaging modality.
[0032] The foregoing features are of representative embodiments and are presented to assist in understanding the invention. It should be understood that they are not intended to be considered limitations on the invention as defined by the claims, or limitations on equivalents to the claims. Therefore, this summary of features should not be considered dispositive in determining equivalents. Additional features of the invention will become apparent in the following description, from the drawings and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 is a high-level flow diagram illustrating a method for automatic separation of segmented tubular and circular objects according to an exemplary embodiment of the present invention;
[0034] FIG. 2 is a detailed flow diagram illustrating the step of tubular model component labeling shown in FIG. 1 ;
[0035] FIG. 3 is an image illustrating a large-scale tubular model component labeling applied to vessels in and around the heart according to an exemplary embodiment of the present invention;
[0036] FIG. 4 is an image illustrating a small-scale tubular model component labeling applied to vessels in the lungs according to an exemplary embodiment of the present invention;
[0037] FIG. 5 is a detailed flow diagram illustrating the step of tubular model component analysis with separation/reconnection shown in FIG. 1 ;
[0038] FIG. 6 is a diagram illustrating two components that were isolated during tubular model component labeling according to an exemplary embodiment of the present invention; and
[0039] FIG. 7 is a block diagram illustrating a system for automatic separation of segmented tubular and circular objects according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0040] Presented herein is a method for separating originally distinct tubular objects with possible noise that does not depend on the use of the airways. The method takes as an input an original image along with an initial segmentation thereof and then outputs a separation of the segmentation into components such as the arteries, veins, and extraneous structures. The method makes use of an expected model for further refinements. Unlike previous methods, which operate during the segmentation, this method operates on the given segmented data itself. Hence, it is applicable to any segmented image of a branching tubular structure regardless of imaging modality and segmentation method.
[0041] The method consists of two phases as shown in FIG. 1 . The first phase ( 103 ) performs a tubular model component labeling of a segmented image. This step separates the segmented image into separate components based on a tubular model. Depending, upon proper scale parameters, this step can clearly differentiate larger structures. With a smaller scale, it tends to create many isolated tree-like components.
[0042] The second phase ( 105 ) operates on the components created by the first phase ( 103 ). Here, the shape and connectivity of each component is analyzed. Using an expected model of the branching structure, each component is either reconnected with other components or further separated for reconsideration. The specific models of expected anatomy can be used for automatic identification of the arterial and venous trees and can provide improved performance.
[0043] The two phases ( 103 ) and ( 105 ) outlined in FIG. 1 for separation of a segmented image into tubular components will now be described under the headings Tubular Model Component Labeling and Component Analysis with Separation/Reconnection, respectively. In the following description, the input is segmented image data and optionally, depending upon the implementation, original image data. All implementation dependent data is represented as proceeding with dotted lines in FIG. 1 . After a general description of each phase, each section is followed by an implementation example. Existing and further applications of the present invention will be described under the heading Applications.
Tubular Model Component Labeling
[0044] As shown in FIG. 2 , the first phase ( 103 ) proceeds by first converting ( 202 ) segmented image data into a structure that reflects the likelihood of centerlines, C, along with a radius estimate at each point, r. This conversion may make use of only the segmented image data but can also depend on the original image data as well. A hand of radii of interest └r 1 , r 2 ] is first specified ( 204 ). This scale range helps determine points that are candidates for core components. Hence, each point within the image such that its radius estimate is r 1 ≦r≦r 2 becomes a candidate. Next, the candidates are grouped together into a set of n groups based on their physical proximity and their radii estimates ( 206 ). Depending upon the physical location and the radius estimates, two given seeds are assigned to the same group. If additional seeds are also in close proximity, they will be added to this group as well. If no seeds are grouped together, the total number of groups will be the total number of initial seeds. In the case of all seeds being grouped together, only a single group will result. In practice, the actual number of groups falls between these two extremes. At this early stage, since the total number of groups n is already known, changes to the scale and parameters can be made until the minimum expected number of groups are found (this is represented by the dashed line in FIG. 2 ). Once the groups and corresponding candidates are determined, they are used to partition the segmented image into different components by competing against each other within the likelihood measure C ( 208 ). Depending upon the scale factors chosen, these could be many components or just several.
[0045] Visual examples of this phase are shown in FIGS. 3 and 4 . In both cases a single component of the vessels connected to the main pulmonary artery and vein are given as input. In FIG. 3 a band of [9 mm,+∞] was used. This isolated major components such as the pulmonary artery 302 , the pulmonary vein 304 a / 304 b , and the aorta. The aorta was removed automatically based upon size and location. Note that although larger components are separated, smaller components are fused together. In some cases, the smaller arteries and veins produce good separation at the smaller level, but this is not always the case. When taking the band to [3 mm,7 mm] as shown in FIG. 4 , the smaller components show good separation into individual tree structures (as indicated by the differences in shading). These components can then be reconnected into complete tree structures as will be described for the second phase under the heading Component Analysis with Separation/Reconnection.
[0046] The general description of this phase can be implemented in several different ways. In the examples shown in FIGS. 3 and 4 , a Euclidean distance transform was applied to the segmented image data. This transform labeled each point based upon its distance to the surface and served as both the radius estimate and the centerline likelihood. Points were collected based upon their radius measurements. Candidates were grouped if their physical distance was less than the minimum of either of their radius estimates. Once grouped, a competitive region growing was performed. This process took each group and allowed them to -row into neighboring points based upon a set of rules taken from the distance transformed image and the individual group and point characteristics. In the implementations for FIGS. 3 and 4 , the distance measure gave priority to those points growing from larger radii. There was also priority for growing into the same value regions and penalty for growing into regions of high differences. These rules were coded into the competitive region growing algorithm.
[0047] As mentioned before this is just one possibility for this method. Obtaining a radius estimate to collect candidates can also involve the original image data by taking a distance transform of strong edges. Using a scale for a line filter can also provide this estimate. Once the grouped candidates are obtained multiple possibilities exist for the competition of the seeds. Besides competitive region growing, fuzzy seeded region growing, level-set methods, fast marching methods, and watershed transforms can be used. Basically, any method that accepts seeds to define regions can be used. The rules by which the seeds grow need to be governed by the tubular structure of the object to allow is/or better partitioning into components. Depending upon the method, this can be encoded into a transform of the image. The same distance transform can work as a speed image for a level-set or fast marching method. The level-set method can additionally prefer a tubular shape to allow for better isolation into separate components.
Component Analysis with Separation/Reconnection
[0048] As shown in FIG. 1 , the second phase ( 105 ) is applied to the output of the first phase (I 03 ). Multiple components are given as input. Each component is classified into two possible groups. The first group is a normal isolated tree component. The second group is a tree component with additional components such as extraneous segmentation noise or other tree structures. The expected model helps classify each component into these two categories.
[0049] Next, components in the second grouping are further separated to ensure all components are only isolated portions of the tree. This separation is done based on the expected model of the tree branching structure. All components are then reconnected based upon what is expected with the given model. Physical connections and predicted headings of the tree structure are used to determine if two components should he connected or considered separate. The end result is separate tree segmentations along with clean up of false positive artifacts not consistent with the expected model.
[0050] As with the first phase, multiple implementations are possible. The goal here is to not only classify and process the components but also to be able to decide how to reconnect them. In a planned implementation, as shown in FIG. 5 , a tree structure is computed for each component via a skeletonization based method as described, for example, in A. P. Kiraly, J. P. Helferty, E. A. Hoffman, G. McLennan, and W. E. Higgins “3D Path Planning for Virtual Bironchoscopy”, IEEE TMI, pp. 1365-1379, Vol. 23, November 2004, the disclosure of which is incorporated by reference herein in its entirety. This method describes the component as a series of connected branches and allows an estimate of the branch lengths and angles.
[0051] Given the tree structure, a method similar to that presented in U.S. Patent Application Publication No. 2006/0056685 and A. P. Kiraly, E. Pichon, D. P. Naidich, C. L. Novak, “Analysis of arterial sub-trees affected by Pulmonary Emboli,” SPIE Medical Imaging 2004, 5370, 2004, the disclosures of which are incorporated by reference herein in their entirety, can be used for analysis here ( 502 ). For example, in U.S. Patent Application Publication No. 2006/0056685 and A. P. Kiraly, E. Pichon, D. P. Naidich, C. L. Novak, “Analysis of arterial sub-trees affected by Pulmonary Embloli, “SPIE Medical imaging 2004, 5370, 2004, complementary angles in branches are analyzed to detect abnormalities. Additionally, branch angles that are less than 90 degrees can be eliminated or separated. In this case, the problem is greatly simplified since a component is simpler than a sub-tree. FIG. 6 illustrates a component 602 with an extraneous branch 603 that can be eliminated based upon angles. The requirement of angles greater than a specified amount is one way to introduce an expected model into this phase. Additionally, since the components are only small sections of the entire tree, branch lengths can be used to identify outliers.
[0052] Once each component is properly isolated, the physical connectivity between the components coupled with the branch headings can determine if the two components should be connected ( 504 ). For example, in FIG. 6 , the component 602 and another component 601 (which were isolated in the labeling step 103 ) can be reconnected since the headings of their branches are in agreement. Their radius estimates can also play a role in this decision. If the estimated radii are similar and beyond a certain threshold, the connection can definitively be made. Given additional information such as a known artery and vein can help further discriminate the two tree structures.
Applications
[0053] Many applications exist for the above-described method. Due to its generality, it can be applied to any vasculature in the body such as that in the liver, legs, lungs, and the brain. It can be used for vessel separation or for cleaning up false positives within the segmentation. Hence, it can be coupled with any segmentation method available and can be applied with any imaging modality.
[0054] As described above, the separation of different components in the segmentation of the vessels around the heart helps provide isolation of the pulmonary arteries, veins, and the aortic arch. As discussed earlier, the method was used in an application for visualizing pulmonary embolism. (PE) in pulmonary vessels, both for separating the main arteries and veins as well as for eliminating the aortic arch. The end result for a single case is shown in FIG. 3 . Here, a minimum diameter of 9 mm was specified for the seed points; thus, the main pulmonary artery and pulmonary veins were clearly separated. Further, processing may be applied to the peripheral vessels but the component labeling demonstrates good results for the major vessels. These are just the results of the first phase 103 .
[0055] Using a narrow radius band of 3 mm to 7 mm as shown in FIG. 4 created many components. Some individual components were properly separated, i.e., they only contained an artery or vein. However, a small number of components may have contained slight errors. In any event, the problem of separation is greatly simplified by the smaller components as fewer possible errors exist. The knowledge of arteries and veins from the previous run with a larger band can also be used during or at the end of the second phase 105 along with this narrow band data. This information can then be used in the second phase 05 to determine which components need to be reconnected and which components need further separation before reconnection.
[0056] The method can also be applied to computed tomographic angiography (CTA) or magnetic resonance angiography (MRA) data of the legs for separation of the arteries and veins. This application can reduce difficulty in the precise timing of the scan currently necessary for proper diffusion of contrast material.
[0057] In addition, even if the segmented tree structure is that of a single tree, errors can still exist. In this case, the method can be used to remove extraneous artifacts from the tree structure. Hence, the method can be applicable to segmentations of the airway tree to clean up false positives.
[0058] Presented above is method for dividing a single segmented object of tree structures while at the same time clearing errors in segmentation. It proceeds in a two phase approach where individual components are separated based on automatically placed groups of seeds competing to create individual components. These components are then analyzed and regrouped in the second phase according to a model. Additional information involving arterial or venous locations can be applied for automatic identification of the separated trees.
[0059] A system in which the above-described exemplary embodiments of the present invention may be implemented will now be described
[0060] As shown in FIG. 7 , a system 700 includes an acquisition device 705 , a personal computer (PC) 710 and an operator's console 715 connected over a wired or wireless network 720 . The acquisition device 705 may be a CT imaging device or any other three dimensional (3D) high-resolution imaging device such as a magnetic resonance (MR) scanner or ultrasound scanner.
[0061] The PC 710 , which may be a portable or laptop computer, a medical diagnostic imaging system or a picture archiving communications system. (PACS) data management station, includes a central processing unit (CPU) 725 and a memory 730 connected to an input device 750 and an output device 755 . The CPU 725 includes a tubular component labeling/analysis module 745 that includes software for executing methods in accordance with exemplary embodiments of the present invention. Although shown inside the CPU 725 , the tubular component labeling/analysis module 745 can be located outside the CPU 725 .
[0062] The memory 730 includes a random access memory (RAM) 735 and a read-only memory (ROM) 740 . The memory 730 can also include a database, disk drive, tape drive, etc., or a combination thereof. The RAM 735 functions as a data memory that stores data used during execution of a program in the CPU 725 and is used as a work area. The ROM 740 functions as a program memory for storing a program executed in the CPU 725 . The input 750 is constituted by a keyboard, mouse, etc., and the output 755 is constituted by a liquid crystal display (LCD), cathode ray tube (CRT) display, printer, etc.
[0063] The operation of the system 700 can be controlled from the operator's console 715 which includes a controller 765 , e.g., a keyboard, and a display 760 . The operator's console 715 communicates with the PC 710 and the acquisition device 705 so that image data collected by the acquisition device 705 can be rendered by the PC 710 and viewed on the display 760 . The PC 710 can be configured to operate and display information provided by the acquisition device 705 absent the operator's console 715 , by using, e.g., the input 750 and output 755 devices to execute certain tasks performed by the controller 765 and display 760 .
[0064] The operator's console 715 may further include any suitable image rendering system tool/application that can process digital image data of an acquired image dataset (or portion thereof to generate and display images on the display 760 . More specifically, the image rendering system may be an application that provides rendering and visualization of medical image data, and which executes on a general purpose or specific computer workstation. The PC 710 can also include the above-mentioned image rendering system/tool/application.
[0065] It should be understood that the present invention may be implemented in various forms of hardware, software, firmware, special purpose processors, or a combination thereof. In one embodiment, the present invention may be implemented in software as an application program tangibly embodied on a program storage device (e.g., magnetic floppy disk, RAM, CD ROM, DVD, ROM, and flash memory). The application program may be uploaded to, and executed by, a machine comprising any suitable architecture.
[0066] It should also be understood that because some of the constituent system components and method steps depicted in the accompanying figures may be implemented in software, the actual connections between the system components (or the process steps) may differ depending on the manner in which the present invention is programmed. Given the teachings of the present invention provided herein, one of ordinary skill in the art will be able to contemplate these and similar implementations or configurations of the present invention.
[0067] It is further understood that the above description is only representative of illustrative embodiments. For the convenience of the reader, the above description has focused on a representative sample of possible embodiments, a sample that is illustrative of the principles of the invention. The description has not attempted to exhaustively enumerate all possible variations. That alternative embodiments may not have been presented for a specific portion of the invention, or that further undescribed alternatives may be available for a portion, is not to be considered a disclaimer of those alternate embodiments. Other applications and embodiments can be implemented without departing from the spirit and scope of the present invention.
[0068] It is therefore intended, that the invention not be limited to the specifically described embodiments, because numerous permutations and combinations of the above and implementations involving non-inventive substitutions for the above can be created but the invention is to be defined in accordance with the claims that follow. It can be appreciated that many of those undescribed embodiments are within the literal scope of the following claims, and that others are equivalent. | A method for labeling connected tubular objects within segmented image data, including: receiving segmented image data; and labeling the segmented image data to identify a plurality of components in the segmented image data, wherein the labeling includes: processing the segmented image data to create a processed image that represents centerline and radii estimates of the connected tubular components; determining seed point candidates in the processed image that are within a band of radii; grouping the candidates based on their physical distance from each other and their radii estimates; partitioning the segmented image data in accordance with the grouped candidates; and assigning a separate color label to each of the plurality of components that are different from each other. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention generally relates to a method and apparatus for the deacidification of cellulosic materials. More particularly, the invention relates to an improved method for handling the cellulosic materials such as books, magazines, newspapers, documents and the like during the deacidification process.
2. Description of the Invention Background
The deterioration of paper, books and newspapers is wellknown and of growing concern to librarians and archivists throughout the world. The causes of paper deterioration are numerous and include inherent acidity, photodegradation, oxidation, and even microbiological attack under certain conditions. These factors combined with initial paper quality have severely reduced the permanence of library and archival collections.
The demand for large amounts of printing paper over the last century has led to the introduction of pulp fiber produced from wood by chemical or mechanical means. However, paper made from untreated wood pulp is too absorbent to allow sharp image imprint. Therefore, chemicals have to be added to the wood fibers during processing. These additives allow the paper to accept inks and dyes and increase paper opacity. Unfortunately, most of these chemicals are either acidic or are deposited by acidic mechanisms which initiate the slow, but relentless acidic deterioration of paper. Other contributions to the acidification of paper are supplied by man through industrial emissions of sulphur and nitrogen and carbon oxides or by natural processes such as sea salt spray. Even books or paper of neutral and alkaline character are not immune. As neighboring papers of acidic nature degrade, volatile acids are produced which either diffuse through adjoining books or permeate the atmosphere and may ultimately acidify even the "safe or stable" books.
In order to arrest this acidic degradation, paper materials must be deacidified and provided with an alkaline reserve or buffer to retard a return to an acidic state. There are several known processes for deacidifying paper whether bound or unbound. U.S. Pat. Nos. 3,472,611; 3,703,353; 3,676,182; 3,939,091; 3,676,055; 3,969,549; and 4,318,963 are exemplary.
Unfortunately, most of these processes suffer from one or more of a number of drawbacks that have prevented their widespread acceptance. These drawbacks include high cost, toxicity, complexity of treatment, residual odor, deleterious effects on certain types of paper and inks, lack of an alkaline reserve, and the necessity of drying the book or paper to very low moisture contents before treatment.
U.S. Pat. No. 4,522,843 which issued on Jun. 11, 1985 to Robert Kundrot describes a process in which acidic cellulosic materials can be treated in a manner which obviates or minimizes many of the problems of the prior art including the necessity for drying the book or paper prior to treatment. This method can be used on cellulosics (paper) even when such paper is imprinted and bound. More particularly, the Kundrot patent demonstrates that books, imaged paper and other imaged material having a cellulose base can be preserved by treatment with alkaline particles of basic metal oxides, hydroxides or salts (hereinafter referred to as alkaline material) in an amount and for a time sufficient to increase the pH of the material and provide an alkaline buffer or reserve in the pages. The alkaline particles are deposited and adhere tightly to both the fibrous structure of the paper and on the surface.
In the past, as described in the Kundrot patent, the books were dipped vertically into a treatment medium. Following treatment, a small section of each page, adjacent the binding of a book for example, remained untreated, even after repeated dippings. Neutralization of the small section would eventually occur. The mobile acid species in the untreated areas eventually migrate across the page to the particles of basic metal oxides, hydroxides, or salts which are distributed through the cellulosic or paper web of the pages, where they are neutralized. However, this process may take a prolonged period of time until it has been completed. Thus, it is preferable to deacidify the entirety of each page of the book during the treatment process to prevent deterioration of the book. Accordingly, it is desirable to develop a method of handling the cellulosic materials during treatment which ensures that the pages of the book are treated completely by the deacidification process.
Another problem associated with the treatment of cellulosic materials was that the alkaline material was often visible as a powdery substance on the surface of pages after treatment was completed. This detracts from the appearance and utility of the treated books.
Therefore, a method of deacidification is needed which overcomes the aforementioned deficiencies of the methods used in the past and will substantially, and preferably completely, treat each page of a book or other cellulosic material without leaving a visible residue of the treating material.
SUMMARY OF THE INVENTION
A method and apparatus for deacidification of materials such as books, magazines, newspapers, documents and the like is provided which ensures that substantially the entirety of each page of the book is treated. The method includes the steps of submerging cellulosic materials in a bath of a treating medium, and causing relative movement between the cellulosic materials and the treating medium in a generally axial direction relative to the cellulosic materials at a predetermined velocity and continuing such relative movement for a first period of time effective for deacidifying substantially all of the cellulosic materials. Thereafter, the cellulosic materials are dried, preferably in a dryer, by means of flowing a stream of warm air over the cellulosic materials. The relative movement is preferably achieved by moving the cellulosic materials in a generally horizontal, preferably reciprocating motion, through the treating medium at a predetermined speed and over a predetermined distance preferably by controlling the stroke speed and stroke length of a means for providing the reciprocating motion.
Alternatively, the relative movement may flow the treating fluid past the cellulosic materials in an axial direction at the predetermined velocity. The method preferably also includes applying ultrasonic energy to the bath during the treatment process to disperse particles within the treating medium.
The cellulosic materials are placed in a carrier configured to hold the materials in a manner which permits exposure of each page of any such material to the treating medium. A suitable carrier is provided by a V-shaped carrier in which the spine of the book is placed adjacent the apex or spline of the V. The V-shaped carrier includes a plurality of holes therethrough to allow fluid to pass through the holes and to allow securing members, such as clamps to be attached to the V-shaped carrier. A book, for example, may be clamped or otherwise fastened to the sides of the V-shaped carrier such that the front cover of the book is securely attached to one side of the carrier, and the back cover of the book is securely attached to the other side of the carrier. Axial movement of the book or other material is prevented by the use of adjustable stops inserted at desired location in the holes on the carrier's spline. During treatment, the carrier must be held down due to the buoyant force of the books. Following treatment, the book is released. The carrier includes handles which may be gripped to submerge the carrier and its cargo into a vat containing the treating medium, such as a dispersion having particles of an alkaline material. The treating medium is preferably of the type described in U.S. Pat. No. 4,522,843 to Kundrot, the disclosure of which is hereby incorporated by reference.
The vat may be circular, donut shaped or rectangular. It may also include a support frame. In one embodiment, a rectangular support frame is provided which has two opposing longitudinal members and two opposing transverse members configured to support a carrier. The support frame is slidably mounted on the vat. Means are provided which are operatively connected to the support frame which cause the frame to move at the desired velocity, and preferably to reciprocate in a generally horizontal orientation within the vat.
The reciprocating means may include a driving member pivotally attached at one end to the support frame preferably by a clevis and pin arrangement and pivotally attached at its other end to a flywheel. The point of attachment of the driving member to the flywheel can be varied to adjust the stroke length of the driving member. As will be readily apparent to one of ordinary skill in the art, when the driving member is attached to the flywheel at a point closest to the axis of rotation of the flywheel, the reciprocation stroke is relatively short. Conversely, when the driving member is attached to the flywheel further away from the axis of rotation of the flywheel, closer to the perimeter of the fly wheel, the reciprocation stroke is relatively long. The flywheel is rotated by means of a motor, belt and pulley system. A rotating motor rotates a driving pulley via a gear box which is connected by a belt to a driven pulley. As will be apparent to one of ordinary skill in the art, by varying the size of the pulleys, the speed of rotation of the flywheel can be varied. As the speed of rotation of the flywheel is varied the stroke speed of the driving member is also varied.
The reciprocation of the support frame causes corresponding reciprocating movement of the carrier through the medium in the vat. The pages of books secured to the carrier are thereby caused to fan out, and the treating medium thus comes into contact with the full surface areas of each page of each book in the carrier. It has been determined that reciprocation at a stroke length of about 12 inches and a speed of about 12-16 cycles per minute for about fifteen minutes will completely deacidify even the most difficult to treat books. A shorter time period may suffice for other cellulosic materials. The variables of stroke length, stroke speed and time may be changed depending on several factors such as the size of the pages of a book or other document, the number of pages and the pH of the pages or other document prior to treatment. After reciprocating the support frame at a predetermined stroke speed and stroke length for a predetermined period of time such that each page of the book is treated substantially in its entirety, the carrier is removed from the bath. It is then preferably either transported by hand or conveyed automatically to a dryer.
Preferably, the dryer is constructed in the form suitable for receiving the carrier. Alternatively, the dryer may include a holder in the form of fixed shelving or made of flexible meshed webbing or netting which is disposed between each of a series of support rods. The books may be removed from the carrier and placed on the shelving or the meshed webbing. Air, which has preferably been preheated, is circulated through the dryer to evaporate any excess residual treating medium on the surface of the pages. The air stream carries the evaporated residual treating medium from the books to a condenser where it is cooled to form a condensate of the treating medium.
The liquid condensate is preferably collected so that it may be recycled to the vat. Additionally, it is preferable to provide covers on both the vat and the dryer to minimize evaporative losses of the treating medium.
The process described herein ensures that substantially the entirety of each page of the book is treated and deacidified during the treating process. These and other advantages and benefits of the present invention will become apparent from the detailed description of the preferred embodiment hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
The preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying Figures wherein like members bear like reference numerals and wherein:
FIG. 1 is a perspective view of the treatment apparatus constructed according to the present invention with the lid removed;
FIG. 2 is a side cross-sectional view of the treatment apparatus of the present invention;
FIG. 3 is a top plan view of the treatment apparatus of the present invention with the lid removed;
FIG. 4 is a perspective view of a V-shaped carrier of the present invention;
FIG. 5 is a partial end view of the of the V-shaped carrier of FIG. 4 with showing a book placed therein;
FIG. 6 is a side cross-sectional view of the dryer of the present invention; and
FIG. 7 is a top view of a drying rack for use in the dryer of FIG. 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, which are for the purpose of illustrating the preferred embodiment of the invention and not for the purpose of limiting the same, FIGS. 1-5 show the treatment apparatus 10 and FIGS. 6-7 show the drying apparatus used in connection with the process of the present invention.
The treatment apparatus 10 includes generally a tub or vat 12 for holding a bath of treatment medium, a support frame 51 slidably mounted on vat 12, a carrier 64 for holding the cellulosic materials to be treated which is supported in vat 12 by the support frame 51 and means for imparting reciprocating movement in a generally horizontal direction to the support frame 51. The reciprocating movement of the support frame causes corresponding movement of the carrier 64, thereby effecting reciprocation of the cellulosic materials back and forth through the treating medium in a generally horizontal direction. The generally horizontal reciprocating movement of the cellulosic materials through the medium has been found to eliminate the incomplete treatment heretofore experienced. However, any suitable sustained velocity of treatment materials flowing axially past the pages of the cellulose based materials will suffice. A relative bulk flow velocity of up to 5 feet per second between the fluid and the paper should serve as the guideline for relative velocity between the paper and the treatment fluid. Such movement may be achieved, for example, by moving the cellulose based materials in a circular path through the treatment bath in a vat having a circular or donut shape. The movement may be continuous in one direction, or may occasionally be reversed. Alternatively, the book or the cellulose based material may be motionless and the fluid may be moved past the pages at the desired relative velocity in an axial direction, using conventional means, such as, pumps or pistons. In a third embodiment, the cellulose based material and the treatment fluid may both be in motion. For example, the cellulose based materials may be reciprocated as described in more detail below while the treatment fluid simultaneously flows past the reciprocating materials.
The vat 12 is provided for holding the treating medium of preferably alkaline materials, and more preferably a liquid dispersion of particles of a basic metal oxide, hydroxide or salt, as described above. The vat 12 shown in the drawings has four sides, two longitudinal sides 14 and two transverse sides 15. The longitudinal sides 14 of the vat 12 have attached thereto horizontally disposed support members 18 and 20. Horizontal support member 18 has attached thereto, at each end of its upper side 19, bearing rods 22 and 24. Similarly, horizontal support member 20 has attached thereto, at each end of its upper side 21, bearing rods 26 and 28. The bearing rods are constructed of a durable, rigid material such as, for example, bearing steel. The bearing rods 22, 24, 26 and 28 are spaced from and supported above the associated horizontal support members 18, 20 by vertical rod holders 30. Each bearing rod has a block 46 or 48 attached thereto such that each block 46, 48 may slide back and forth on its associated bearing rod in the horizontal plane. As stated above, however, the vat 12 can assume a variety of shapes depending on the method chosen for effecting relative movement between the pages and the treating fluid.
The support frame 51 includes a frame made up of support members, which may be in the form of rods, bars, or lines. In one embodiment, a transverse angled member 54 is rigidly attached at each end to opposing blocks 46 on opposing support members 18,20. Similarly, a transverse angled member 56 is rigidly attached at each end to opposing blocks 48. Member 54 is preferably parallel to member 56. Parallel spaced longitudinal angled members 58 and 60 operatively connect members 54 and 56 by spanning the distance between members 54 and 56. Other known means of operatively connecting members 54 and 56 may be provided. A rectangular opening 62 is defined by transverse angled members 54 and 56 and longitudinal angled members 58 and 60 which can move in the longitudinal direction over vat 12 when blocks 46, 48 slide along bearing rods 22, 24, 26 and 28. Those of ordinary skill in the art will also recognize that angled members 54, 56, 58 and 60 can alternatively be made of a variety of shapes and are shown as angled members for illustration purposes only.
Turning now to FIGS. 4-5, a carrier for supporting the books during treatment is shown in the form of a V-shaped carrier 64. Each carrier 64 may support several books or other materials. V-shaped carrier 64 has adjustable angled sides 66 and 68 and a spline 74 to permit change of the angle of the V. The angled sides 66, 68 and spline 74 have a plurality of holes 70 therethrough. The V-shaped carrier 64 is designed such that the books 72 or any other types of cellulosic materials in booklet or bound form to be treated may be placed end to end between the angled sides 66 and 68 with the spine of the book or booklet adjacent the apex of the V at spline 74. Means, such as clamp members 76 and 78 are used to attach the front cover 80 and back cover 82, respectively, to a desired location on the V-shaped carrier 64 utilizing holes 70. Clamp members 76 and 78 are secured by means of a bolt, screw or other fastener passed through a hole 70. Other suitable means for securing the materials to the carrier 64 may be provided, such as, for example, netting, strapping or suction means. Axial stops 77 are placed in the holes 70 in the spline 74 of the carrier 64 to prevent axial motion of books. The V-shaped carrier 64 includes vertical members 84 which have attached thereto horizontal support members 88. Additionally, handles 92 project above horizontal support members 88 to permit carrier 64 to be easily grasped. The V-shaped carrier 64 is constructed such that it may be inserted into the preferably rectangular opening 62 and the horizontal support members 88 may be supported anywhere along the longitudinal angled members 58 and 60. In this way, several carriers 64 may be lined up in series in support frame 51 to treat many books simultaneously. Alternatively, a single carrier 64 may be used or multiple carriers 64 may be placed in parallel. In the latter situations, the transverse angled members 54, 56 can be used to support the carrier's support members 88. Locking members such as hooks 57 or clamps are provided on members 54 and 56 or on support members 88 to secure carrier 64 within frame 51 to counteract the buoyant forces of the books in the treating medium.
Carrier 64 may assume other shapes. It must be constructed in a manner which permits the particular cellulosic materials to be treated to be securely held in the carrier during treatment and must permit complete exposure of the cellulosic material the treating medium. Documents, for example, may be held in a box like carrier that includes slots or an accordion style slotted carrier of any open weave, grid or mesh construction to permit fluid passage among the slots. A mesh type screen to fully enclose loose pages which could otherwise float away should also be provided. Another alternative is to provide a flat plate to which the V shaped carrier, the box like carrier or any other holder can be fastened.
The means for imparting reciprocating movement to the support frame 51 is preferably provided by a motor 116 having a gear box 117 attached by pulleys 114, 120 to a flywheel 104 which is in turn connected to the support frame 51 by a drive member or drive arm 100. Drive member 100 is pivotally attached to transverse angled member 54 by means of a pin 101 through a clevis 103. The drive member 100 is rotatably attached to the flywheel 104 by means of a pin 105 in one of several attachment points or holes 106. A shaft 108 extends outwardly from the center of the flywheel 104. The shaft 108 is attached at its other end 109 to a pulley 114. Pulley 114 is operatively connected by means of belt 122 to second pulley 120. Pulley 120 is driven by drive rod 118 which extends from gear box 117. Motor 116, gear box 117 and bearings 112 are attached to a base 110. Pulley 120 lies in the same plane as pulley 114. Instead of the belt and pulley drive, it will be recognized that other suitable drive mechanisms may be utilized, such as, for example, gear drives or piston (hydraulic or pneumatic) drives to achieve varying stroke length and speed. Alternatively, a variable speed drive directly coupled to the flywheel may be provided to avoid changing the pulleys. A further alternative is to use a pendulum-type drive to swing the books through the medium. The movement in this case is not truly horizontal, but is more arcuate in a generally horizontal direction. As stated, the relative flow velocity is believed to be the critical movement criteria.
In operation, motor 116 and gear box 117 rotate pulley 120 which, through belt 122, turns pulley 114. As this occurs, flywheel 104 rotates which in turn moves the driving member 100; because the driving member 100 is pivotally attached to frame 51 via transverse angled member 54, the support frame 51 reciprocates. Accordingly, the carrier 64 reciprocates within the vat 12 causing the book 72 and other cellulosic materials to be pulled back and forth through the medium in the vat 12 in a generally horizontal orientation at a predetermined speed and over a predetermined length. The reciprocating movement of the book 72 causes the pages of the book to fan out as shown in FIG. 5, thereby exposing the entire surface of each page of each such book to the treating medium within vat 12.
Tests were done to determine the stroke lengths and stroke speeds of drive member 100 that provide the most thorough treatment of the books. The results are shown in the following Tables. Each run was tested with a relatively large volume from an encyclopedia (Colliers) and a relatively smaller book, such as a text book or a novel, some less than half the size in area and page numbers as the encyclopedia volumes. The book types are designated (L) for large and (S) for small. The pH of the books was measured before (B) and after (A) treatment at several locations on various pages within the books treated. A swab of chlorophenol red was used to spot the test locations. Nine spots were checked per page tested. The chlorophenol red turns purple when thee pH become alkaline.
As the test results below demonstrate the pH of every page tested and at every section of every page tested was raised from the acidic values measured before treatment to the alkaline values measured after treatment. The treatment method of the present invention even raised the pH of the area adjacent the spine of the books, which heretofore had been difficult to effectively deacidify.
The chlorophenol red swab spot test demonstrates that improved results are obtained by varying the stroke length and stroke speed of the drive member 100. It can be seen also that large books appear to fair better with a longer stroke length at a slower speed. For example, runs 4 and 5 show that a speed of 12-16 rpm and a stroke length of 12 inches resulted in 100% deacidification for both large and small books, whereas runs 8 and 9 demonstrate that small books faired better than large books when the stroke speed was 23 rpm. The poorest results for large books were obtained in runs 3 and 6 when the stroke length was reduced to four inches.
______________________________________TREATING TRIALS______________________________________ Stroke TreatmentRun Speed Length Time Book TypeNo. (rpm) (inches) (minutes) (Large or Small)______________________________________1 12 12 15 L1 12 12 15 S2 12 8 15 L2 12 8 15 S3 12 4 15 L3 12 4 15 S4 12 12 25 L4 12 12 25 S5 16 12 15 L5 16 12 15 S6 16 4 15 L6 16 4 15 S7 23 12 15 L7 23 12 15 S8 23 12 25 L8 23 12 25 S9 23 8 15 L9 23 8 15 S______________________________________pH Measurements (Before & After Treatment)Run pH-Left-Top pH-Left-Btm pH-CenterNo. Page B A B A B A______________________________________1 331 5.1 8.8 5 8.9 5.1 91 165 4.7 9 4.7 8.8 4.7 9.22 361 5 8.6 5 9 4.9 9.12 119 4.5 8.9 4.4 8.9 4.4 9.13 321 5.4 8.8 5 8.8 5 8.93 143 4.8 8.7 4.4 9 4.4 94 339 5.6 8.4 4.9 9 5.2 8.54 99 5.9 9.4 5.6 8.7 5.6 9.25 381 5.3 8.8 5.5 8.9 4.9 9.15 175 5 8.9 4.6 9.2 4.6 9.26 529 5.7 8.6 5 8.9 5.2 8.96 127 4.9 8.4 4.6 8.9 4.6 8.77 371 5.7 9 5 9.2 4.9 9.27 281 5.1 9 5 8.8 4.7 9.28 407 5.4 9 5.2 9.2 5.2 9.28 187 4.9 9.5 4.9 9.4 4.8 9.59 383 5.6 9.1 5.2 9.1 5.1 9.19 131 4.9 8.9 4.7 9.3 4.6 9.1______________________________________pH Measurements (Before & After Treatment)Run pH Rgt-Top pH-Rgt-Btm pH-Ctr-SpineNo. B A B A B A______________________________________1 4.8 8.6 5 8.8 4.7 91 4.8 8.6 4.9 8.7 4.7 92 5.3 8.9 5 9 5.1 9.12 4.6 8.8 4.6 8.7 4.3 9.13 5.3 8.6 5 8.7 5 9.13 4.7 8.7 4.2 8.8 4.6 8.64 5.3 9 5 8.8 4.9 8.74 5.7 9 5.9 9.3 5.9 9.35 5.4 8.6 5 9 5 9.15 4.9 9.2 4.8 9.3 4.8 96 5.4 8.7 5.1 8.7 4.9 8.16 4.9 8.3 4.7 8.8 4.9 97 5.2 9.1 5 9 4.8 9.27 5.3 9.1 5.1 9 4.8 98 5.5 9 5.2 9.2 5.1 98 5.1 9.4 4.8 9.5 5 9.39 5.5 9 5.2 9.1 5.1 8.89 4.9 9.2 4.7 9 4.8 9.1______________________________________Completeness of Treatment - Chlorophenol Red Swab Spot TestNine (9) Spots Checked Per PageNumber of Treated (purple) Spots on Page Avg. % ofCtr 1/4 Way 1/8 Way 5 Pages Percent BookRun of Into Into In From of Book Treated ForNo. Book Book Book Cover Treated Each Run______________________________________1 7 8 9 9 91.71 9 8 8 9 94.4 93.12 9 7 9 9 94.42 9 9 8 9 97.2 95.83 9 6 6 9 83.33 9 6 8.5 8.5 88.9 86.14 9 9 9 9 100.04 9 9 9 9 100.0 100.05 9 9 9 9 100.05 9 9 9 9 100.0 100.06 6 5 5 9 69.46 9 9 7 9 94.4 81.97 9 8 8 9 94.47 9 7 8 9 91.7 93.18 8 9 9 9 97.28 9 9 9 9 100.0 98.69 7 8 9 9 91.79 9 9 9 9 100.0 95.8______________________________________
To facilitate the contact between the book 72 and the particles suspended within the medium in vat 12, sonic energy can be introduced into the vat 12 by an ultrasonic generator 130 which breaks up and prevents the formation of agglomerates of particles and causes the particles to disperse. The ultrasonic generator may be run continuously or periodically during the treatment process, as needed. If desired, a recirculation system 162 may be used in connection with the vat 12 to provide movement of the fluid through the vat 12 and also to filter the fluid In the vat 12. A pipe 170 is in fluid communication with the vat 12 such that fluid may flow out of the vat 12 when a suitable valve 175 is opened. Fluid is drawn out of the vat 12 by pump 166 and passes through filter 168 before flowing back into the vat 12 through line 164. If desired, valves 172 and 174 may be provided to allow for the vat 12 to be drained either before or after passing the fluid through filter 168.
After the books 72 have been exposed to the treating medium for a predetermined period of time effective for deacidifying the book, they are dried. The dryer may be a separate unit or a separate section within an interconnected system or may be part of the vat 12. In the latter embodiment, the treating fluid would be drained from the vat and transferred to a holding tank (not shown). Warm air may be piped into vat 12 as described below for dryer 140.
Turning to FIGS. 6-7, a separate dryer 140 is shown. It includes a rack 180 made of flexible meshed webbing 142 secured to rods 144. The webbing drapes loosely between adjacent rods. Each rod 144 is attached to the top portion of a rectangular frame. The dryer 140 has four sides 170, a bottom 172 and is preferably covered by a lid 152 to define an enclosed chamber. A closed drying system is thereby provided. Following treatment, the books 72 are moved into dryer 140. The books or other cellulosic materials may be placed on the meshed webbing 142. Alternatively, the carrier 64 may be lifted from vat 12 and transferred to the chamber of the dryer 140. A further alternative is to provide fixed shelving in the dryer 140 or some other support surface. Whatever the means of supporting the materials, the meshed webbing of the rack, the fixed shelving or support surface and the carrier must be structured to allow air flow to contact the books and other documents placed therein. Drying occurs preferably by means of flowing a stream of warm air over the books 72. Alternatively, evaporation at room temperature may be employed. The temperature and humidity are preferably controlled, however, to optimize recovery of treating fluid without damaging the books. The temperature must not be so high, nor the humidity level so low that the books or other documents would be damaged. The precise temperature and humidity levels will depend on the types of materials being treated, including the bindings and cover materials.
In the preferred method of drying, air is warmed in a heater 158 and passed into the chamber (whether dryer 140 or vat 12) through an inlet 177 in an end wall of the chamber. It is drawn through the chamber and over and around the books by means of a pump 176 proximate the outlet 178 at the bottom of the chamber. The warm air evaporates any excess residual treating medium on the pages. As indicated above, treating material will be retained in and on the pages as a reserve. The excess residual medium referred to herein is not the alkaline particles held in the fibers or on the surface of the pages as reserve but is the medium in which the alkaline particles had been dispersed and now lies unattached or unbound on the surface of the pages. Air is removed from the dryer 140 through the outlet and may be directed to a condenser 154. In the condenser 154, the air stream is cooled and the excess residual medium is thereby condensed out of the air. The resulting condensate is then preferably drained into a collector 156. Water may also condense. It is separated, usually by decanting, prior to reusing the treating medium. The now cooled air is then preferably directed back to the heater 158 where it is again warmed and circulated back into the dryer 140 through line 160. The air path thus defined is a closed system which permits recycling of excess treating medium and prevents exposure of workers to vapors. In alternative arrangements, the condensing coils may be placed directly in the drying chamber employing natural circulation to condense treating materials evaporated from the treated materials.
If desired, a conveyor (not shown) could connect the vat 12 to the dryer 140. The conveyor would provide automatic transfer of a carrier 64 from the vat 12 to the dryer 140. The conveyor would preferably be enclosed in a housing (not shown) to minimize evaporative losses of the treating medium.
Although the present invention has been described primarily in conjunction with books, the invention may be used with other types of cellulosic material such as magazines, newspaper, maps, documents and the like. Those of ordinary skill in the art will appreciate the fact that there are a number of modifications and variations that can be made to specific aspects of the method and apparatus of the present invention without departing from the scope of the present invention. Such modifications and variations are intended to be covered by the foregoing specification and the following claims. | A method and apparatus for deacidification of cellulosic materials such as the pages of books, magazines, newspapers, documents and the like are provided which ensures that substantially the entirety of each page is treated. The method includes placing the materials within a carrier such that the pages are free for exposure to the treating medium. The carrier is submerged in a vat preferably containing a dispersion of treating material including particles of an alkaline metal oxide, hydroxide or salt. The vat includes a support frame which supports the carrier and is slidably mounted on the vat such that the carrier and materials it holds may reciprocate in a generally horizontal direction. The reciprocation of the support frame causes the pages of a book, for example, to fan out, and the treating material in the medium thus comes into contact with each page of the book, magazine or other document. After reciprocating the support frame at a preselected speed and stroke length for a preselected length of time such that each page of the book is treated, preferably in its entirety, the carrier is removed from the bath and transferred to a dryer. The dryer includes a flexible meshed webbing which is loosely draped over a series of support rods mounted on a frame. The cellulosic materials are placed on the meshed webbing and preheated air is passed through the dryer to evaporate any excess residual treating medium. | 3 |
BACKGROUND OF THE INVENTION
As is well known, the installation of a typical drain assembly in a sink or the like is a cumbersome operation for one man. He must insert the assembly from above the sink and hold it while it is secured, as by a ring nut or the like, from below the sink. All this, besides requiring not a little manual dexterity, consumes considerable time, ten to twelve minutes not being unusual in many instances.
Since the cost of labor is an increasingly large part of building expense, anything which reduces the time necessary for various equipment installations reduces that cost. This is true even in so mundane an installation as that of drain assemblies, especially in larger projects in which many such assemblies must be installed. It is thus the primary object of the present invention to provide a drain assembly which can be installed by one man alone from above a sink in a small fraction of the time now required and which simultaneously accommodates sinks or the like of various wall thicknesses.
SUMMARY OF THE INVENTION
The object of the present invention is achieved by eliminating the typical ring nut or other clamping mechanism and replacing it with a unique retaining sleeve. The body of the drain assembly, in a preferred form, is deep drawn from a single piece of stainless steel to provide a retaining flange at its upper end which seats in the usual manner against the upper face of the sink bottom wall around the drain aperture. The lower end of the body is formed for connection to the drain pipe while between the latter and the retaining flange is provided a circular well into which fits a typical basket-stopper. Over the exterior of the well is slipped the retaining sleeve of the present invention, which at one end abuts the retaining flange and is secured by a locking ring abutting its other end. From the outer periphery of the sleeve extends a number of fins generally parallel to the sleeve axis and resiliently flexible in both first and second circumferential directions relative to the sleeve body. In a preferred version, the sleeve and the fins are a one-piece injection molding. The fins are divided into several sets or groups of equal numbers of fins, the groups being uniformly disposed about the sleeve body. Each group of fins is provided with two sets of opposite side edges. The first set are "retaining edges" which oppose the retaining flange, the retaining edges of successive fins of each group taken in the first circumferential direction about the sleeve body being located at increasingly greater distances from the retaining flange and inclined away from the latter. The second set of side edges are "installing edges" which are all uniformly distant from the retaining flange and are inclined toward it as well as being transversely beveled toward the second circumferential direction about the sleeve body. The under face of the retaining flange is provided with an annulus of seal material, such as plumber's putty, which may be protected by a strippable film covering until ready for use.
The foregoing parts are pre-assembled by the manufacturer in the manner just described and furnished as a unitary assembly for installation in the field. For the latter purpose the workman merely removes the protective covering, pushes the assembly, lower end first, down into the drain aperture with a twisting action in the second circumferential direction referred to. The "installing edges" of the fins first engage the drain aperture and cause all the fins to flex circumferentially enough so that the assembly slips down through the drain aperture. Then some of the fins in each group snap back out again to varying extents, depending upon the thickness of the sink bottom wall, until their retaining edges contact the under side of the drain aperture. If the sink is stainless steel, for example, and thus relatively thin, the fins of each group whose retaining edges are furthest from the retaining flange will return fully to their normal position since they will be too far away to engage the sink bottom wall. But those fins whose retaining edges are progressively closer to the retaining flange will engage the sink bottom wall and remain in various states of flex with their retaining edges tightly engaged with the sink bottom wall, thus clamping the latter between the retaining edges and the body flange. If the sink is cast iron, on the other hand, and so thicker, only the retaining edges of those fins of each group which are further from the retaining flange will engage the sink bottom wall and clamp the drain assembly while the other fins will remain fully flexed against the wall of the drain aperture. The drain assembly of the present invention thereby automatically adjusts itself to sink walls of varying thickness, and can be completely and permanently installed in but a few seconds.
Other features and advantages of the drain assembly of the present invention will become apparent from the drawings and from the more detailed description which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric view of the drain assembly according to the present invention shown installed in a typical stainless steel sink, a portion of the bottom wall of the latter being broken away.
FIG. 2 is an axial section through the installation shown in FIG. 1 taken generally along the line 2--2 of that Figure.
FIG. 2A is a partial bottom plan view of FIG. 2.
FIG. 3 is similar to FIG. 2 but illustrates installation of a drain assembly according to the present invention in a cast iron sink.
FIG. 3A is a partial bottom plan view of FIG. 3.
FIG. 4 is a top plan view of the retaining sleeve of the present invention.
FIG. 5 is a sectional view along the line 5--5 of FIG. 4.
FIG. 6 is a side elevation of one group of fins of the retaining sleeve of FIG. 4 showing the fin pattern of the group in flat.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIGS. 1 and 2 the bottom wall of a typical stainless steel sink (or any other of relatively thin wall) is designated at 10 and its drain aperture at 11. As mentioned, the drain assembly of the present invention consists of a drain body, generally designated at 12, deep drawn from suitable stainless steel to provide a retaining flange 13 at its upper end, an annular well 14 (into which fits a typical basket-stopper assembly 15), and a necked-down, lower drain end 16 provided with rolled threads 17 for connection to a drain pipe (not shown). When installed in the drain aperture 11 (see FIG. 2), a ring of seal material 18 between the retaining flange 13 and the area surrounding the drain aperture 11 seals the joint between the two. The outer surface of the body well 14 tightly receives a drain assembly retaining sleeve, generally designated at 20, having its upper end abutting the underface of the retaining flange 13 and located on the body well 14 by a locking ring 21 of the Tinnerman type abutting its lower end.
Turning to FIGS. 4- 6 in particular, the retaining sleeve 20 is preferably an integral injection molding from a suitable plastic, such as polypropylene or polyethalene, and consists of an inner annular collar 22 having four sets or grous of 1-6 trapezoidal shaped, blade-like fins 23 each whose planes are radially disposed with respect to the collar 22 and parallel to its axis. The overall diameter of the sleeve 20 is greater than that of the drain aperture 11, but that of the collar 22 is less. Owing to the nature of their material, the fins 23 are resiliently flexible in both circumferential directions, indicated by the arrows A and B in FIGS. 1, 2A, 3A, 4 and 6, relative to the collar 22. The roots of all the fins 23 begin at the lower end of the collar 22, but only the roots of each fin 1 extend the full height of the latter, their upper ends in fact preferably standing slightly proud of the upper end of the collar 22 to form noses 23a. The roots of the corresponding successive fins 2-6 in each group, taken in the same circumferential direction A (see FIG. 6), however, terminate at uniformly progressively greater distances from the retaining flange 13 so that the upper side edges of fins 1-6 in each group form a set of stepped-down retaining edges 23b which generally oppose the underface of the flange 13 and are all uniformly inclined away from the latter, an angle of about 20° between the two having proved suitable. The opposite or lower side edges of all the fins 23 of each group, on the other hand, are all uniformly distant from the retaining flange 13, are inclined toward the latter at an angle of about 45° and are transversely beveled at the same angle toward the circumferential direction B in order to provide installing edges 23c. Additionally, the roots of all the fins 23 are undercut at 23d along their vertical walls facing in the circumferential direction A in order to hinge them relative to the collar 22.
As previously mentioned, the parts are preassembled at the factory, and supplied as a unitary assembly for installation in the field. That is to say, the retaining sleeve 20 and locking ring 21 are in place on the drain body 12 and the seal material applied to the lower face of the retaining flange 13 and protected by a protective covering (not shown). When the drain assembly is to be installed in a sheet metal, such as stainless steel, sink, as shown in FIGS. 1, 2 and 2A, the workman simply removes the protective cover strip over the putty 18, grasps the retaining flange 13 with one hand and inserts the drain end 16 down into the drain aperture 11 until the fin installing edges 23c contact the latter. He then pushes down and at the same time twists the drain assembly in the circumferential direction B, whereupon the inclined and beveled edges 23c, assisted by the undercuts 23d, cause the fins 23 to flex and fold back along the collar 22 so that all the fins 23 can pass down through the drain aperture 11 until the retaining flange 13 and putty 18 seat against the sink bottom wall 10 surrounding the aperture 11. If the edges 23c were not inclined and beveled as described, it might, especially in the case of a sheet metal sink, be necessary to bend the fins 23 back one-by-one with the end of a screwdriver, for instance, or otherwise hold them bent back upon the collar 22, in order to get the retaining sleeve 20 down into the aperture 11. In any event, as fins 23 in each group whose retaining edges 23b are then below the sink bottom wall 10, for instance, fins 3-6 in FIG. 2A, will snap back to their original radial positions, but the retaining edges 23b of the remaining fins 23 in each group, for instance, fins 1 and 2 in FIG. 2A, since they are much closer to the retaining flange 13 and thus the sink bottom wall 10, will resiliently engage the rim of the drain aperture 11 and remain in various flexed positions as indicated in FIG. 2A. Thus the sink wall 10 is effectively clamped between the flange 13 and the retaining edges 23b of the two fins 23 in each group. Observe that the clamping action thereby occurs at uniformly spaced locations about the drain aperture 11.
Installation in cast iron sinks is in an identical manner except, as shown in FIGS. 3 and 3A and owing to the thicker sink portion wall 10', more fins 23 remain in a flexed position, with, say, fins 1-3 in each group, as shown in FIG. 3A, folded completely back on the collar 22 within the aperture 11', their retaining edges 23b therefore being wholly out of engagement with the latter. On the other hand, fins 4-6 in each group, say, will be partially flexed with their retaining edges 23b in various states of engagement with the rim of the drain aperture 11', as indicated in FIG. 3A. Observe that here too the clamping action is uniformly spaced about the drain aperture 11'. More or fewer fins 23 of course could be employed in each group, depending upon the application, and the number of groups of them could also be varied so long as the resulting clamping action is uniformly distributed. In the foregoing manner, therefore, the groups of fins 23 cooperate to permit sinks of various wall thicknesses to be readily accommodated by a single drain assembly without need for any field adjustment or other means to secure it in position. And the entire operation can be performed in a few seconds by a single workman from above the sink.
It has been found in practice that a drain body 12 whose well 14 is about 23/4 inches deep and a retaining sleeve 20 which is about 1-7/16 inches in axial length will accommodate all stainless steel sinks and most all cast iron sinks. In that case the fins 23 may have a radial length of about 0.7 inches and a thickness of about 0.06 inches, with an outer diameter of the collar 22 of about 31/4 inches. The noses 23a of fins 1 may extend about 0.015 inches above the upper end of the collar 22 while the inner ends of the retaining edges 23b of fins 2-6 step down progressively therefrom, beginning with 0.028 inches for fins 2 and ending with 0.40 inches for fins 6. This assures that there will be, as is preferable, the retaining edges 23b of at least two fins 23 in each group in engagement with the rim of the drain aperture no matter how thin the sink bottom wall may be. While it is preferable that the retaining edges 23b step down in the circumferential direction opposite to that in which the drain assembly is twisted when installed, that is not mandatory, though it does insure engagement of the retaining edges 23b nearer their inner ends with the rim of the drain aperture and thus a better grip upon the latter. Finally, it is conceivable that the drain body 12 and the fins 23 could even be a one-piece plastic molding, thus eliminating the need for a separate collar 22 and locking ring 21.
There are a few cast iron sinks, however, whose wall thickness is so great that they cannot be accommodated by a drain assembly of the foregoing dimensions. In those cases, the drain body well 14 would need to be deeper and a spacer used between the retaining flange 13 and the retaining sleeve 20 or a modified one of the latter employed. If a spacer were used, it would be placed between the retaining sleeve 20 and the locking ring 21 when the drain assembly were used with other sinks of thinner walls. But these very thick walled sinks are so few in number that it has not been deemed necessary to go to the expense of manufacturing and distributing additional or special parts for them. That could be done, however, and still embody the essential principles of the present invention.
Hence, though the present invention has been described in terms of a particular embodiment, being the best mode known of carrying out the invention, it is not limited to that embodiment alone. Instead, the following claims are to be read as encompassing all adaptations and modifications of the invention falling within its spirit and scope. | A drain assembly for a sink or the like employs a plastic sleeve below a retaining flange, the periphery of the sleeve being provided with several groups of flexible fins extending out therefrom parallel to its axis, the fins of each group being located at successively increasing distances from the retaining flange. The assembly can be installed by one person from above the sink or the like simply by pushing it down into the drain aperture with a twisting motion until at least some of the fins in each group tightly engage the under surface of the drain aperture, the fins thereby readily accommodating both stainless steel and cast iron sinks or the like of various wall thicknesses. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a multilayer or duplex papermaking fabric having a high open area. In particular, the invention relates to a papermaking fabric which is suitable as the base or supporting fabric for an embossing papermakers fabric and has a top plane surface with an open area of at least forty-percent (40%).
2. Backqround of the Art
Disposable paper products, such as towels, facial tissues, sanitary tissues, wipers and the like are made from one or more layers or webs of tissue paper. As such disposable products have grown in use, it has become desirable to enhance certain physical characteristics. Among the most important characteristics of the disposable paper products are strength, softness or feel and absorbency.
In producing such products, the papermaking fabric will have a substantial impact on the final product characteristics. In the present state of the art, fabrics which are known as embossing fabrics are utilized to produce many of the products. Embossing fabrics are generally comprised of a base or substrate fabric which has been modified through the application of a material which forms a paper contact surface. Such materials are generally curable resins. The resin material is applied to the fabric to produce certain geometric forming surfaces which will impart the fabric characteristics. In one process for producing the embossing fabric, the fabric is coated with a liquid photosensitive resin to a preselected value or thickness. The resin is exposed to light, having an activating wave length, through a mask which develops a pattern on the paper carrying surface. Uncured resin is removed from the fabric and the resulting embossing fabric will have a specific preselected geometry. One prior art example of such a process is set forth in U.S. Pat. 4,528,239, the specification of which is incorporated herein by reference as if fully set forth.
SUMMARY OF THE INVENTION
The present invention sets forth an improved papermaker's fabric which is particularly useful as a substrate in the embossing fabric art.
The improved fabric is characterized by having at least two systems of machine direction yarns which are arranged in a vertical stacked arrangement. Cross machine direction yarns are preferably interwoven with the machine direction yarns to establish a symmetric weave and to avoid unbalanced forces on the machine direction yarns. The cross machine direction yarns are further woven so as to lock the machine direction yarns against horizontal and vertical movement in the fabric. The woven fabric will have a top plane with an open area of at least forty-percent (40%). That is to say, the interstices between the interwoven yarns will total at least 40% of the total fabric surface area.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a section cut through the machine direction yarns and parallel to the cross machine direction yarns of the preferred embodiment of the invention.
FIG. 2 is an illustration showing the interweaving of the first and second cross machine direction yarns in the weave of FIG. 1.
FIG. 3 is an illustration of the interweaving of cross machine direction yarns 3 and 4 in the weave of FIG. 1.
FIG. 4 is an illustration of the interweaving of cross machine direction yarns 5 and 6 in the weave of FIG. 1.
FIG. 5 is an illustration of the interweaving of cross machine direction yarns 4, 5 and 6 of the weave of FIG. 1.
FIG. 6 is an illustration of the interweaving of cross machine direction yarns 4, 5 and 6 of the weave of FIG. 1.
FIG. 7 is a top plan view of one repeat of the fabric according to the weave of FIG. 1.
FIG. 8 is a section of an alternative embodiment of the invention in a different weave pattern from that shown in FIG. 1.
FIG. 9 is an illustration of the weave of FIG. 8 with the addition of stuffer yarns.
DETAILED DESCRIPTION OF THE INVENTION
While the specification will employ certain terms for the purposes of description, it will be understood that the art recognizes alternative terms for the same element and that such alternative terms are intended to be within the scope of the claims appended hereto. Likewise terms, such as upper, lower, left and right, are used relative to the drawing figures and are not intended as absolute directions. The terms "machine direction" and "cross machine direction" refer to the direction of use and not the loom designation of the respective yarns. Fabrics according to the invention may be woven flat or endless and with or without seams. In each of the drawing figures, like elements are identified with the same numeral.
With reference to FIG. 1, there is shown a fabric 10 which is of a duplex or multilayer construction. The fabric 10 is comprised of a first system 7 of machine direction yarns 11 through 22, a second system 8 of machine direction yarns 23 through 34, and a system of cross machine direction yarns 1 through 6. The machine direction yarns 11 through 22 which comprise the system 7 are vertically stacked above the machine direction yarns 23 through 34 which comprise system 8. In the present specification, the term "stacked" means that a machine direction yarn of system 7 and the associated machine direction yarn of system 8 are in the same vertical plane. Likewise, all of the yarns within machine direction systems 7 and 8 are parallel to each other and lie in a respective common horizontal plane. This relationship will be discussed further hereinafter with respect to FIG. 7. The cross machine direction yarns are interwoven in a pattern of two over and four under. Those skilled in the art will recognize that twelve harnesses are utilized to produce the weave pattern.
With reference to FIGS. 2 through 6, it can be seen that the cross machine direction yarns are interwoven in a pattern which will produce a plurality of floats and interlacings which sequentially isolate and lock a given machine direction yarn in a preselected position. Furthermore, it can be seen that the weave pattern produces a fabric having an upper or top surface and a lower or bottom surface which are essentially mirror images of each other.
With reference to FIG. 2, cross machine direction yarn, as it progresses to the right, floats above machine direction yarns 11 and 12 then turns downward to pass between machine direction yarns 13 and 25 and under machine direction yarn s 26 and 27. Cross machine direction yarn 1 then turns upwardly between machine direction yarns 16 and 28. Thereafter, cross machine direction yarn 1 will repeat the interweaving with systems 7 and 8. Cross machine direction yarn 2 weaves in the mirror image of cross machine direction 1.
With reference to FIG. 3, cross machine direction yarn 3, as it progresses to the right, passes between machine direction yarns 11 and 23, over machine direction yarns 12 and 13, between machine direction yarns 14 and 26 and under machine direction yarns 27 and 28. Beginning with machine direction yarns 17 and 29, cross machine direction yarn 3 repeats the pattern. Cross machine direction yarn 4 weaves in the mirror image of cross machine direction yarn 3.
With respect to FIG. 4, cross machine direction yarn 5, as it progresses to the right, interweaves between machine direction yarns 12 and 24, over machine direction yarns 13 and 14, down between machine direction yarns 15 and 27 and beneath machine direction yarns 28 and 29 before repeating the pattern. Cross machine direction yarn weaves in the mirror image of cross machine direction yarn 5.
As can be seen from the above, the pattern and sequencing of interweaving produces a structure in which the cross machine direction yarns weave over under and across each of the machine direction yarns in a pattern which isolates and interlocks the respective machine direction yarn. By weaving the cross machine direction yarn in a symmetric weave, it is possible to avoid uneven forces on the machine direction yarns and to lock the yarns against both vertical and horizontal movement. In the final weave structure, the machine direction yarns are effectively straight throughout their length with the majority of the take up and most of the crimp concentrated in the cross machine direction yarns.
With reference to FIGS. 5 and 6, it is possible to see the locked position of the machine direction yarns according to the invention. With reference to FIG. 5 and machine direction yarn 13, it can be seen that cross machine direction yarn 1 passes along side and beneath the left hand portion of yarn 13; cross machine direction yarn passes along side and beneath the right hand portion of yarn 13 and cross machine direction yarn 3 passes over the top of machine direction yarn 13 In the final weave, cross machine direction yarns 1 through serve to capture and position machine direction yarn 13. With reference to FIG. 6, it can be seen that the interweaving of cross machine direction yarns 4, 5 and 6 do not capture machine direction yarn 13. However, the machine direction yarn 24 is captured by the interweaving of cross machine direction yarns 4 through 6 in a manner similar to that previously described with respect to FIG. 5.
With reference to FIG. 7, the weave structure of FIG. 1 can be further understood. As noted previously, the weave is a twelve harness weave and the cross machine direction yarns are woven in a two, four twill pattern. In the top plan view of FIG. 7, the machine direction yarns of system 7 along with the upper floater of cross machine direction yarns 1 through 6 will form the upper or top fabric surface. The machine direction yarns of system 8 will be aligned vertically below the machine direction yarns of system 7 and are indicated by the phantom lead lines. It will be understood by those skilled in the art that the interweaving of the cross machine direction yarns 1 through 6 with the machine direction yarns of system 8 will be partially visible when the fabric is viewed from the top plan as shown in FIG. 7. For purposes of clarity and description, only cross machine direction yarn 1 has been fully illustrated. All other cross machine direction yarns are illustrated as they would appear in the top plane.
Further with reference to FIG. 7, it can be seen that the described weave structure provides a number of interstices 40. In order to achieve the minimum open area of forty-percent (40%) according to the invention, the total area of interstices 40 must equal at least 40% of the surface area of the fabric. In the preferred embodiment, the machine and cross machine direction yarns are 5.91 mils or 0.15 mm and the fabric is woven with a mesh count of 60.
With reference to FIG. 8, there is shown an alternative embodiment of the fabric according to the invention woven on eight harnesses in a one, three repeat pattern. Thus, the length of the repeat pattern encompasses at least four adjacent top layer machine direction yarns. The machine direction systems 7 and 8 will be as shown previously and the interweaving of cross machine direction yarns 1 through is illustrated in a manner similar to FIG. 1.
With reference to FIG. 9, there is shown another alternative embodiment of the fabric 10 according to the instant invention. In FIG. 9, the weave is a twelve harness weave which incorporates the addition of a stuffer system 9 of machine direction yarns. Like FIG. 8 the repeat pattern is one, three and the interweaving of cross machine direction yarns 1 through 4 is illustrated. Once again, the upper and lower planes of the fabric are mirror images. The stuffer yarns, like the other machine direction yarns are captured and maintained in place by the cross machine direction weave. In general, the stuffer yarns will be of substantially smaller diameter than the machine direction yarns and will be used to control the air permeability of the fabrics. Although it is critical to maintain the open area of at least 40% in the top fabric plane, it is also necessary to control air permeability through the fabric.
Generally, air permeability in fabrics according to the invention is greater than 900 CFM and is preferably in the range of 1,000 to 1,300 CFM. Air permeability is measured on the Frazier High Pressure Differential Permeability Testing Machine which will be known to those skilled in the art.
With respect to the fabric caliper, it is preferred that the substrate fabric have a caliper of about 24 mils. Although fabrics as high as 29 mils have been tried, it has been found that base fabrics in excess of about 26 mils hamper the curing process associated with the resin coating which may be applied to the fabric 10 when used as a substrate for an embossing fabric.
As can be seen from the foregone, it is necessary to utilize a cross machine direction weave pattern which captures and vertically stacks the machine direction yarn. This weave structure must accomplish a minimum top layer or plane open area of 40% and must provide the required air permeability through the fabric of about at least 900 CFM. Fabrics according to the instant invention are suitable for resin coating in accordance with the disclosure of U.S. Pat. 4,528,239. | A papermaker's fabric is disclosed. The fabric is comprised of at least top and bottom machine direction yarn systems, each machine direction yarn system being formed of a plurality of yarns which defines a respective top or bottom plane of machine direction yarns. The yarns of the systems are vertically aligned and the top and bottom planes are parallel. A cross machine direction yarn system is interwoven with the machine direction yarn systems in a repeated pattern encompassing at least four adjacent top plane machine direction yarns, with the fabric top plane having an open area of at least 40% and the fabric having an air permeability of at least 900 CFM. The fabric as a substrate has special utility for an embossing fabric. | 3 |
BACKGROUND
[0001] The invention relates to a (preferably hydraulic) master cylinder for an actuating device of a clutch or a brake of a motor vehicle, such as a car, truck, bus, or agricultural utility vehicle, comprising a cylinder housing having a pressure cylinder section, as well as a piston movably provided in reference to the cylinder housing, with the piston being arranged in the actuated state within the pressure cylinder section in order by a piston to control a fluid pressure in a pressure chamber, fluidically sealed via a sealing device, and being arranged in a pressureless state such that the pressure cylinder section is fluidically connected to a retention system.
[0002] Generic master cylinders as well as actuating devices are known from prior art in various embodiments, with for example DE 10 2013 204 561 A1 disclosing a sealing arrangement, particularly a piston cylinder unit. The sealing arrangement comprises an annular seal with a static sealing lip and a dynamic sealing lip, which are connected to each other, with the seal being provided in a seat which has at least one circumferential wall and at least one axial wall. The seal rests here with the static sealing lip radially at the circumferential wall, with the dynamic sealing lip contacting another wall abutting the seat, being dynamically supported. The additional wall has in an axial section a plurality of axial grooves, provided distributed in the circumferential direction, and the dynamic sealing lip has in an axial section of its extension a plurality of axial grooves, provided distributed in the circumferential direction. The axial grooves of the dynamic sealing lip are connected to each other via a circumferential groove.
[0003] However it has been shown in these embodiments known from prior art that in case of an extended contact of the respective sealing lip/seal in the groove area, for example in a parking position in which the seal is located in a shut-off state of the master cylinder, disadvantageously a lasting deformation of the sealing lip can occur due to the environmental circumstances; because when the sealing lip, for example in a parking position, at relatively low ambient temperatures abuts an uneven area over an extended period of time, here a deformation of the sealing contour can occur at the seal. When the master cylinder is actuated anew the cold sealing lips can then remain deformed, at least partially and over a first period of time, resulting in the master cylinder exhibiting strong leakage. A reliable function of the master cylinder is then no longer ensured under such circumstances.
[0004] It is further disadvantageous in the embodiments known from prior art that the seals/sealing devices require a relatively expensive assembly. Here, particularly when inserting the piston into the cylinder housing, the seals may be subjected to excessive mechanic stress, which can even lead to an abrasion of material at the seals. This would lead to a defect of the respective seat.
SUMMARY
[0005] The objective of the present invention is to correct the disadvantages known from prior art and to provide a master cylinder in which operation free from leakage shall be ensured even after an extended downtime of the motor vehicle and simultaneously an uncomplicated and reliable assembly of the sealing device shall be obtained.
[0006] This objective is attained according to the invention in that the seal of the sealing device is embodied and arranged at the piston such that at least in a parking position, in the pressureless state, it contacts a seal protecting section of a stop element.
[0007] This way it is possible to fasten the seal responsible for sealing the pressure cylinder section directly at the piston and to connect said piston to the respective stop element already before inserting it into the cylinder housing. Subsequently the stop element only needs to be fastened to the cylinder housing, with a protected contacting of the seal at the seal protecting section. This allows a particularly gentle assembly of the seal, with simultaneously in the respective parking position the seal contacting in the protecting section allowing any unintentional deformation of the seal to be prevented.
[0008] Other advantageous embodiments are claimed in the dependent claims and explained in greater detail in the following.
[0009] According to another embodiment it is advantageous for the piston to be arranged in a pressureless state outside the pressure cylinder section. The pressure cylinder section represents here preferably the section of the cylinder housing, which shows a homogenous section extending in a cylindrical fashion. The pressure cylinder section is preferably embodied circularly. This way a particularly effective ability for shifting the master cylinder is implemented.
[0010] If the stop element is furthermore embodied as a part separated from the cylinder housing (separated from the material thereof) the stop element can be produced in a particularly cost-effective fashion.
[0011] In this context it is also beneficial for the stop element to be embodied as a cold formed, for example deep-drawn part. Further preferred, the stop element is formed like a cup/sheath. This way an even more cost-effective production is possible.
[0012] If the stop element forms the seal protecting section at an internal circumferential area, with the internal circumferential area showing a first diameter, constant over the circumference in the area of the seal protecting section, the seal protecting section can be produced in a particularly simple fashion. Thereby the production of the master cylinder is further promoted.
[0013] If the first diameter of the seal protecting section is greater than a second diameter of the pressure cylinder section the seal of the sealing device can slightly relax in the parking position inside the stop element and thus slightly expand in the radial direction such that this way the trend to leak is further minimized.
[0014] If the cylinder housing advantageously comprises a transitional section, expanding in the axial direction of the stop element chronically away from the pressure cylinder section and showing several radial grooves connected to the retention system, this way a snifter operation can also be implemented easily with this master cylinder in which it is not required to completely retract the piston into the parking position in order to compensation pressure peaks. This renders the master cylinder to be particularly powerful.
[0015] It is furthermore advantageous for the seal to be embodied in an annular fashion, with a sealing lip of the seal being embodied such that it can be made to contact the seal protecting section as well as the pressure cylinder section. This sealing lip is preferably in contact with the sealing protecting section, at least in the parking position/in the pressureless state, as well as in contact with the pressure cylinder section in the actuated state. This way a particularly efficient seal is implemented.
[0016] It is also beneficial for the stop element to show a retention system embodied at a radial exterior side, formed like a clamp, which in the operating state is inserted into a receptacle of the cylinder housing in a radially fixed but axially displaceable fashion. This allows a particularly simple fastening of the stop element and further facilitates the assembly.
[0017] If the stop element is pre-stressed via a disk spring in the direction of the pressure cylinder section, the approaching to the reference point is also easily possible. Here the disk spring is preferably arranged such that the piston can be pulled from the parking position further away from the pressure cylinder section, which leads to a displacement of the stop element in the same direction. A reference point is then reached when the disk spring contacts a reference stop and is essentially located in a vertical alignment. In this reference point the stop element is always held by the restraint system still in the radial direction in the cylinder housing. Further preferred, the displacement path of the piston is calculated directly via a spindle, driving the piston, as a function of the rotations performed. This allows implementing a master cylinder in which a path sensor can be waived for determining the position of the piston. This way the master cylinder is embodied in a particularly cost-effective fashion. Consequently, when moving between a parking position and a reference position/a reference point the piston is located inside the stop element such that the seal contacts the seal protecting section during this motion.
[0018] Furthermore, the invention also relates to a method for assembling this master cylinder according to one of the above-mentioned embodiments, comprising at least the following steps performed successively:
[0019] Inserting the piston into the stop element such that the seal is inserted/positioned and contacts the seal protecting section in the stop element (being in the parking position),
[0020] Inserting the stop element, receiving the piston, into a receptacle in the cylinder housing until the stop area of the stop element contacts the counter stop area of the cylinder housing, and
[0021] Fastening at least one lid element at the cylinder housing with the stop element axially being pre-stressed in the direction of the pressure cylinder section.
[0022] This way the assembly of the master cylinder is embodied in a manner particularly gentle for the seal.
[0023] In other words, the present invention provides as a solution for any “freezing” the seal/the sealing lip of the seal at low temperatures that the sealing lip rests in the reference position and in the parking position respectively on an interior area of the cylinder free from grooves (seal protecting section). This interior area of the cylinder is provided by a sheath (stop element) comprising an internal diameter (first diameter) which is greater than the internal diameter (second diameter) of the pressure chamber of the pressure cylinder (pressure cylinder section). This way even for a “frozen” position here a respective compression for sealing is ensured when pressure develops. In the proximity of the snifter groove (radial groove) of the housing/cylinder housing of the pressure cylinder the seal leaves the sheath section (seal protecting section) and impinges the interior area of the housing (transition section). For this purpose the interior area of the housing is designed in a conical fashion, with a (third) diameter in the direction of the sheath/the stop element being greater than the internal diameter of the sheath. When the sealing lip is displaced in the area of the pressure cylinder here it contacts not any edge but rather a diagonal section which contracts slowly to the internal diameter of the cylinder/pressure cylinder section. This way damages can be avoided. The snifter apertures and perhaps also snifter grooves/radial grooves are provided in this conical section (transition section) of the cylinder housing of the pressure cylinder. The conical section may have centering elements by which the centering of the sheath with regards to the cylinder can be at least supported. The sheath/guide sheath is here embodied such that it cannot follow the feed of the piston in the conical section, but exhibits a pre-stressing which contacts a stop of the cylinder housing. Accordingly the sheath fulfills the dual function that it is designed in one piece and also represents the contact point of the piston to the disk spring in order to determine the reference point. The piston is here pressed against the reference stop with increased force in reference to the “normal force” for moving the piston without here the piston being pressed open or shut. The reference stop is here sized such that it can also bridge resistances in the spring section, which are caused for example by soiling. Other embodiments include forming the sheath as an additional reference stop and the embodiment towards the housing stop and the expansion and the conical form of the cylinder in the proximity of the snifter bore holes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] In the following the invention is explained in greater detail based on figures.
[0025] Shown are:
[0026] FIG. 1 a longitudinal cross-section of a master cylinder according to the invention in a first embodiment, with particularly the pressure cylinder section, the retention system, as well as the piston of the master cylinder cooperating with the pressure cylinder section being shown,
[0027] FIG. 2 a detail of the longitudinal cross-section already shown in FIG. 1 in the proximity of the piston as well as the stop element, with the piston being in a parking position of the pressureless state and a transitional section being discernible, connecting the pressure cylinder section via radial grooves to the retention system,
[0028] FIG. 3 a detailed longitudinal cross-section of the master cylinder in the proximity of the piston as well as the stop element similar to FIG. 2 , with in FIG. 3 the piston as well as the stop element being sectioned in an area offset from the radial grooves,
[0029] FIG. 4 an isometric illustration of the cylinder housing of the master cylinder in the proximity of the pressure cylinder section, with the transition section and its radial grooves being clearly discernible,
[0030] FIG. 5 an isometric illustration of the stop element, with its longitudinal sectional area being indicated and shown from a side which in the operating state faces away from the pressure cylinder section,
[0031] FIG. 6 a longitudinal cross-section of an assembly between the stop element and the piston and/or the piston head thereof, which accepts the seal of the sealing device,
[0032] FIG. 7A a longitudinal cross-section of a master cylinder, with the section of the piston accepting the seal as well as the stop elements being shown, and with the piston including the stop element being displaced into a referencing position/reference position,
[0033] FIG. 7B a longitudinal cross-section of the master cylinder according to FIG. 7A , with the piston including the stop element being in a parking position,
[0034] FIG. 7C a longitudinal cross-section of the master cylinder according to FIGS. 7A and 7B , with the piston being displaced out of the stop element in the direction of the pressure cylinder section such that the seal with its external side contacts the pressure cylinder section with its exterior, at a snifter point, just before completely sealing it, but a fluidic connection is still given between the pressure cylinder section to the retention system, and
[0035] FIG. 7D a longitudinal cross-section of the master cylinder, as already illustrated in FIGS. 7A to 7C , with the piston being in the actuating state in which it is inserted into the pressure cylinder section and the seal contacts the interior surface of the pressure cylinder section in a sealing fashion.
[0036] The figures are only of a schematic nature and exclusively serve to explain the invention. Identical elements are marked with the same reference characters.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] FIG. 1 shows in a clear fashion a first embodiment of the master cylinder 1 according to the invention. The master cylinder 1 is provided for the use in a hydraulic actuator device, not shown in greater detail for reasons of clarity, of a clutch in a drivetrain or in a brake of a motor vehicle. Preferably the master cylinder 1 is however embodied as a hydraulic master cylinder. The hydraulic master cylinder 1 is here preferably inserted as the actuating element in a hydraulic clutch actuator. Alternatively it is also possible though to insert the hydraulic master cylinder 1 in an actuating device, which is embodied as a modular clutch actuator. The master cylinder 1 is designed according to the so-called “snifter system”.
[0038] The master cylinder 1 comprises a pressure cylinder section 2 , which is arranged in a cylinder housing 3 of the master cylinder 1 . The pressure cylinder section 2 is formed essentially circularly with regards to its cross-section and extends cylindrically. At a first axial end section the pressure cylinder section 2 comprises a connection 11 , which connection 11 is hydraulically connected to the element of the actuating device respectively to be operated, for example a clutch actuator bearing (engagement or disengagement bearing) or a brake piston (in the operating state). At a second axial end section, which is located opposite the first axial end section, the pressure cylinder section 2 has an opening through which a piston 4 can be inserted into the pressure cylinder section 2 .
[0039] The piston 4 (also called pressure piston) is supported in a displaceable fashion in the axial direction of the pressure cylinder section 2 in reference to the cylinder housing 3 . The piston 4 is arranged coaxially in reference to the pressure cylinder section 2 . The piston 4 is arranged in an operating state of the master cylinder 1 inside the pressure cylinder section 2 , i.e. inserted in the pressure cylinder section 2 . The piston 4 comprises a sealing device 5 , which cooperates in the operating state with the pressure cylinder section 2 such that the piston 4 and the pressure cylinder section 2 form a sealed pressure chamber 6 . As a function of the axial position/axial displacement position of the piston 4 within the pressure cylinder section 2 here the pressure is controlled inside the pressure chamber 6 and thus also in the proximity of the connection 11 . In a pressureless state of the master cylinder 1 the piston 4 is placed in reference to/outside the pressure cylinder section 2 such that the pressure cylinder section 2 is connected fluidically to the restraint system 7 (also called restraint storage or reservoir) in a fluidic/hydraulic fashion. The sealing device 5 comprises a seal 8 , which seal 8 is arranged in the axial direction/axially fixed to the piston 4 . The piston 4 is here at least in a parking position of the master cylinder 1 , in the pressureless state, inserted in a stop element 9 , with the seal 8 contacting the seal protecting section 10 .
[0040] It is furthermore clearly discernible in connection with FIGS. 2 and 3 that the pressure cylinder section 2 showing a circular cross-section (hereinafter called second diameter) transfers at its second axial end section into a transitional section 12 . The transitional section 12 is embodied/connected integrally to the pressure cylinder 2 . The transitional section 12 therefor follows in the axial direction to a side of the pressure cylinder section 2 facing away from the connection 11 . The transitional section 12 comprises a conically extending internal circumferential side 13 , which is enlarged in its diameter from the pressure cylinder section 2 in the axial direction away from the pressure cylinder section 2 . The transitional section 12 therefore shows at the axial end, facing away from the pressure cylinder section 2 , a third diameter which is greater than the second diameter.
[0041] The embodiment of the transitional section 12 is particularly clearly discernible in FIG. 4 . The transitional section 12 is essentially formed in a circular fashion. Several radial grooves 14 are inserted in the transitional section 12 at a front area facing away from the pressure cylinder section 2 . Due to the fact that the transitional section 12 is embodied integrally with the pressure cylinder section 2 , the radial grooves 14 are therefore inserted in the cylinder housing 3 . The radial grooves 14 are open towards the interior circumference 13 and connect the radial interior of the transitional section hydraulically/fluidically to the retention system 7 , which in turn is connected via at least one connection groove 15 to the radial grooves 14 .
[0042] At the axial end of the transitional section 12 , facing away from the pressure cylinder section 2 , the transitional section 12 also extends essentially annularly and is embodied in the form of a facial groove. The receptacle 16 serves to accept the stop element 9 . In the actuating state the stop element 9 is inserted into the receptacle 16 and contacts with an axial stop area directly a counter stop area of the transitional section 12 . In this context FIG. 2 shows in a particularly illustrating fashion a parking position of the master cylinder 1 , with the stop element 9 being formed via a clamp-like and annular restraint system 17 , which is preferably formed by beading, inserted into the receptacle 16 . The radial interior circumference of the receptacle 16 and the exterior circumference of the restraint system 17 abutting it are here with regards to their diameters adjusted to each other such that the stop element 9 is held in the radial direction in reference to the cylinder housing 3 , however still allows displacement in the axial direction.
[0043] The stop element 9 (also called guide sheath), essentially embodied like a cup, further comprises a first step 18 extending in the radial direction, at which a disk spring 19 is arranged at the axial side, facing away from the pressure cylinder section 2 , so that the stop element 9 is held in the cylinder housing 3 protected from getting lost. The seal protecting section 10 is formed directly by an interior circumferential area 20 of the stop element 9 . The interior circumferential area 20 comprises a circular, planar/flat surface area. Additionally, the interior circumferential area 20 shows a diameter, namely a first diameter, which is also greater than the second diameter, i.e. the diameter of the pressure cylinder section 2 . The first diameter is however embodied smaller than the third diameter. A second radial step 21 , which is arranged radially inside the first radial step 18 as well as the interior circumferential area 20 , is further provided for the purpose to serve as a stop for the piston 4 . The second step 21 therefore prevents the piston 4 from being pulled out in the axial direction, away from the pressure cylinder section 2 .
[0044] The further embodiment of the stop element 9 is particularly clearly discernible in FIGS. 5 and 6 as well. Here it is also clearly shown that the seal 8 is embodied as a lip seal and has the sealing lip 22 , which when seen in the longitudinal cross-section extends from a base section 23 in the radial direction as well as the axial direction towards the pressure cylinder section 2 . The base section 23 abuts flat along the circumference of an exterior of a piston head of the piston 4 . The seal 8 is embodied continuously along the entire circumference, i.e. embodied in an annular fashion. The sealing lip 22 contacts in its parking position, as shown in FIG. 2 , preferably at the seal protecting section 10 . As furthermore clearly discernible in connection with FIG. 3 as well as in connection with FIG. 5 the stop element shows in a radial section between the retention system 17 and the second step 21 several compensation openings distributed evenly over the circumference in the form of penetrating bores, via which an additional pressure is released, which may develop perhaps behind the sealing lip 22 , i.e. in an axial direction facing away from the pressure cylinder section 2 .
[0045] Furthermore, the various shifting states of the master cylinder 1 are shown in greater detail in connection with FIGS. 7A to 7D . The piston 4 is a part of a spindle drive, which is not shown in greater detail for reasons of clarity. Consequently a rotary motion of a spindle causes the axial displacement of the piston 4 in the direction of the pressure cylinder section 2 , into it or out of it. FIG. 7A shows a reference position/referencing position of the master cylinder 1 . In this reference position the piston 4 is retracted in the axial direction away from the pressure cylinder section 2 such that its disk spring 19 comes to contact a secondary reference stop 25 . In this referencing point, based on the embodiment of the master cylinder 1 without a path sensor, the initial position of the piston 4 is metrologically checked such that it can be securely assumed that the piston 4 is positioned in the desired position in the further displacement range, in the pressureless state as well as the actuated state.
[0046] In this reference position, based on the stop of the disk spring 19 at the reference stop 25 and the axial displacement of the disk spring 19 , the stop element 9 is slightly pulled out of the receptacle 16 in reference to the parking position according to FIGS. 2 and 7B , however still guided in the radial direction in the receptacle 16 . After the metrological detection/determination/checking of the reference position/referencing position a start position is allocated to the piston 4 , from which the piston 4 then is moved back into the parking position according to FIG. 7B . In the parking position the retention system 17 contacts with its axial face (also called contact area), facing the pressure cylinder section 2 , in the axial direction the receptacle 16 (also called counter contact area). In this parking position once more the axial support of the stop element 9 and the spring-elastic pre-stressing in the direction of the pressure cylinder section 2 is provided via the disk spring 19 .
[0047] Finally, if the pressure chamber 6 shall be impinged with a certain hydraulic pressure in order to actuate a clutch or a brake, according to FIG. 7C the piston 4 is inserted into the pressure cylinder section 2 . Due to the fact that the first diameter is smaller than the third diameter and the interior circumference 13 of the transitional section 12 extends in a conically tapering fashion from the receptacle 16 to the pressure cylinder section 2 , the sealing lip 22 is particularly carefully inserted into the pressure cylinder section 2 with the axial motion in the pressure cylinder section 2 . By a sealing contact of the sealing lip 22 at the pressure cylinder section 2 , according to FIG. 7D further any arbitrary pressure can be generated in the pressure chamber 6 . If during operation, for example due to temperature fluctuations, undesired pressure peaks develop, the piston 4 is again via the drive withdrawn from the pressure cylinder section 2 to such an extent that the sealing lip 22 contacts in a so-called snifter point at the level of the transitional section 12 according to FIG. 7C . In this snifter point it is ensured that the sealing lip 22 is still essentially contacting/compressed on the radial level of the second diameter, however a brief opening of the pressure chamber 6 to the restraint reservoir 7 is ensured via the radial grooves 14 . This way brief pressure compensation can occur. If finally the actuating process is completed, the piston 4 is once more brought into the pressureless state, with the pressureless state representing the state in which the pressure cylinder section essentially shows the same pressure as the retention system. The parking position in this pressureless state (see FIG. 7B ) shows the piston 4 in the pushed-back state.
[0048] Based on the improved design of the stop element 9 as well as the piston 4 including the sealing device 5 the assembly of the master cylinder 1 is also possible in a particularly simple fashion. For this purpose, as clearly discernible in FIG. 6 , initially the piston 4 is inserted such that the sealing lip 22 already contacts the seal protecting section 10 and is compressed to the first diameter. Then the assembly of the stop element 9 and the piston 4 is inserted into the cylinder housing 3 , leading to the retention system 17 contacting the receptacle 16 , which receptacle 16 therefore forms a type of counter stop area. Subsequently then a lid element 26 is fastened at the cylinder housing 3 such that the stop element 9 is positioned in the cylinder housing 3 via the disk spring 19 in a spring-elastic fashion and protected from getting lost.
[0049] In other words, with the master cylinder 1 according to the invention a primary seal 8 is provided, which sits in a parking position on a closed annular area, namely the interior circumferential area 20 . This annular area 20 can be placed fixed to the housing/fixed to the cylinder housing or floating on a stop element 9 for referencing/plausibility checking. The stop element 9 is advantageously centered in reference to the hydraulic housing/cylinder housing 3 (via transitional sections 12 in the actuated state). The actual pre-stressing (caused by the disk spring 19 ) of the stop element 9 ensures the reduction/minimization of a gap between the closed park area/annular area (interior circumferential area 20 ) and the snifter groove section (equivalent to the transitional section 12 ). The assembly of the primary seal 8 in the hydraulic housing 3 is simplified, with initially the piston 4 being preassembled in the parking position.
LIST OF REFERENCE CHARACTERS
[0050] 1 master cylinder
[0051] 2 pressure cylinder section
[0052] 3 cylinder housing
[0053] 4 piston
[0054] 5 sealing device
[0055] 6 pressure chamber
[0056] 7 restraint system
[0057] 8 seal
[0058] 9 stop element
[0059] 10 seal protecting section
[0060] 11 connection
[0061] 12 transitional section
[0062] 13 internal circumferential side
[0063] 14 radial groove
[0064] 15 connection groove
[0065] 16 receptacle
[0066] 17 retention system
[0067] 18 first step
[0068] 19 disk spring
[0069] 20 internal circumferential area
[0070] 21 second step
[0071] 22 sealing lip
[0072] 23 base section
[0073] 24 compensation opening
[0074] 25 reference stop
[0075] 26 lid element | The invention relates to a master cylinder for an actuating device of a clutch or a brake of a motor vehicle, including a cylinder housing having a pressure cylinder section, as well as a piston mounted movable relative to the cylinder housing, wherein the piston is arranged inside the pressure cylinder section in an actuation state in order to control a fluid pressure in a fluidically sealed pressure chamber by a sealing device on the piston side, and is arranged in a pressureless state such that the pressure cylinder section is fluidically connected to a retention system, wherein a seal of the sealing device is configured, and attached to the piston, such that it rests on a seal protection area of a stop element at least in a parking position in the pressureless state; as well as a method for mounting such a master cylinder. | 1 |
FIELD OF THE INVENTION
This invention relates to a paint composition for use on the floor of a fuel or gas station or of a place for storing or applying the fuel, for example, on the floor of a building room, a staircase, a corridor, a veranda, a rooftop, a vehicle or a boat, especially on the floor exposed to the outside air, mainly in the field of architecture.
BACKGROUND OF THE INVENTION
In the relevant art, a gypsum-cement, gypsum-resin, or gypsum-cement-resin compositions are taught in which the water resistance of gypsum is improved. Such compositions are disclosed in Japanese laid-open Patent Application Nos. 49-52823 and 53-144934. In particular, the gypsum-cement-resin composition disclosed in Japanese examined and published Patent Application No.58-30257 provides sufficient water resistance for a short time, around one day. However, when the water resistance test is performed over a longer period of time, one week or longer, a problem arises, namely the composition swells.
In the gypsum-cement-resin composition described in Japanese laid-open Patent Application No. 48-43416, the content of the cement is of a larger ratio than that of the gypsum. Such a composition provides fluidity, water resistance and strength over a long period of time, but not without shortcomings. Primarily, the composition is susceptible to cracking over time.
To solve the aforementioned problems, Japanese laid-open Patent Application No. 6-128009 discloses a floor finish composition which can be applied in a short time and provides water resistance and crack prevention. The composition is mainly composed of 85 parts by weight of α-type hemihydrate gypsum, 15 parts by weight of white cement, 10 parts by weight of white pigment and 40 parts by weight of acrylic emulsion containing 57% of solid content. The composition provides a compression strength of about 80 kg/cm 2 two hours after the composition is applied. Several hours after the composition is applied to the floor, it can provide strength such that people can walk on the floor without any problem. The composition reduces the time for application, is superior in water resistance and fluidity, and is suitable as a self-leveling material and foundation preparing and finishing material.
The floor finish composition disclosed in Japanese laid-open Patent Application No. 6-128009 has superior fluidity, water resistance and early strength for its use on the floor. However, when the composition is exposed to solvents, oil, or the like, it tends to bulge. The strength of the composition is thus deteriorated such that the composition fails to bear use over a long period of time.
For example, in a gas station, a floor finish composition requires a resistance against solvents, oil, and the like, and a strength to bear a vehicle's weight. Especially in the winter season, a strength of at least about 150 kg/cm 2 is required so that the floor is not damaged by vehicles with tire chains. The aforementioned composition disclosed in 6-128009 indicates a relatively high compression strength of about 80 kg/cm 2 two hours after the composition is applied to the floor. However, on the next day the composition provides a compression strength of only about 90 kg/cm 2 . The ratio of increase or rise in strength relative to time is insufficient. In general, when a floor composition is applied, it should set and have the requisite strength so that the floor can be used no later than the next day. Therefore, this conventional floor finish composition is not suited for the floor or the gas station floor.
SUMMARY OF THE INVENTION
Wherefore, an object of the present invention is to provide a floor paint composition superior in oil resistance, solvent resistance and early strength.
To attain this and other objects, the present invention provides a floor paint composition mainly composed of an α-type hemihydrate gypsum, a cement and a synthetic resin emulsion based on an anion copolymer obtained from the copolymerization of an ethylene unsaturated monomer. The ratio by weight of α-type hemihydrate gypsum and cement is between 80:20 and 95:5. The ratio of the solid content of the synthetic resin emulsion relative to 100 parts by weight of the mixture of α-type hemihydrate gypsum and cement is between 15 and 35 parts by weight. In the floor paint composition:
(1) the anion copolymer contains: at least one unit of a monomer selected from the group consisting of ethylene unsaturated carboxylic acid, ethylene unsaturated sulfonic acid, and ethylene unsaturated phosphonic acid; and an ethylene unsaturated monomer having at least an organosilicic radical;
(2) the anion copolymer contains: at least one unit of a monomer selected from the group consisting of ethylene unsaturated carboxylic acid, ethylene unsaturated sulfonic acid, and ethylene unsaturated phosphonic acid; and the synthetic resin emulsion contains epoxy silane; or
(3) the anion copolymer contains: at least one unit of a monomer selected from the group consisting of ethylene unsaturated carboxylic acid, ethylene unsaturated sulfonic acid, and ethylene unsaturated phosphonic acid; and an ethylene unsaturated monomer having at least an organosilicic radical; and the synthetic resin emulsion contains epoxy silane.
The floor paint composition can contain 0.1 to 10 parts by weight of pigment relative to 100 parts by weight of the mixture of α-type hemihydrate gypsum and cement.
In detail, α-type hemihydrate gypsum for use in the present invention is 0.5 hydrate of calcined gypsum or calcium sulfate, preferably containing low moisture and having high solid strength. The cement for use is, for example, portland cement, pozzolan cement, portland blast-furnace slag cement, moderate heat portland cement, sulfate resisting portland cement, white portland cement or other.
In the floor paint composition according to the present invention the ratio of α-type hemihydrate gypsum to cement is in the range between 80:20 and 95:5, thereby providing high early strength. The composition provides a compression strength of at least 200 kgf/cm 2 two or three hours after the composition is kneaded. If the ratio of α-type hemihydrate gypsum to cement deviates from the aforementioned range, the composition provides insufficient early strength and water resistance. If β-type hemihydrate gypsum or another replaces the α-type hemihydrate gypsum, the composition has its early strength, water resistance, oil resistance or other properties remarkably deteriorated and fails to bear its practical use.
The synthetic resin emulsion for use in the present invention is based on anion copolymer obtained from the copolymerization of an ethylene unsaturated monomer. The minimum filming temperature (referred to as MFT below) of the emulsion is preferably higher than the curing temperature of plastic viscous mortar mixture, for example, between 23° C. and 100° C., especially between 30° C. and 50° C. The glass transition temperature in the unit of Tg is preferably higher than 23° C., especially higher than 30° C. The synthetic resin emulsion is for example, (meta-)acrylic acid/styrene copolymer and/or (meta-)acrylate copolymer.
In the synthetic resin emulsion based on the anion copolymer obtained from copolymerization of ethylene unsaturated monomer:
(1) the anion copolymer contains: (i) at least one unit of monomer selected from the group consisting of ethylene unsaturated carboxylic acid, ethylene unsaturated sulfonic acid, and ethylene unsaturated phosphonic acid; and (ii) an ethylene unsaturated monomer having at least one organosilicic radical;
(2) the anion copolymer contains (i) at least one unit of monomer selected from the group consisting of ethylene unsaturated carboxylic acid, ethylene unsaturated sulfonic acid and ethylene unsaturated phosphonic acid, and (iii) the synthetic resin emulsion contains epoxy silane; or
(3) the anion copolymer contains (i) at least one unit of monomer selected from the group consisting of ethylene unsaturated carboxylic acid, ethylene unsaturated sulfonic acid and ethylene unsaturated phosphonic acid, and (ii) an ethylene unsaturated monomer having at least one organosilicic radical, and (iii) the synthetic resin emulsion contains epoxy silane.
The percentage by weight of the aforementioned composition elements (i)-(iii) relative to the solid content of the synthetic resin emulsion is not especially restricted. Preferably, the percentage of element (i) is between 0.025 and 2.5% by weight, that of element (ii) is 1% by weight or less, and that of element (iii) is 1% by weight or less. In the aforementioned feature (3), the percentage of elements (ii) and (iii) in total is preferably 1% by weight or less. As element (ii), for example, vinyl silane, vinyl siloxane or other can be used. The synthetic resin emulsion can contain, in addition to water, an anionic or nonionic surface active agent as an emulsifier.
The floor paint composition according to the present invention includes a solid content of the synthetic resin emulsion of 15 to 35 parts by weight relative to 100 parts by weight of the mixture of α-type hemihydrate gypsum and cement. Conventionally, by adding resin content to the composition including a large amount of gypsum, water resistance and wear resistance are enhanced. In this solution, however, when the amount of synthetic resin emulsion is increased, the working life during which the composition can be applied without any problem is disadvantageously extended. Furthermore, the setting time during which the strength or hardness of the composition reaches a predetermined level is increased. To solve this problem, in the present invention, the content of the synthetic resin emulsion is restricted such that the duration of the working life, the duration of the setting time and the value of the early strength are well balanced. As shown in the graph of FIG. 1, the working life indicates the time from when kneading is completed till an inflection point at which the rate of rise in viscosity of the composition relative to time is rapidly increased, and the setting time indicates the time from when kneading is completed till an inflection point at which the rate of rise in viscosity of the composition relative to time is rapidly decreased. Preferably, the working life is about 20 minutes and the setting time is within two hours. If the solid content of the synthetic resin emulsion is less than 15 parts by weight, water resistance and oil resistance are worsened over a long time, the setting time is excessively shortened, or wear resistance is deteriorated. To the contrary, if the content exceeds 35 parts by weight, early strength is remarkably impaired and the setting time is excessively lengthened.
When the compression strength of the composition obtained by kneading the synthetic resin emulsion together with the particles of α-type hemihydrate gypsum and cement is at least 70 kgf/cm 2 two hours after they are kneaded, the composition provides no cracks or indentations during the actual walk test. At a compression strength of at least 150 kgf/cm 2 , the composition can also bear against the force of a vehicle with tire chains attached thereto, producing no flaws or recesses on its surface during the run test.
The floor paint composition according to the present invention can contain 0.1 to 10 parts by weight of pigment relative to 100 parts by weight of the mixture of α-type hemihydrate gypsum and cement. Various inorganic pigments, having resistance to wear and weather, are preferably used in white and other various colors. The composition can be colored with various known pigments. For example, titanic oxide, zinc flower, lithopone, zirconia, calcium carbonate as white extender pigment, silicate pigment, or clay is white inorganic pigment. Red pigment is synthetic iron oxide or loess. Green pigment is chromium oxide. Blue pigment is cobalt blue, or ultramarine blue pigment. Typical black pigment is synthetic iron oxide, or carbon black. For organic pigments, red pigment is brilliant carmine 6B, watching red, lake red 4R, chromophthal red, thioindigo, or quinacridone red. Yellow organic pigment is hanza yellow G, disazo-yellow G, chromophthal yellow 3G, anthra-pyrimidine, or isoindoline yellow. Blue pigment is copper phthalocyanine, or indanthrone. Green pigment is chlorinated copper phthalocyanine, or other.
In addition to the aforementioned four components: α-type hemihydrate gypsum; cement; synthetic resin emulsion; and pigment, an appropriate quantity of the following agents can be added. The particles composed of α-type hemihydrate gypsum and cement, including pigment, can additionally contain the following agents: lignosulfonate, oxyorganic salt, alkyl aryl sulfonate or other water reducing agent; Na salt of the high condensate of melamine sulfonic acid and formalin or other high performance water reducing agent; fluidization agent; sodium aluminate, sodium carbonate or other set accelerating agent; calcium chloride, potassium sulfate, calcium nitrate or other hardening accelerator agent; lignosulfonate, lactic acid, tartaric acid, citric acid or other retardant; dispersant; rust preventives; waterproofing agent; expanding agent; abrasion proofing agent; or other. Furthermore, an appropriate quantity of dispersant, wetting agent, thickening agent, antifoam agent, antiseptic agent, mildewproofing agent or other can be added to the aforementioned liquid component composed of the aforementioned synthetic resin emulsion. These additives can be added by an appropriate quantity within the range of the present invention. The viscosity of the composition of the present invention can be adjusted by adding water to the composition as required.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described, by way of example, with reference to the drawings, in which:
FIG. 1 is a graph showing the change in viscosity of the composition over time.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In Embodiment 1, particles were prepared by blending 85 parts by weight of α-type hemihydrate gypsum, 15 parts by weight of white cement, 10 parts by weight of white pigment consisting of 3 parts by weight of titanium oxide and 7 parts by weight of calcium carbonate, 0.1 parts by weight of retardant or citric acid, and 7 parts by weight of reaction accelerator or calcium nitrate. The liquid component was prepared by blending 40 parts by weight of artion synthetic resin emulsion including 50% of solid content, 15 parts by weight of water, 0.4 parts by weight of dispersant having the tradename of Disconate N-14 manufactured by Daiichi Kogyo Seiyaku Kabushiki Kaisha, 0.7 parts by weight of thickening agent having the tradename of Thilose MH2000 manufactured by Hoechst Industry Co., Ltd., 0.2 parts by weight of antifoam agent having the tradename Adecanate B940 manufactured by Asahi Denka Kogyo Kabushiki Kaisha, and 0.2 parts by weight of antiseptic and mildewproofing agent having the tradename Melgirl AF manufactured by Hoechst Industry Co., Ltd.
As anion synthetic resin emulsion, the synthetic resin emulsion was based on anion copolymer composed of 53 parts by weight of styrene, 42.7 parts by weight of n-butyl acrylate, 2 parts by weight of acrylic acid, 1.5 parts by weight of ethylene unsaturated monomer including sulfonic acid, and 0.8 parts by weight of vinyl silane. Furthermore, the emulsion was additionally blended with 0.7 parts by weight of epoxy silane. The emulsion also included the emulsifying agent composed of 0.6% by weight of alkaline metal salt of hemlester of sulfuric acid and oxyethyl tributyl phenol, and 2% by weight of tributyl phenol polyglycol ether having an ethylene oxide unit of about 30, relative to the anion copolymer. By adding water, the solid content in the anion synthetic resin emulsion was adjusted to 50%.
In Embodiment 1, the composition of the present invention was prepared by kneading 10 kg of the particles and 4 kg of the liquid component in a kneading container. By adding water to the composition, the fluidity was adjusted and the viscosity was adjusted to a workable level or 2000 cps. Various tests were conducted on the kneaded slurry.
For the measurement of compression strength, the kneaded slurry was first east in an iron frame having inner dimensions of 4 cm×4 cm×16 cm, and cured in a room at a temperature of 20° C. and a relative humidity of 60%. The compression strength was measured two hours and 24 hours after a mold was finished. Results were 80.5 kgf/cm 2 two hours after, and 162 kgf/cm 2 24 hours after.
For the water resistance test, a test piece, molded from the same iron frame as aforementioned, was half immersed in water at 20° C. The water was changed and the test piece was visually observed every day. As a result, the test piece showed no abnormal appearance three days later and one week later.
For the test of resistance to oil and solvents, a method of testing the resistance of plastic to chemicals, K7115 according to Japanese Industrial Standards, was used. A test piece having a diameter of 50 mm and a thickness of 3 mm was prepared and cured in a room at 20° C. with a relative humidity of 60% for seven days. Subsequently, the test pieces were immersed in the following respective chemicals: gasoline; kerosene; toluene; and gas oil, and left at rest in a constant temperature unit at a temperature of 23°±2° C. for seven days. The surface of the test pieces was wiped off and the mass change rate of the test pieces was measured. As a result, the test piece, immersed in gasoline, had a gain of 2.11% in mass: kerosene 1.03%; toluene 2.97%; and gas oil 0.92%, respectively. There was no craze, swelling, warpage or bite on the surface of the test pieces.
The abrasion resistance test was conducted using a Taber abrader at a load of 1 kg and a revolution number of 1000 rpm. To prepare test pieces, a slurry having its viscosity adjusted to 2000 cps was cast in a disc iron frame having a diameter of 10 cm and a height of 2 mm and cured at 20° C. and 60% relative humidity for seven days. As a result, wear weight was 0.7 g.
The setting time was measured using a four-barrel automatic setting test machine. The time until a needle having a predetermined load failed to be inserted into the slurry was measured at 45 minutes, as a result.
The compositions according to Embodiments 2-5 and References 1-6 were classified into the particles and the liquid component, as shown in Table 1. In Table 1, each component is shown in a unit of parts by weight. For these embodiments and references, the same synthetic resin emulsion as in Embodiment 1 was used.
The compositions of the present invention shown in Table 1 were prepared. By adding water to the compositions, the viscosity of the kneaded slurry was adjusted to between 1500 and 2000 cps. In the same manner as in Embodiment 1, the compression strength test, the water resistance test, the chemicals resistance test, the measurement of setting time, and the abrasion resistance test were conducted on the kneaded slurry having its viscosity adjusted. Results are shown in Table 2.
TABLE 1__________________________________________________________________________ EMBODIMENT REFERENCE 1 2 3 4 5 1 2 3 4 5 6__________________________________________________________________________PARTICLEα-TYPE HEMIHYDRATE 85 95 80 85 85 100 70 50 85 85GYPSUMβ-TYPE HEMIHYDRATE 85WHITE CEMENT 15 5 20 15 15 15 0 30 50 15 15TITANIUM OXIDE 3 3 3 0 0 3 3 3 3 3 3CALCIUM CARBONATE 7 7 7 0 0 7 7 7 7 7 7RETARDANT 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1REACTION ACCELERATOR 7 7 7 7 7 7 7 7 7 7 7LIQUIDSYNTHETIC RESINEMULSION (N.V = 50%) 40 45 45 35 65 45 45 45 45 20 90WATER 15 10 10 16 0 10 10 10 10 20 0DISPERSANT 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.4THICKENING AGENT 0.7 0.7 0.7 1 0.5 0.7 0.7 0.7 0.7 1 0.5ANTIFOAM AGENT 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2ANTISEPTIC · MILDEW- 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2 0.2PROOFING AGENT__________________________________________________________________________
TABLE 2__________________________________________________________________________COMPRESSIONSTRENGTH RESISTANCE TO OIL · SOLVENTS(kgf/cm.sup.2) WATER RESISTANCE (MASS CHANGE RATIO %)2 24 3 DAYS ONE WEEK GAS- KER- GAS SETTING WEARHOURS LATER LATER LATER OLINE OSENE TOLUENE OIL TIME (g)__________________________________________________________________________EMBODI-MENT1 81 162 NO NO 2.11 1.03 2.97 0.92 45 MINUTES 0.70 PROBLEM PROBLEM2 87 168 NO NO 2.25 1.12 2.82 0.82 50 MINUTES 0.70 PROBLEM PROBLEM3 82 162 NO NO 2.31 1.08 3.03 0.91 65 MINUTES 0.62 PROBLEM PROBLEM4 103 175 NO NO 2.88 1.63 2.77 0.99 35 MINUTES 1.08 PROBLEM PROBLEM5 80 166 NO NO 2.01 0.82 3.41 0.79 100 MINUTES 0.51 PROBLEM PROBLEM6 88 173 NO NO 2.39 1.02 3.86 1.10 45 MINUTES 0.63 PROBLEM PROBLEM7 83 168 NO NO 2.41 1.13 3.03 1.42 70 MINUTES 0.91 PROBLEM PROBLEMREFER-ENCE1 26 53 COLLAPSED 11.35 10.22 28.51 6.31 >8 HOURS 4.962 62 141 SLIGHTLY SWELL 2.76 1.27 3.45 1.35 40 MINUTES 2.83 SWELL3 65 96 NO SLIGHTLY 2.71 1.22 3.51 1.28 65 MINUTES 3.17 PROBLEM SWELL4 38 87 COLLAPSED 3.41 2.01 3.40 1.61 >8 HOURS 2.535 147 159 SWELL SWELL 16.37 6.92 21.59 3.42 20 MINUTES 3.24 AND COLLAPSED6 23 36 COLLAPSED 1.02 0.87 4.11 0.62 >8 HOURS 0.917 78 136 NO NO 15.29 10.36 29.15 9.27 6 HOURS 1.44 PROBLEM PROBLEM8 61 121 NO SLIGHTLY 17.32 11.51 31.91 9.36 2 HOURS 1.96 PROBLEM SWELL__________________________________________________________________________
Embodiments 6, 7 and References 7, 8 have the same composition of particles as in Embodiment 1, but a composition of liquid different from that in Embodiment 1. In the same manner as the other embodiments and references, the kneaded slurry was prepared, and the slurry or the cured composition was tested for compression strength, water resistance, resistance to chemicals, setting time and abrasion resistance. Results are shown in Table 2.
Regarding the synthetic resin emulsion, Embodiment 6 is the same as Embodiment 1, except in that the synthetic resin emulsion contains no epoxy silane. Embodiment 7 is the same as Embodiment 1, except in that no vinyl silane is contained as a component of the anion copolymer basing the synthetic resin emulsion. Reference 7 is the same as Embodiment 1, except that the synthetic resin emulsion contains no epoxy silane and the anion copolymer basing the emulsion contains no vinyl silane. Reference 8 is the same as Embodiment 1, except that cation styrene acryl emulsion is used as the synthetic resin emulsion.
As seen in Table 2, in Embodiments 1-7, the early strength, two hours later, is not less than 80 kg/cm 2 and the next day strength, 24 hours later, is not less than 160 kg/cm 2 . The rising strength or increase rate of strength with time is high and the early strength is superior. Even after immersed in water, the compositions show no abnormal appearance. Even after immersed in gasoline, kerosene, toluene and gas oil, the compositions provide only small percentage changes in mass. The compositions are superior in resistance to water, oil and solvents, and are also superior in abrasion resistance. Therefore, even when the composition of the present invention is applied onto the floor of, for example, the gas station, it can be prevented from being expanded with oil or solvent, and can be prevented from being scratched or depressed by a tire chain attached to the vehicle wheels. Also as seen in Table 2, in Embodiments 1-7, the setting time is between 35 and 100 minutes, therefore within two hours, and the compression strength two hours after application is not less than 80 kg/cm 2 . The setting time is sufficiently long such that the floor paint composition can be applied or poured on a predetermined section of the floor. Additionally, the composition sets in a sufficiently short time such that people can walk on the floor with the composition applied thereon early, thereby providing superior workability. The floor paint composition according to these embodiments is clearly superior in workability.
Reference 1, in which β-type hemihydrate gypsum is used instead of α-type hemihydrate gypsum, has early strength, next day strength, water resistance, oil resistance, solvent resistance and abrasion resistance all inferior to those in Embodiments 1-7. The setting time is also remarkably extended. References 2-4, in which the ratio of α-type hemihydrate gypsum to white cement is deviated from that of the present invention, have early strength, next day strength, water resistance and abrasion resistance inferior to those in Embodiments 1-7. Reference 5, in which the rate of synthetic resin emulsion is less than that of the present invention, has resistance to water, oil, solvents and to abrasion inferior to those in Embodiments 1-7. Reference 6, in which the ratio of synthetic resin emulsion is larger than that of the present invention, has early strength, next day strength and water resistance remarkably inferior to those in Embodiments 1-7, and has a remarkably longer setting time. References 7, 8, in which the synthetic emulsion other than those for use in the present invention is used, have early strength, next day strength, oil resistance, solvent resistance and abrasion resistance all remarkably inferior to those in Embodiments 1-7, and have a remarkably longer setting time.
The floor paint composition according to the present invention gains a compression strength of not less than 80 kgf/cm 2 only several hours after the composition is kneaded and applied onto the floor, such that people can walk on the floor only several hours after application. The composition can gain a compression strength of not less than 150 kgf/cm 2 24 hours after application. The composition is thus provided with superior early strength, and can sufficiently bear the load locally applied, for example, by tire chains. The composition is also superior in resistance to oil and solvents.
Since the floor paint composition according to the present invention is superior in early strength, oil resistance and solvent resistance, the construction term is shortened. The floor is prevented from being occupied for a long period of time due to repair work. The floor paint composition can also be used in various industrial fields for leveling or finishing the floor to be applied with oil, solvents or other materials. Furthermore, the composition can be effectively used, for example, on the floor of a gas station, which is subject to oil, solvents or other materials and requires high strength. By adding an adequate quantity of pigment to the composition, the floor surface can be aesthetically finished.
This invention has been described above with reference to the preferred embodiment as shown in the figures. Modifications and alterations may become apparent to one skilled in the art upon reading and understanding the specification. Despite the use of the embodiment for illustration purposes, the invention is intended to include all such modifications and alterations within the spirit and scope of the appended claims. | A floor paint composition superior in resistance to oil and solvents, and in early strength. The composition is mainly composed of a synthetic resin emulsion based on an from anion copolymer obtained from the copolymerization of α-type hemihydrate gypsum, cement and ethylene unsaturated monomer. The ratio of weight of α-type hemihydrate gypsum to cement is between 80:20 and 95:5. The ratio of the solid content of the synthetic resin relative to 100 parts by weight of the mixture of α-type hemihydrate gypsum and cement is between 15 and 35 parts by weight. The anion copolymer contains at least one unit of a monomer selected from the group consisting of ethylene unsaturated carboxylic acid, ethylene unsaturated sulfonic acid and ethylene unsaturated phosphonic acid. The copolymer can include an ethylene unsaturated monomer having at least one organic silicon radical. The synthetic resin emulsion can include epoxy silane. | 2 |
BOTANICAL/COMMERCIAL CLASSIFICATION
[0001] Rosa hybrida /Floribunda Rose Plant
VARIETAL DENOMINATION
[0002] cv. ‘BAIprez’
SUMMARY OF THE INVENTION
[0003] The new variety of Rosa hybrida Floribunda rose plant was created by artificial pollination wherein two parents were crossed which previously had been studied in the hope that they would contribute the desired characteristics. The female parent (i.e., the seed parent) of the new variety was the ‘Playboy’ variety (non-patented in the United States). The male parent (i.e., the pollen parent) was the ‘Earth Song’ variety (non-patented in the United States). The parentage of the new variety can be summarized as follows:
‘Playboy’בEarth Song’
[0004] The seeds resulting from the above pollination were sown and small plants were obtained which were physically and biologically different from each other. Selective study resulted in the identification of a single plant of the new variety.
[0005] It was found that the new variety of Floribunda rose plant of the present invention possesses the following combination of characteristics:
[0006] (a) exhibits a vigorous, compact and bushy growth habit,
[0007] (b) forms in abundance on a nearly continuous basis attractive semi-double self-cleaning blossoms with reflexed yellow-orange petals that are strongly bordered with red,
[0008] (c) forms abundant dark green glossy foliage that contrasts nicely with the blossom coloration, and
[0009] (d) exhibits above average resistance to Black Spot.
[0010] The new variety well meets the needs of the horticultural industry. It is particularly well suited for providing distinctive ornamentation in the garden.
[0011] The new variety can be readily distinguished from its parental varieties. More specifically, the ‘Playboy’ variety forms single blossoms that are yellow blushed with orange, bear bright yellow stamens, and readily set hips. The ‘Earth Song’ variety forms Tyrian Red to Tyrian Rose blossoms that include substantially more petals.
[0012] The new variety of the present invention possesses a combination of characteristics that differs from that of the ‘Wekplapic’ variety (U.S. Plant Pat. No. 11,517) that is marketed under the BETTY BOOP trademark. The petals of the new variety are yellow-orange with a red border while those of the ‘Wekplapic’ variety are ivory-yellow with a red border. The blossoms of the new variety commonly possess more (e.g., approximately 15 to 18) petals and are more tightly aligned. The blossoms of the ‘Wekplapic’ variety commonly possess approximately 6 to 12 petals. Also, the new variety readily sets hips at West Grove, Pa., U.S.A., and the ‘Wekplapic’ variety does not set hips at such location.
[0013] The new variety of the present invention also can be readily distinguished from the ‘Meimonblan’ (U.S. Plant Pat. No. 12,579) and ‘Meizebul’ (U.S. Plant Patent Application No. 10/870,155, filed Jun. 18, 2004) varieties. The blossoms of the ‘Meimonblan’ variety are completely tangerine orange in color, and possess a lesser number of petals. The ‘Meizebul’ variety forms slightly fragrant salmon-colored blossoms having more petals. The blossoms of the new variety of the present invention possess no fragrance.
[0014] The new variety has been found to undergo asexual propagation at Wasco, Calif., U.S.A., by budding. Such asexual propagation has shown that the characteristics of the new variety are strictly transmissible from one generation to another, and that the new variety can be asexually propagated in a true to type manner.
[0015] The new variety has been named the ‘BAIprez’ variety.
BRIEF DESCRIPTION OF THE PHOTOGRAPHS
[0016] The accompanying photographs show as nearly true as it is reasonably possible to make the same in color illustrations of this character typical specimens of the new variety. The rose plants of the new variety were two years of age and were photographed on Jun. 10, 2004 while growing in a garden setting on ‘Dr. Huey’ rootstock at West Grove, Pa., U.S.A.
[0017] FIG. 1 illustrates from above a flowering plant of the ‘BAIprez’ variety where the blossoms are at full maturity.
[0018] FIG. 2 illustrates three open blossoms at medium maturity and the attractive dark green glossy foliage of the ‘BAIprez’ variety.
[0019] FIG. 3 illustrates a close view from above of a newly-opened blossom of the ‘BAIprez’ variety.
DETAILED DESCRIPTION
[0020] The chart used in the identification of the colors is that of The Royal Horticultural Society (R.H.S. Colour Chart). The description is based on the observation of two year-old specimens of the new variety which were observed during June 2004 while growing outdoors on ‘Dr. Huey’ rootstock at West Grove, Pa., U.S.A.
Class: Floribunda. Plant:
Height.— approximately 90 to 140 cm on average at the end of the growing season. Width.— approximately 105 to 130 cm on average at the end of the growing season. Habit.— compact and bushy.
Branches:
Color.— young stems: commonly between Yellow-Green Group 144A and Yellow-Green Group 146B, and often moderately suffused with Greyed-Red Group 178A to Greyed-Purple Group 183D. — adult wood: commonly between Yellow-Green Group 144B and Yellow-Green Group 146C. Thorns.— some large thorns of approximately 0.8 to 1.3 cm in length, almost straight and angled slightly downwards with a moderately narrow base, and near Yellow-Green Group 144B in coloration, as well as a very few smaller prickles of similar shape and coloration.
Leaves:
Arrangement.— alternate and pinnately compound. Size.— commonly approximately 8 to 12 cm in length, and approximately 6 to 10 cm in width at the widest point. Leaflets.— number: commonly 3 or 5 and formed in abundance. — length: approximately 5 to 7 cm. — width: approximately 3 to 5 cm at the widest point. — shape: typically ovate to elliptical. — apex: acute to cuspidate. — base: generally obtuse. — texture: very glossy, and physically moderately thick. — margin: serrate. — venation: pinnate. — general appearance: compact, rather dense, dark green, and very glossy. — color (young foliage): upper surface: commonly between Green Group 137C and Yellow-Green Group 144A, and usually suffused with between Greyed-Purple Group 183A and Greyed-Purple Group 187A. under surface: commonly between Green Group 138B and Yellow-Green Group 144B, often moderately suffused with Greyed-Purple Group 183B. — color (adult foliage): upper surface: commonly between Green Group 137A and 139A. under surface: commonly between Yellow-Green Group 147B and 147C. Petiole.— length: commonly approximately 24 mm on average. — diameter: commonly approximately 2 mm on average. — surface texture: smooth. — color: commonly between Green Group 137A and Green Group 139A. Rachis.— somewhat smooth in texture, average caliper, the upper side is moderately grooved with some stipitate glands on the edges of the grooves and sometimes suffused with near Greyed-Purple Group 183B, and the underside is moderately smooth with a few stipitate glands and sometimes with 1 or 2 very small prickles. Stipules.— size: commonly approximately 0.7 to 1.2 cm in length, and moderately narrow in width with medium long points that often turn out at an angle of more than 45 degrees. — color (adult foliage): upper surface: commonly between Green Group 137A and Green Group 139A. under surface: commonly between Yellow-Green Group 147B and 147C.
Inflorescence:
Number of flowers.— singly, and commonly in irregularly rounded clusters of 3 or 4 per stem on strong short to medium length stems of approximately 16 to 22 cm. A very short time between bloom cycles has been observed. Peduncle.— erect, commonly approximately 2.2 to 4.2 cm in length, average to heavy caliper, moderately smooth, with many stipitate glands and few hairs, between Green Group 137C and Yellow-Green Group 144A, and sometimes moderately blushed on the side exposed to the sun between Greyed-Red Group 178A and Greyed-Purple Group 183B. Sepals.— number: five. — texture: the inner surfaces are covered with fine wooly tomentum, the margins are lined with many stipitate glands and hairs, and sometimes 1 or 2 or more small slender foliaceous extensions are present. — length: commonly approximately 30 mm on average. — width: commonly approximately 8 mm on average at the widest point. — color: Yellow-Green Group 144C at the base and gradually changing to Yellow-Green Group 144A at the apex with some streaks of Red-Purple Group 59C on the outer surface. Buds.— shape: commonly very pointed to ovoid with a conspicuous hypanthium. — size: before the calyx breaks commonly approximately 1.2 to 1.6 cm in diameter at the widest point and approximately 1.7 to 2.5 cm in length, and after the calyx breaks approximately 1.7 to 2.2 cm in diameter at the widest point and approximately 2.4 to 2.8 cm in length. — texture: commonly bear a few stipitate glands and hairs. — color: before the calyx breaks between Green Group 137C and Yellow-Green Group 144A, and sometimes moderately blushed on the side exposed to the sun between Greyed-Red Group 178A and Greyed-Purple Group 183B. Flower.— form: semi-double, and moderately high centered when partially open, and flat to cupped when fully opened. — diameter: commonly approximately 7 to 9 cm when fully open. — color when newly opened: upper surface: between Yellow Group 13C and Yellow-Orange Group 15D suffusing to a broad edge of between Red Group 46A and Red Group 53B, and near Yellow Group 7A at a small zone at the point of attachment. under surface: between Yellow Group 13C and Yellow-Orange Group 15D suffusing gradually towards the edge between Red Group 46B and Red Group 53B, and Yellow Group 7C at a small zone at the point of attachment. — color three day-old flower: upper surface: at the interior portion between Red Group 49D and White Group 155B suffusing to a very broad edge between Red Group 53B and 53C, and Yellow Group 8C at a small zone at the point of attachment. under surface: at the interior portion between Yellow Group 11D and Yellow-Orange Group 19D suffusing gradually to a moderately thin edge between Red Group 53B and 53C, and Yellow Group 8B at a small zone at the point of attachment. — color of spent bloom: between Red Group 49D and White Group 155B edged with Red Group 53C to 53D. — petal configuration: typically nearly round to broadly obovate with apices that commonly are rounded to sometimes murcronate, moderately indurated, and reflexed. — petal length: commonly approximately 39 mm on average. — petal width: commonly approximately 34.3 mm on average. — petal number: commonly approximately 15 to 20. — petaloids: commonly approximately 1 to 3 arranged irregularly, commonly approximately 11 mm in length on average, commonly approximately 6 mm in width on average, and Red Group 49D blended with White Group 155B in coloration. — petal arrangement: loosely spiraled. — petal texture: physically medium to thick in thickness, very satiny to somewhat velvety on the upper surface, and moderately shiny to satiny on the under surface. — fragrance: slight spiced-tea. — pistils: approximately 70 on average, and approximately 7 mm in length. — stigmas: near Yellow-Orange Group 18A in coloration. — styles: moderately short, somewhat uneven, thin to average in caliper, very bunched, and near Red Group 50A in coloration. — ovaries: typically enclosed in the calyx. — stamen number: commonly approximately 110 on average, and arranged regularly about the pistils. — filaments: commonly approximately 10 mm in length, most bear anthers, and between Yellow-Orange Group 19A and 20A in coloration. — anthers: medium in size, commonly approximately 3.9 mm in length on average, commonly approximately 1.7 mm in width on average, all open at substantially the same time, and between Yellow-Orange Group 19A to 20A in coloration. — pollen: formed in a somewhat sparse quantity and near Yellow-Orange Group 16C in coloration. — lasting quality: approximately 4 or 5 days or more on the plant depending upon the environmental conditions that are encountered. — petal drop: the petals commonly detach cleanly.
Development:
Vegetation.— very vigorous. Blooming.— abundant and nearly continuous. Hardiness.— has been shown to grow well in U.S.D.A. Hardiness Zone Nos. 6A to 9A to date. Further cold hardiness testing is underway. Aptitude to bear fruit.— none observed under growing conditions at West Grove, Pa., U.S.A. Resistance to diseases.— above average disease resistance with respect to Black Spot and Powdery Mildew when compared to other commercial Floribunda varieties at West Grove, Pa., U.S.A.
[0048] Plants of the new ‘BAIprez’ variety have not been observed under all possible environmental conditions to date. Accordingly, it is possible that the phenotypic expression may vary somewhat with changes in light intensity and duration, cultural practices, and other environmental conditions. | A new and distinct variety of rose plant of the Floribunda Class is provided which abundantly forms on a nearly continuous basis attractive semi-double self-cleaning blossoms with reflexed yellow-orange petals that are strongly bordered in red. A very short time between bloom cycles is observed. The growth habit is vigorous, compact, and bushy. Dark green glossy foliage is formed in abundance that contrasts nicely with the blossom coloration. Above average disease resistance, especially with respect to Black Spot is displayed. The blossoms possess a slight spice fragrance, and no hips have formed during observations to date. The new variety is well suited for providing distinctive ornamentation in the garden. | 0 |
CROSS-REFERENCE TO RELATED PATENT APPLICATION
[0001] This application claims the benefit of Korean Application No. 2005-134553, filed Dec. 29, 2005, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] An aspect of the present invention relates to a battery, and, more particularly, to a pouch-type battery using a pouch as an external case.
[0004] 2. Description of the Related Art
[0005] Generally, a lithium secondary battery employs a non-aqueous electrolyte due to the reactivity of lithium with water. The non-aqueous electrolyte may be a solid polymer containing a lithium salt or a liquid in which a lithium salt is dissociated in an organic solvent. Lithium secondary batteries may be classified as either a lithium metal battery and a lithium ion battery, which use liquid electrolytes, or a lithium ion polymer battery, which uses a polymer electrolyte, depending upon types of the electrolyte employed by the batteries.
[0006] A problem of leakage of an organic electrolyte can occur in a gel-type lithium ion polymer battery containing an organic electrolyte, while the problem does not occur in a solid-type lithium ion polymer battery. This leakage may be prevented by a relatively simple operating method for the lithium ion polymer battery, in comparison with that of a lithium ion battery using the liquid electrolyte. For example, in the lithium ion polymer battery, a multi-layered pouch including a metal foil and one or more polymer membranes, which cover top and bottom surfaces of the metal foil, are used instead of a metal can that is used in the lithium ion battery.
[0007] When the multi-layered pouch is used, it is possible to reduce the weight of the battery, to reduce the thickness of the battery, and to relatively freely change the shape of the battery, in comparison with those cases in which the metal can is used.
[0008] FIG. 1 is a perspective view of a conventional pouch-type lithium secondary battery illustrating a status in which a pouch is not sealed. As shown in FIG. 1 , the conventional pouch-type lithium secondary battery includes an electrode assembly 30 and a pouch 20 to receive the electrode assembly.
[0009] With reference to FIG. 1 , in a general method of assembling a pouch-type lithium secondary battery, a middle portion of an approximately rectangular pouch membrane is folded to form a front side 21 and a rear side 22 of the pouch. A groove 223 , in which the electrode assembly 30 is accommodated, is formed on the rear side 22 by a process, such as a press working process. The indented portion 223 formed in this manner makes an installation of the electrode assembly 30 in post-processes possible, thereby making a performance of the assembling processes relatively easy. In addition, owing to the presence of the groove 223 , a sealing part of the pouch 20 around the groove 223 may be arranged, thereby allowing for a compact formation of the pouch.
[0010] A multi-layered film, which is formed by sequentially stacking a positive electrode 31 , a separator 33 , and a negative electrode 35 , is wound in a spiral form to form the conventional electrode assembly 30 to form an arrangement resembling a jelly roll. When the jelly roll is formed by winding the multi-layered film, a separator is added to an external electrode surface that is exposed from the jelly roll or an internal electrode surface to prevent an occurrence of a short circuit between the positive electrode 31 and the negative electrode 36 . The formed jelly roll is disposed in the groove 223 of the rear side 22 , and the front and rear sides 21 and 22 of the pouch 20 are heated and pressed to form a bare cell of a battery while the front side 21 of the pouch 20 and a flange part 225 , which is flange shaped, of the rear side 22 of the pouch 20 are brought into tight contact with each other.
[0011] Electrode taps 37 and 38 or electrode leads to electrically connect the positive and negative electrodes 31 and 35 of the electrode assembly 30 to an external circuit outside the pouch 20 are respectively formed in one side of the positive electrode 31 and one side of the negative electrode 35 . These electrode taps 37 and 38 are formed to be projected from the jelly roll in the direction perpendicular to the winding direction of the jelly roll and are drawn out through one side of the pouch 20 to be sealed.
[0012] In the process of sealing the pouch 20 , a predetermined ingredient may be added to a surface of the polymer membrane to reinforce the bonding between the polymer membrane inside the pouch 20 and a metal constituting the electrode taps 37 and 38 . In addition, an insulating tape 39 may be further included to prevent an occurrence of a short circuit between the electrode taps 37 and 38 and the exterior frame of the pouch 20 before the pouch is sealed.
[0013] Accessories or structures such as a protective circuit module (PCM) (not shown) or a positive temperature coefficient (PTC) (not shown) may be attached to the bare cell, of which the pouch has been sealed, to form a core cell. Thereafter, the core cell is inserted into a hard case to form a hard pack battery. Recently, in order to save space of the battery and to simplify the assembling process, a type of a battery has been developed, in which the external shape thereof is formed by closing both ends of a pouch of the battery in the longitudinal direction of the pouch and in which a circuit board and a protection member are attached to the pouch with a hot melt resin. In this type of battery a hard case is not required.
[0014] FIG. 2 is a perspective view of a conventional pouch-type lithium secondary battery in a state in which edges of two sides of a bare cell that are opposed to each other from which the electrode taps are not drawn out, are folded. FIG. 3 is an enlarged cross-sectional view of the conventional pouch-type lithium secondary battery taken along line A-A in FIG. 2 .
[0015] When a hard pack is formed without a folding of sealing parts 25 of the bare cell, or where, more particularly, the sealing parts 25 of two opposite sides from which the electrode taps 37 and 38 are not drawn out, an unnecessary space corresponding to the width of these portions is formed in the hard case. Accordingly, while the core pack is formed of the bare cell, both sealing parts 25 are folded toward the groove 223 in which the electrode assembly is disposed. When the pouch forms an external shape of the battery without an insertion of the pouch into the hard case, the sealing parts 25 of both sides of the pouch are folded to decrease the entire width of the battery in the same way as is described above.
[0016] Accordingly, in the processes of assembling the conventional pouch, the groove 223 is first formed on the rear side 22 thereof. Thereafter, a flange part, which is an edge portion around the groove 223 , and an edge portion of the front side, which becomes a cover of the groove 223 , are welded to each other and sealed. Thereafter, the sealing parts 25 , on the opposite sides of the conventional pouch in the widthwise direction are bent toward the groove 223 .
[0017] Recently, battery makers have been required to provide that two sides of the pouch are formed in a curved shape due to a problem in a design of a pouch-type battery or an electric or electronic device such as a cellular phone that is fitted with the pouch-type battery. Here, since the electrode assembly of the pouch-type battery has an elliptic or track shape and not an angled shape, when the sides of the pouch-type battery are formed in the curved shape, the electrode assembly fits inside the pouch-type battery substantially without any empty space. Accordingly, improvement in capacity-to-volume ratio of the battery may be expected.
[0018] However, in the case of the conventional pouch in which the groove is formed, a portion forming the side walls of the groove and a flange part around the groove are approximately perpendicular to each other in a deep-drawing process to form the groove. In other words, angled corners are formed. When both sealing parts are bent toward the groove after the sealing, the bent portions form sharp corners due to the sharp corners which have already been formed in the rear side of the conventional pouch. Thus, it is difficult to form the sides of the pouch into a curved surfaces. Thus, the ratio of capacity to volume of the battery is decreased.
[0019] In addition, the entire width of the bare cell of the battery is increased by the width (W+W=2W) of the sealing parts formed on both sides of the pouch. Accordingly, when the width of the battery is fixed to a predetermined value, increasing a space in a widthwise direction of the battery to receive the electrode plates and electrolyte required to increase the capacity of the battery is relatively difficult. In addition, in the subsequent processes, the sharp corners may be easily damaged due to contact with an external part.
SUMMARY OF THE INVENTION
[0020] Aspects of the present invention provide a pouch-type battery and a method of assembling the pouch-type battery in which side walls of a pouch receiving an electrode assembly are formed in a curved surface.
[0021] Aspects of the present invention also provide a pouch-type battery and a method of assembling the pouch-type battery, in which the capacity-to-volume ratio of the battery is enhanced.
[0022] According to an aspect of the present invention, there is provided a pouch-type battery, comprising an electrode assembly, in which first and second electrodes, each comprising an electrode tap, and a separator interposed between the first and second electrodes are stacked and wound; and a pouch-type case including: a rear part having a side wall of a groove, in which the electrode assembly is disposed, a bottom surface of the groove, and a flange part extending from a first pair of opposite sides around the groove and a front part having two extended parts extending from a pair of second opposite sides around the groove, sides of the flange part being connected to the second pair of the sides to cover the electrode assembly disposed in the groove, wherein ends of the two extended parts overlap and are welded to form a front sealing part, and wherein the overlapped portion of the front sealing part over the flange part is at least partially welded to a corresponding portion of the flange part to form upper and lower sealing parts.
[0023] In addition, while the two ends of the extended parts are overlapped with and welded to each other, a predetermined tensile force may be applied to the two ends so that a pulling force between the two ends is applied. In this case, forming the short sides in which the second pair of the sides is located as curved surfaces corresponding to an outer circumference surface of the electrode assembly is relatively easy.
[0024] According to an aspect of the present invention, there is provided a method of assembling a pouch-type battery, the method comprising: preparing a pouch exterior frame having a groove, two flange parts which are located around the groove and which are opposed to each other, and two extended parts which are opposed to each other; winding and electrode assembly, including two electrodes having electrode taps and a separator interposed between the two electrodes; disposing the electrode assembly in the groove with the electrode taps being drawn out of the pouch exterior frame through one of the flange parts; partially overlapping and welding two ends of the two extended parts with each other on the electrode assembly to form a front sealing part; and forming a seal between at least one of the flange parts and the overlapped portion of the two extended parts.
[0025] In addition, the method may further comprise injecting an electrolyte solution into an opening portion of the flange part and the overlapped portion of the two extended parts.
[0026] Additional and/or other aspects and advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0028] FIG. 1 is a perspective view of a conventional pouch-type lithium secondary battery illustrating a status in which a pouch is not sealed;
[0029] FIG. 2 is a perspective view of a conventional pouch-type lithium secondary battery illustrating a status in which edges of two sides of a bare cell opposed to each other from which the electrode taps are not drawn out, are folded;
[0030] FIG. 3 is an enlarged cross-sectional view of the conventional pouch-type lithium secondary battery taken along line A-A in FIG. 2
[0031] FIGS. 4 to 7 are state diagrams to illustrate an assembly of a pouch-type lithium secondary battery according to an embodiment of the present invention; and
[0032] FIGS. 8 and 9 illustrate another embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0033] Reference will now be made in detail to the present embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0034] FIGS. 4 to 7 are diagrams illustrating major processes for assembling a pouch-type lithium secondary battery according to an embodiment of the present invention.
[0035] FIG. 4 illustrates an electrode assembly 30 disposed in a pouch exterior frame 40 having a groove 43 . The groove 43 includes a bottom and a pouch wall body forming four sides. The groove 43 is formed by a deep drawing process, so that corners where the bottom meets the sides form smooth curved surfaces. The groove 43 is formed in a shape of a plane rectangle, and flange parts 42 and 44 are formed around the pair of the short sides of the groove 43 , which are to be understood as the first pair of the four sides of the groove 43 . Two extended parts 46 and 48 are located on both sides of the pair of the long sides of the groove 43 , which are to be understood as the second pair of the four sides of the groove 43 , and flange parts 42 and 44 which are connected to the pair of the long sides of the groove 43 . The two extended parts 46 and 48 may be formed to have a same width. This shape may be formed by deep drawing a portion of the plane rectangular pouch exterior frame 40 corresponding in size to the groove 43 .
[0036] Generally, a multi-layered membrane constituting the pouch includes a core part made of a metallic material, such as aluminum (Al), a heat fusion layer formed on an inner side of the core part, and an insulation membrane formed on an outer side of the core part. The heat fusion layer serves as an adhesive layer made of a modified polypropylene such as a casted polypropylene (CPP). The insulation membrane may be made of a resin material such as nylon and polyethylene terephthalate (PET).
[0037] The electrode assembly 30 may have an elliptical or track-like shape so as to be similar to a conventional shape of an electrode assembly of a conventional rectangular battery. The electrode assembly 30 may be formed by winding two electrodes and a separator by a mandrel, so that the electrode assembly has a multi-layered structure comprising a separator, a first electrode, a separator, a second electrode or the first electrode, a separator, the second electrode, and a separator.
[0038] Each electrode is formed by forming a slurry layer containing an active material on at least one side of a metal foil or a metal mesh comprising a current collection body in which a tap is combined with a portion of the current collection body for an electrical connection to an external circuit.
[0039] In the first electrode of this embodiment, a first aluminum electrode tap 37 , which is projected a predetermined length from the electrode assembly 30 , is welded to a current collection body that is made of an aluminum (AL) material. In the second electrode, a second electrode tap 38 , which is generally made of a nickel (Ni) material, and which is projected a predetermined length from the electrode assembly 30 , is welded to a current collection body that is made of a copper material. An insulation tape is also provided to prevent a short circuit between the first electrode tap 37 or the second electrode tap 38 and the plane rectangular pouch exterior frame 40 .
[0040] The first and second electrode taps 37 and 38 are drawn out of the pouch exterior frame 40 via an upper flange part 42 of the pouch exterior frame 40 and, then, are electrically connected to a protection circuit module (not shown) outside the pouch.
[0041] The active material of the slurry layer, which is formed on at least one side of a current collection body of the first electrode, may comprise a chalcogenide compound, such as a mixed metal oxide selected from the group consisting of LiCoO 2 , LiMn2O 4 , LiNiO 2 , LiNi1-X CoXO 2 (0<x<1), and LiMnO 2 . An active material of the slurry layer, which is formed on at least one side of a current collection body of the second electrode, may be selected from the group comprising a carbon (C) based material, a silicon (Si), a tin (Sn), a tin oxide, a tin alloy composite, a transition metal oxide, a lithium metal nitride, or a lithium metal oxide.
[0042] According to an embodiment of the invention, the electrode taps 37 and 38 pass through the upper flange part 42 in portions of the pouch exterior frame 40 through which the electrode taps 37 and 38 are drawn out. In this case, a resin tape, which is a type of an insulation tape, may be included in the portion through which the electrode tap is drawn out.
[0043] As shown in FIG. 4 , the pouch exterior frame 40 is bent along borders between a portion of the pouch exterior frame 40 , which includes the groove 43 of the pouch exterior frame 40 and flanges 42 and 44 , and the two extended parts 46 and 48 , so that the extended parts 46 and 48 cover the electrode assembly 30 in the groove 43 . Two ends 461 and 481 of the bent extended parts meet with each other and the upper flange part 42 , through which the electrode taps 37 and 38 are drawn out, and are welded to each other, so that an upper sealing part 52 and a front sealing part are formed as shown in FIGS. 5A through 5C . In detail, the two ends 461 and 481 of the extended parts 46 and 48 are welded to each other, so that resin layers having a hot plate weldability, which are located in an inside of the pouch membrane, are opposed to each other as illustrated in FIG. 5B , and a welded front sealing part 51 is folded so as to contact the other extended part of the pouch. Alternatively, the ends 461 and 481 , which are to be welded, of the two extended parts 46 and 48 may be disposed in opposition to each other, and the ends 461 and 481 are bent to contact a front side of the pouch. Thereafter, the ends 461 and 481 may be welded to each other. The welding of the two ends and the welding of the upper flange part 42 , through which the electrode taps are drawn out, may be performed in an arbitrary order or may be performed simultaneously.
[0044] As shown in FIG. 5C , when the two ends 461 and 481 of the extended portions 46 and 48 are welded to each other, the two ends 461 and 481 are then bent toward a middle portion of the pouch exterior frame 40 , with respect to a widthwise direction of the pouch exterior frame 40 , where the welding occurs, if the welding has not already been completed. In the process, the directions the two ends 461 and 481 each face are changed from a direction facing the outside of the pouch exterior frame 40 to a direction facing the pouch. Accordingly, an angled shape of a portion in which the groove is formed in the pouch exterior frame 40 , at which long sides of the groove 43 are connected to the extended parts 46 and 48 is straightened. Here, a curved surface having the same shape as the outer surface of the electrode assembly is formed in a long side portion of the groove 43 of the pouch exterior frame 40 , having the outer surface of the electrode assembly 30 as a reference for support, so that an entire side 53 of the pouch-type bare cell forms a curved surface.
[0045] Referring to FIG. 6 , a second sealing part (i.e., a lower sealing part) is disposed in a side opposite the first sealing part (i.e., an upper sealing part 52 ), through which the electrode taps 37 and 38 are drawn out. The second sealing part is not heat welded in the structure illustrated in FIG. 5A so that the second sealing part may act as a pathway to allow for a supplying of an electrolyte solution 60 into the electrode assembly 30 inside. Accordingly, the electrolyte solution 60 may be injected into the open second sealing part inside the pouch.
[0046] In conventional pouch-type lithium batteries, the electrolyte solution is injected through the long side of the groove of the pouch. In such batteries, it is difficult for the injected electrolyte solution to flow into the interior of the electrode assembly since the electrolyte solution is blocked by at least one electrode plate. Thus, the electrolyte solution first moves into upper and lower sides of the electrode assembly and flows from the upper and lower sides of the electrode assembly into the inside of the electrode assembly through a gap between the separator and the electrodes.
[0047] However, when the electrolyte solution 60 is injected into the open flange part, the upper or lower side of the electrode assembly 30 is reachable through the gap between the electrode plate and the separator. Accordingly, the electrolyte solution may flow relatively easily into inside of the electrode assembly 30 . In an alternative embodiment, a portion of the first sealing part 52 , through which the electrode taps are drawn out, may be open and the oppositely located second sealing part may be sealed. Here, the electrolyte solution is injected into the first sealing part 52 of the pouch 50 .
[0048] Referring to FIG. 7 , in a state in which the electrolyte solution is injected, as illustrated in FIG. 6 , heat welding for the opening portion of the flange part is performed to form a lower sealing part 57 ′ so that the pouch is completely sealed from the exterior of the pouch. The lower sealing unit 57 ′ may then be bent to cover the bottom surface 55 in FIG. 6 . In this case, since a cover composed of the lower sealing part 57 ′ includes two folds of the multi-layered membrane, the bottom surface portion, which comprises one fold of the multi-layered membrane, may be protected by the cover's support for the bottom surface portion of the pouch-type case.
[0049] FIGS. 8 and 9 illustrate another embodiment of the present invention. In comparison with the embodiment illustrated in FIG. 7 , the second sealing part 64 , which is located opposite to the first sealing part 72 of the upper portion is extended in a long direction thereof A gas room 81 is disposed in a portion of the extended part. The groove 63 in which the electrode assembly is disposed and the gas room 81 are connected with each other through a connection groove 85 formed in the second sealing part 64 . The connection groove 85 serves as a pathway through which the electrolyte solution is injected, and through which gas is collected into the gas room 81 . In order to form the connection groove 85 , a side wall 55 for a bottom side wall among the four side walls constituting the groove 63 is partially removed. The removed portion may be regarded as a groove of the side wall 55 formed on the bottom side wall and is hereinafter referred to an opening portion 552 . After the electrolyte solution is injected into an open lower flange part 64 , the pouch is sealed by welding a lower end 77 of the lower flange part 64 . The gas generated from an initial charging process is then collected into the gas room 81 formed in the lower flange part 64 .
[0050] Thereafter, a final welding portion 79 of the lower flange part 64 of the pouch, which is adjacent to the groove 63 , is welded to form a lower sealing part. The gas room 81 , into which the gas generated by the initial charging process is collected, and the groove 63 , in which the electrode assembly is disposed, are each separated by the welding of the final welding portion 79 . A portion of the second flange part 64 located below the final welding portion 79 is then removed. As illustrated in FIG. 9 , the final welding portion 79 is bent toward the bottom of the pouch, so that the lower sealing part 79 , which is the final welding portion, protects the bottom of the pouch. In this case, the lower sealing part 79 is bent so as to decrease the length of the pouch, thereby increasing the capacity-to-volume ratio of the battery to be assembled.
[0051] The opening portion in this embodiment may be formed in the embodiments, in which the gas room is not formed, illustrated in FIGS. 4 to 7 . The opening portion prevents the electrolyte solution from being injected unevenly, which may be caused by an injection of the electrolyte solution along the front side of the pouch-type case when the electrolyte solution is injected therein. In other words, the opening portion enables the electrolyte solution to infiltrate the interior of the electrode assembly 30 along the gap, which is formed through the entire bottom surface of the electrode assembly, between the electrode and the separator by evenly supplying of the electrolyte solution to the entire bottom surface, which is exposed through the opening portion, of the electrode assembly 30 .
[0052] As shown in FIG. 6 , a front sealing part 51 , which is located in a front side of the formed bare cell of the pouch, may be located between the two electrode taps 37 and 38 , which are drawn out of the pouch, in a widthwise direction of the pouch (i.e., a direction in which a first pair of sides is stretched) and may be located in a middle portion of the pouch. For example, generally a tap has a width of about 0.1 mm, and, thus, spaces between the electrode and the separator and between the electrode assembly and the wall body of the pouch in the widthwise direction of the pouch, respectively, are insufficient to allow for a fitting of a portion in which the tap is formed in the electrode assembly. Accordingly, the electrode taps are commonly disposed at positions separated from the electrode assembly so as not to overlap with each other. Two ends of the electrode assembly in the widthwise direction of the pouch form curved portions to reduce the space between the electrodes in the electrode assembly. On the other hand, the remaining portion in which the electrode tap is not located (i.e., a width portion between the electrode taps) has a comparatively sufficient space. Thus, when the front sealing part is disposed in the remaining portion from outside of the pouch, the substantial width of the secondary battery is relatively hardly increased. When the front sealing part 51 is formed, the side 73 of the pouch 70 forms a curved surface along the outer surface of the electrode assembly inside.
[0053] Although the embodiments according to aspects of the present invention have been described mainly for the lithium secondary batteries, the present invention, except the initial charging/discharging process and the formation of the gas room, may be applied to all pouch-type batteries.
[0054] Further, according to aspects of the present invention, a side of a pouch, which receives an electrode assembly, of the battery may be formed as a curved surface. Thus, relatively easy installation of the battery to an electric or electronic apparatus requiring a curved surface of the battery is possible. In addition, a side wall of the pouch is formed as a curved surface. Thus, receiving an electrode assembly having a cross-section of an ellipse or stadium shape without having an empty space is also possible. Thus, the width of the pouch, compared with a battery in which the sealing part of a pouch is located in the side of the pouch, is decreased, and the capacity of the battery over the volume is increased. In addition, directly injecting the electrolyte solution into top or bottom surfaces is possible, thereby reducing the time required to inject the electrolyte assembly.
[0055] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | A pouch, in which an electrode assembly of a battery is held, including a frame, including a groove into which the electrode assembly is inserted with a front of the electrode assembly temporarily exposed, upper and lower flanges bordering upper and lower ends of the groove, and extended parts on either side of the groove, front and upper sealing parts formed when the extended parts are folded over the front of the electrode assembly and the upper and lower flanges and sealed together and to the upper flange, respectively, the front and upper sealing parts defining a pocket in which an electrolyte solution is injected toward the electrode assembly, and a lower sealing part formed when the folded extended parts are sealed to the lower flange. | 8 |
REFERENCE TO PRIOR APPLICATION
This application is a continuation-in-part of application Ser. No. 227,681 filed Jan. 23, 1981 now U.S. Pat. No. 4,403,430 issued June 20, 1983.
FIELD OF THE INVENTION
The present invention relates to a railroad track relaying machine comprising a plough of the type used in railroad track relaying machines for disaggregating the compact old ballast, after removing the old rails and ties, and preparing the lie for laying new ties.
THE PRIOR ART
Ploughs utilized for this purpose are already known in the art. These ploughs operate by simply penetrating into the ballast as a consequence of the forward travel of the machine supporting them, and have to overcome a considerable drag on the one hand because the gravel of the old ballast is extremely compact due to the ramming action exerted by the railroad traffic and also by the cementing action produced by mud, sludge, metal dust and other substances deposited upon, and penetrating into the bottom pitching, and on the other hand also because the relatively low operating speed of the machine cannot promote a regular flow of gravel displaced by the plough. Consequently, it is scarsely possible to plough a relatively deep furrow with ploughs of this type. In actual practice, the limit consists in levelling the ballast by pouring back into the furrows left by the removed old ties the gravel previously existing between adjacent ties, so that only a relatively small amount of gravel is pushed laterally. Thus, the new ties are laid at a higher level than required and a special machine must subsequently be used for excavating the pitching under the new ties in order to lower them sufficiently to restore the proper laying level upon completion of the subsequent packing operation necessary for raising the ties by one or two inches. In many cases the laying level of the new ties should be lower than that of the preceding ties, due to the laying of higher ties and/or rails, and also to the necessity of maintaining the rail plane at the same level as before, since standard requirements such as the height of the overhead feed lines, the tunnel and level crossing gage, and the like, must be met in all cases.
SUMMARY OF THE INVENTION
It is the primary object of the present invention to increase the efficiency of a machine of the type broadly set forth hereinabove so that this machine can plough without difficulty a furrow of such a depth that it can receive the new ties, without resorting to any subsequent operation for lowering the tie level, even when the new ties are higher, and the new rails heavier, than the old ties and rails, respectively.
For this purpose, the plough according to the present invention comprises in its ploughshare area a plurality of members adapted to disaggregate and/or push the ballast, said members being movably mounted on the plough frame and adapted to be driven by a mechanism for performing a periodic movement having a component perpendicular to the ploughshares and such that the outwardly directed ends of said members protrude from the ploughshares when said members are in their external operative positions in relation thereto.
Thus, the efficiency of the ploughshares pushing back the ballast in the conventional manner as the plough progresses along the track is increased by the action exerted by said members which further permits of disaggregating the ballast before the latter is pushed laterally by the ploughshares, since these members protrude at certain times below the lower edges of the ploughshares.
According to a preferred form of embodiment of the invention of companion application Ser. No. 227,681 filed Jan. 29, 1981, said members consist of piston-like ejectors extending through apertures formed in the lower portions of the ploughshares, said ejectors being adapted to be moved across the normal direction of travel of the plough by an actuating mechanism imparting a reciprocating motion thereto between inner positions in which they do not protrude from the lower portion of the ploughshares and outer positions in which they projects in relation to said ploughshares.
With this arrangement each ejector, during its movement from its inner position to its outer position, is caused to push or thrust positively a certain amount of gravel to one side, so that this amount of gravel is disaggregated and shifted without deriving the necessary energy from the plough forward motion, therefore by exerting a force which can be predetermined when designing and adjusting the actuating mechanism. During the next phase the ejector is retracted and does not interfere with the plough travel. Any mass of gravel thus moved by an ejector is subsequently taken over by the next ejector which, as a consequence of the divergent arrangement of the plough blades, operates on a greater width, until the gravel is pushed aside, that is, laterally of the cutting formed by the plough for laying the new ties. As a consequence of these repeated positive thrusts exerted on the masses of gravel to be disaggregated, the plough is capable of forming a furrow considerably deeper than those obtainable without using ejectors, and the cutting depth may be so selected that any subsequent lowering of the newly laid ties can be dispensed with.
In order to avoid the exertion of excessive lateral efforts on the plough-supporting machine, the actuating mechanism is preferably so designed that while a given number of ejectors are moved on one side a corresponding number of other ejectors are moved on the opposite side, so that the lateral stresses at least substantially balance each other.
The deeper excavation required centrally of the cutting for relieving the central portions of the cross-ties may be performed by a deeper pointed portion of each plough blade, as in conventional devices of this type, or by using a horizontal rotary cutter adapted to be rotated in one or the other direction according as it is desired to have a greater amount of gravel discharged on one or the other side of the cutting.
According to a preferred form of embodiment of the invention of the present application the aforesaid movable members comprise a pair of blades, preferably formed with teeth or the like on their outer surface and disposed under the ploughs and at least substantially parallel thereto, the actuating mechanism being adapted to impart a movement substantially of translation to said blades along a closed path.
Thus, the ballast is perfectly disaggregated by the blades which, as a consequence of their closed-loop movement combined with the forward travel of the machine, operate somewhat like a grinder.
Finally, in a further form of the embodiment of the present invention the ejectors and blades mentioned in the foregoing can be combined into a same plough.
The invention will now be described more in detail with reference to the accompanying drawings illustrating diagrammatically by way of example various forms of embodiment.
THE DRAWINGS
FIG. 1 is a plane view showing on a relatively small scale a form of embodiment of a ballast plough according to the invention of companion application Ser. No. 227,681 filed Jan. 29, 1981;
FIG. 2 is a side elevational view showing on a still smaller scale the same plough associated with certain elements of a track relaying machine, shown in dash and dot lines;
FIG. 3 is a fragmentary vertical section taken along the line III--III of FIG. 2;
FIG. 4 is a cross section showing the cutting formed by the plough;
FIG. 5 is a fragmentary plan view from beneath showing a modified form of embodiment of the front portion of the plough of FIG. 1;
FIG. 6 is a fragmentary elevational view of the modified version of FIG. 5;
FIG. 7 is a plan view from above of a preferred form of embodiment of a ballast plough according to this invention;
FIG. 8 is a fragmentary, diagrammatical detail view showing on a larger scale and in section taken along the line VIII--VIII of FIG. 7 the relationship between the two eccentrics;
FIG. 9 is a diagrammatic view showing the blade mounting linkage means in order to afford a clearer understanding of its combined movements, and
FIG. 10 is a side elevational view showing another form of embodiment of the plough which is a combination of the forms of embodiment shown in FIGS. 1 and 7.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will first be made to FIGS. 1 to 6 illustrating a first form of embodiment of a track relaying plough.
In FIG. 2 the reference numeral 1 designates a longitudinal member of the frame structure of a railroad track relaying machine of a type known per se, to which the plough of the present invention is attached. Reference numeral 2 designates a toothed wheel of this machine which, by cooperating with guide members 3, is adapted to remove the old cross-ties 5 from the old ballast 4, thus forming spaced empty transverse cavities 6. This machine also comprises means for laying the new ties 7, which comprise inter alia lateral metal plate 8 adapted, during the laying of new ties 7, to prevent the loosening or crumbling of the lateral gravel heaps formed by the plough. These heaps then slip partially behind the tail ends of the said plates 8, thus holding in position the freshly laid new ties 7. This plough is suspended from the frame structure 1 by means of supports 9. All these component elements, shown in dash and dot lines, are well known in the art. Furthermore, the dash and dot line 10 designates the level of the maximum depth attainable with a plough of conventional type, subject to the above-mentioned limitations.
In FIGS. 1-6 reference numeral 11 designates the two ploughshares or blades set at an angle to each other to constitute the plough according to the teachings of the present invention. These ploughshares are supported in the known fashion by a frame 12 suspended from the main frame structure of the machine by means of the above-mentioned supports 9. This frame 12 also carries vertical side plates 13 parallel to the direction of travel of the machine and constituting part extension of the rear ends of ploughshares 11; the function of these plates 13 consists in supporting the side heaps of gravel which, after having been released by said plates 13, are still temporarily retained by the lateral plates 8 of the machine. The ploughshares 11 have as usual a concave profile with an upper outwardly curved portion, substantially in the fashion of a mold-board for thrusting the gravel heaps formed by the plough towards the sides of the railroad track.
In the lower portion of each ploughshare 11 and more particularly in the portion thereof which is to be sunk into the ballast 4 to be disaggregated, horizontally spaced apertures 14, which in this exemplary form of embodiment are four in number and of substantially square cross-sectional configuration, are formed. The pair of apertures 14 nearest to the V-shaped apex of the plough have slidably fitted therein a pair of corresponding ejectors or pistons 16 movable in a transverse direction between guide members 17 and interconnected by a rod 18 so that the pair of ejectors 16 are caused to move in unison in said transverse direction as shown by the arrow T (FIG. 1). Similarly, the second pair of apertures 14 are occupied by a pair of ejectors 19, respectively, also interconnected by a rod 20 and guided for movement in the transverse direction T. The third and fourth pairs of apertures 14 are likewise occupied by third and fourth pairs of ejectors 21 and 23, respectively, interconnected by rods 22 and 24, respectively.
Rods 18 and 20 are interconnected in turn by a rocker lever 25 having arms of unequal lengths; this rocker lever 25 is pivoted to the fixed frame of the plough and has a third, transverse arm 26 rigidly attached thereto, as shown. Similarly, rods 22 and 24 are interconnected by a rocker lever 27 also provided with unequal arms and pivoted to the fixed frame of the plough; this rocker lever 27 is also provided with a transverse arm 28 rigidly attached thereto. Finally, the outer ends of transverse arms 26 and 28 are coupled by a rod 29 pivotally connected to the outer end of the piston rod of a hydraulic double-acting cylinder 30 reacting against the plough frame 12.
It is clear that when pressure fluid is supplied alternatively to one and the opposite end of cylinder 30, the rod 29 is reciprocated and imparts through transverse arms 26 and 28 an oscillatory motion to rocker levers 25 and 27, and also a rectilinear transverse reciprocation to the various ejectors 16, 19,21 and 23, so that while two ejectors move in one direction the other two move in the opposite direction. Moreover, the difference between the various lever arms is such that the amplitude of this movement increases from ejector 16 to ejector 23.
Each time an ejector is moved outwards and protrudes from the relevant aperture 14 formed in plough 11, it exerts a transverse force against the old ballast, thus disaggregating and moving a certain amount of gravel towards one side of the track. When subsequently the ejector is retracted an empty space is formed through which the plough can progress without having to overcome any appreciable resistance. The already shifted mass of gravel is subsequently taken over by the next ejector behind and also moved laterally outwards, with a greater amplitude of movement to compensate the increased amount of gravel accumulating in front of the following ejectors. Thus, all the ballast gravel is gradually pushed to the track sides and subsequently retained temporarily by the metal plates 13 to prevent the inward fall of this gravel.
Due to the improved efficiency of the plough of this invention, full-depth cuttings can be obtained, i.e. down to the level shown diagrammatically at 31 in FIG. 2, for laying the new ties 7 even if they higher than the old ones, without excavating several times under the ties, in contrast to the procedure required with conventional ploughs which can only cut down to the level shown at 10, by way of comparison, in FIG. 2, that is, a level requiring several passes of a suitable excavating tool.
Preferably, to facilitate the subsequent steps of the track relaying process, a pair of small auxiliary plough adapted to be mounted either to the same track-relaying machine or to another machine to be passed on the railroad line before the renewal thereof, may be used for making small lateral cutting such as the one designated at 33 in FIG. 4 for receiving one portion of the gravel disaggregated by the plough, the excess gravel forming heaps 34 momentarily retained by the metal plates 13 of the plough and then by the plates 8 of the track relaying machine; after the passage of these plates 8, as shown in the right-hand portion of the same FIG. 4, the heap 34 collapses partially, thus forming a slope 35 in which the ends of the freshly laid new ties 7 are embedded and safely held in position. The heaps 34 are formed below the level of the new rails 37 which are lifted temporarily by the machine according to the conventional method along the edges of the cutting, the old rails 36 to be removed overlying the new rails 37, as shown in FIG. 4.
It is also known that the central portion of the cutting formed for laying the new ties 7 must be lowered to level 32 beneath the actual laying level 31 in order to relieve the central portion of the ties themselves. This can be obtained as conventional by providing the ploughshares 11 of the plough of this invention with a complementary front element 11a projecting down to said level 32. The same result may also be obtained according to the invention by mounting under the front end of ploughshare 11 a horizontal cutter 38 (FIGS. 5 and 6) rotatably driven by a suitable electric or hydraulic motor. By using the same cutter 38 is it also possible to shift the dislodged gravel mainly on one side, if desired, by selecting the corresponding direction of rotation R, and in each case the height of the gravel heap 39 formed in front of the plough vertex V is reduced, so as to diminish the drag accordingly.
It will be readily understood by those conversant with the art that various modifications and changes may be brought to the form of embodiment described hereinabove. Thus, for instance, the shape, number and position of the ejectors may vary, as well as the nature and relative arrangement of the means provided for actuating them. Said means may comprise for example linkages operatively connected to a single source of driving power, as in the example described and illustrated, but it is also possible to provide several separate power source coupled directly or indirectly to the ejectors. Hydraulic cylinders may advantageously be used as power sources for this purpose, inasmuch as there is a hydraulic system on board track relaying machines; however, mechanical or electro-mechanical power sources may also be used, if desired or adequate. The ejectors forming a couple on either side of the plough may also be actuated in opposite directions instead of being interconnected by a rod.
Reference will now be made to FIGS. 7, 8 and 9 illustrating diagrammatically a preferred form of embodiment of the plough of this invention. In this form of embodiment, the ejectors or pistons of the first form of embodiment are replaced by a pair of blades 42 disposed beneath, and at least substantially parallel to the two ploughshares 41; these blades are actuated by a suitable mechanism capable of imparting thereto a movement approximatively of translation along a closed loop or path. The mechanism is so conceived that each blade 42 accomplishes a circular movement with its front end and an elliptic movement with its rear end, as will be explained hereinafter.
As in the form of embodiment shown in FIG. 1, the two ploughshares 41 forming an angle in relation to each other are fastened to the plough frame comprising lateral supporting arms 40a. This frame 40 has also detachably mounted thereto a pair of blades 42 complementarily and pivotally interconnected at their front ends through a pair of teeth 52 and a nose member 43, as shown notably in FIG. 7. Each blade 42 has its front end pivotally connected through a bearing 56 to an eccentric 44b depending from and rigid with a shaft 44 (FIG. 8), and the rear portion of blade 42 is pivotally connected through a pin 61 to a link 45 pivoted in turn through another pin 60 to a larger rod 46. This rod 46 carries at its front end a fork 47 shown only diagrammatically in FIGS. 7, 8 and engaged by another eccentric 44a constituting the upper portion of shaft 44. On the other hand, the rod 46 is fulcrumed for free oscillation about a pivot pin 48 carried by the lateral supporting arm 40a of the plough frame. As clearly shown in FIG. 8, the shaft 44 with its integral eccentric portions 44a and 44b is adapted to rotate about the axis 57 and so arranged that the upper eccentric 44a having an axis of rotation 58 is shifted angularly by 180 degrees with respect to the lower eccentric 44b having an axis of rotation 59.
The blades 42 are pivotally connected at their front ends through a pair of rounded teeth 52 to the nose member 43 constituting the foremost element of the plough, the lower edges of this nose member 43 and of both teeth 52 being on the other hand disposed at lower level than the blades 42 in order to cut a deeper central channel or furrow, as already explained with reference to the first form of embodiment.
This mechanism is driven from a power pinion 49 meshing with a toothed wheel 50 rotatably solid with the first eccentric shaft 44, this toothed wheel 50 being in constant meshing engagement with, and driving in turn, another toothed wheel 51 rotatably solid with the other eccentric shaft 44', the gearing being enclosed in a case 40' rigid with frame 40.
The eccentric shaft 44 will thus impart on the one hand to blade 42, through its lower eccentric 44b, a circular motion having a radius corresponding to the throw of this eccentric, as illustrated by the arrow F1, and on the other hand to rod 46, through the fork 47, a oscillatory motion about pivot pin 48, as shown by the arrow F2. The amplitude of the oscillatory motion imparted to the other end of rod 46 and therefore to pivot pin 60 through which the link 45 is pivotally connected to said rod, is subordinate to the lever ratio of rod 46 and also to the throw of eccentric 44a. It is thus possible to vary the amplitude of this oscillation by properly selecting the ratio of the lever arms of rod 46. The end of link 45 and consequently the rear end of blade 42 to which it is pivotally connected by means of pivot pin 61 are thus caused positively to describe an elliptic path illustrated by the arrow F3 (FIG. 7) and this movement results from the circular movement accomplished by the front end of blade 42 and also from the oscillation of rod 46, the major axis of this elliptic path F3 being substantially perpendicular to the blade 42. Therefore, these movements are synchronised by rod 46. Preferably, the lever arm ratio of rod 46 and throw of eccentrics 44a and 44b are selected with a view to amplify the movement performed by the rear portion of the blade with respect to that of its front portion, so that the major axis of the elliptic path be greater than the radius of the circular path described by the front portion of blade 42.
By virtue of this combined movement the amplitude of movement of the rear portions of the plough blades is constantly greater than that of the front portions, and this difference is particularly useful for pushing forward and laterally the ballast accumulating toward the rear of the machine. The principle of this combined movement is illustrated diagrammatically in FIG. 9 in which the two eccentrics 44a and 44b are replaced by a lever 44a,b.
This movement can be modified at any time as a function of the values of throws 44a and 44b, of the eccentric ratio of shaft 44 and of the lever arm ratio of rod 46. Preferably, the arrangement of the various component elements is such that an asymmetric movement is obtained, i.e. when the blade 42 protrudes laterally from the lower portion of ploughshare 41 the other blade is retracted. Since the nose member 43 of the plough is pivotally mounted in relation to the two blades 42 by means of the two end teeth 52, the asymmetric movement of the two blades 42 causes this nose member 43 to follow an oscillatory path adapted to facilitate the penetration of the blades into the ballast.
According to another preferred form of embodiment of the invention, a motor is provided for driving pinion 49 at a velocity of 100 to 300 r.p.m. and the ratios of the eccentrics and of the arms are such that the amplitude of the movement measured at the lower portion of the blade is about 3 centimeters against about 6 centimeters for the rear portion.
In another modified form of embodiment illustrated in FIG. 10, the system described hereinabove, comprising lateral ejectors or pistons 53, is superposed to the system comprising the blades 42, whereby the ballast accumulated as a consequence of the forward motion of the plough can be expelled. This modified arrangement constitutes a combined plough associating the advantageous features of the two previously described plough arrangements.
FIG. 10 further shows a vibrator 54 of a type known per se, which is secured to the plough frame together with a rectilinear plate 55 constituting the extension of ploughshares 41 and serving the purpose of temporarily retaining the gravel accumulated along the edges of the cutting.
Of course other modifications and changes may be contemplated by those skilled in the art in the practical embodiment of the invention without departing from the basic principles thereof. | This plough adapted to be mounted on a railroad tracklaying machine comprises in its plough area members capable of disaggregating and/or thrusting aside the old compact ballast. These members consist of ejectors acting like pistons and extending through apertures formed in the ploughshares; the ejectors movable across the normal direction of travel of the plough under the control are driven by an actuating mechanism imparting a reciprocating motion thereto, and may be replaced by blades disposed beneath, and substantially parallel to, the ploughshares, the actuating mechanism being adapted to impart to these blades a movement substantially of translation along a closed path. | 8 |
RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. application Ser. No. 11/975,370 filed on Oct. 17, 2007, which is herein incorporated by reference in its entirety.
TECHNICAL FIELD
[0002] A device and method used to hold a section of cable while the content within the cable is accessed.
BACKGROUND
[0003] Fiber distribution cables are commonly used to connect a central office or hub to a number of end subscribers. A typical fiber distribution cable houses a large number of separate fibers, which are broken out along the length of the cable and connected to the end subscribers via secondary cables (e.g., drop cables, stub cables, etc.).
[0004] The individual or group of fibers can be broken out from the distribution cables in the field or before the cable leaves the factory. The present invention provides a device and method for breaking out fibers from a main distribution cable.
SUMMARY
[0005] The present disclosure relates to a cable holder. The cable holder can be used when splicing a main fiber distribution cable. In particular, the cable holder can be used to secure a section of cable while the outer protective sheathing is cut and select fibers therein are accessed. In some embodiments, select fibers are pulled out of the main cable to create pigtails, which connect to secondary cables (e.g., drop cables, stub cables). In such embodiments, it is desirable to overmold the splice area to protect it from being damaged in the field. The cable holder can be used to safely transport the cable from work station to work station during cable processing. The cable holder can also serves as a jig or fixture during the overmolding process. In such embodiments, the cable holder holds the section of cable in a fixed orientation and protects the section of cable from being damaged or contaminated during the overmolding process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a cable holder according to a first embodiment of the present disclosure;
[0007] FIG. 2 is a perspective view of the cable holder of FIG. 1 with a section of cable held in the cable holder;
[0008] FIG. 3 is an assembly view of the cable holder of FIG. 1 ;
[0009] FIG. 4 is a top view of the cable holder of FIG. 1 ;
[0010] FIG. 5 is a front view of the cable holder of FIG. 1 ;
[0011] FIG. 6 is an end view of the cable holder of FIG. 1 ;
[0012] FIG. 7 is a perspective view of a cable holder according to a second embodiment of the present disclosure;
[0013] FIG. 8 is a perspective view of a partially disassembled cable holder of FIG. 7 ; and
[0014] FIG. 9 is an end view of the cable holder of FIG. 7 .
DETAILED DESCRIPTION
[0015] The cable holders according to the present disclosure are configured to secure a section of cable, for example, while the protective sheathing of a cable is cut and select fibers therein are accessed, while the section of cable is transported from one location to another, and/or during an overmolding process. The cable holders according to the present disclosure can be configured to hold a section of cable in a fixed orientation and protect it from being damaged (e.g., bent, bumped, contacted, or rotated) and/or contaminated. For example, during overmolding it is generally desirable to prevent the cable from bending and spinning.
[0016] Referring generally to FIGS. 1-6 , a cable holder 10 according to a first embodiment of the present disclosure is shown. The cable holder 10 includes an elongated base plate 12 including a first end 14 , an opposed second end 16 , and a mid portion 18 therebetween. In the depicted embodiment, a first clamp assembly 20 is mounted to the first end 14 , and a second clamp assembly 22 is mounted to the second end 16 . Each clamp assembly includes a cable chuck 24 (also referred to herein interchangeably as an insert) configured to secure a section of cable 25 above the base plate 12 .
[0017] The cable chucks 24 of each clamp assembly 20 , 22 are aligned with each other to support a section of cable 25 in a parallel orientation relative to the elongated base plate 12 . FIG. 1 depicts the second clamp assembly 22 in the disengaged or unlocked position, and the first clamp assembly 20 in the engaged or locked position. In the depicted embodiment each of the first and second clamp assemblies 20 , 22 are identical. However, it should be appreciated that alternative embodiments of the cable holder 10 may include only one clamp assembly or multiple, different clamp assemblies.
[0018] The clamp assemblies 20 , 22 include an upper clamp portion and a lower clamp portion. In the depicted embodiment, the upper clamp portion consists of a four bar linkage bolted to the base plate 12 , and the lower portion consists of a cable chuck 24 secured to the base plate 12 . The upper portion of the clamp assembly is an over-center lock mechanism that includes a clamp pad 26 configured to press a section of cable 25 into the cable chuck 24 . In the depicted embodiment, the four bar linkage clamp member includes a T-shaped handle 28 that is arranged relative to the connector bar 30 , base bar 32 , and extender 34 such that the upper clamp pad 26 locks in place when the T-shaped handle is in the downward or engaged position as shown in FIG. 2 .
[0019] Referring to FIGS. 1-3 , and 6 , the upper portion of the clamp assembly 20 , 22 is described in greater detail. In the depicted embodiment, the base bar 32 of the linkage is bolted to the base plate 12 via risers 36 and pivotally attached to the lower end of the handle 28 and the lower end of the extender bar 32 . The connector bar 30 pivotally connects the handle 28 and the extender bar 34 above the lower ends and below the upper ends of the handle 28 and extender bar 34 . The upper end of the extender bar 34 supports the clamp pad 26 . In the depicted embodiment, the location of the clamp pad 26 relative to the extender bar 34 is adjustable. The extender bar 34 includes a slot 38 through which a bolt 40 extends to connect the clamp pad 26 to the extender bar 34 (see FIG. 2 ). In the depicted embodiment, the clamp pad 26 is X-shaped and includes a resilient material 42 (e.g., foam, rubber, plastic, etc.) on its bottom surface. The resilient material 42 is configured to engage the top surface of a section of cable 25 .
[0020] Still referring to FIGS. 1-3 , and 6 , the lower portion of the clamp assembly 20 , 22 is described in greater detail. The lower portion generally consists of the cable chuck 24 secured to the base plate 12 . In the depicted embodiment, cable chuck 24 is configured to be interchanged depending on the diameter of the section of cable 25 . In the depicted embodiment the cable chuck 24 is held to the base plate 12 via a pair of arms 44 , 46 and a stopper 48 . The pair of arms 44 , 46 , and stopper 48 allow the cable chuck to be easily engaged and disengaged from the base plate 12 . In particular, they engage the base of the cable chuck and allow the cable chuck 24 to slide into engagement with the base plate 12 . The front arm 44 includes a lock member 50 that interlocks with a groove 52 to secure the cable chuck in place. In some embodiments the lock member 50 is a threaded set screw, and in other embodiments it is a spring loaded boss member.
[0021] Referring to FIG. 3 , the cable chuck 24 (insert) is described in greater detail. In the depicted embodiment the cable chuck 24 includes two opposed, generally parallel walls 52 , 54 that extend from a base member 58 . The walls 52 , 54 are separated by a space that generally correlates with the diameter of the section of cable 25 . In the depicted embodiment the base member 58 includes a resilient material 60 that is configured to support the bottom surface of the section of cable 25 . In some embodiments the height of the walls 52 , 54 is less than the distance between the resilient material 60 of the cable chuck 24 and the resilient material 42 of the clamp pad 26 when the clamp pad 26 is in the locked or engaged position.
[0022] Still referring to FIG. 3 , the base plate 12 is described in greater detail. In the depicted embodiment the base plate 12 is generally rectangular in shape and includes a number of apertures 64 therein. The base plate also includes a front lip 66 , a rear lip 68 , and curved over end portions 70 . Optionally, a hood or cover 72 is connected to the base plate 12 . In some embodiments, the cover 72 is generally U-shaped and extends between the clamp assemblies 20 , 22 . In some cable finishing processes, the cable is coated with epoxy or silicon. During such processes it is generally desirable to protect the section of cable from contact and contamination.
[0023] Referring to FIGS. 7-9 , a second embodiment of the cable holder is shown. The cable holder 80 of the second embodiment is similar to the cable holder 10 of the first embodiment. Some differences relate to the shape of the clamp pads 82 and the shape of the base plate 84 . Other differences relate to the manner in which the upper and lower clamp members are mounted to the base plate 84 . The upper and lower clamp members of the cable holder 80 are mounted to the base plate 84 via mounting blocks 86 . The mounting blocks eliminate the risers 36 shown in the first embodiment. In addition, the mounting blocks 86 provide an alternative quick release means for supporting the cable chuck 88 . Instead of the boss and arms shown in the first embodiment, the base 90 of cable chuck 88 is engaged in channels 92 in the mounting block 86 . FIG. 7 also depicts cable chuck 94 and cable chuck 96 . Cable chucks 88 , 94 , 96 can be of different sizes and configurations. The appropriate cable chuck 88 , 94 , 96 can be selected to best fit the specific cable that will be used with the cable holder 80 .
[0024] The above specification, examples and data provide a complete description of the manufacture and use of the composition of the invention. Since many embodiments of the invention can be made without departing from the spirit and scope of the invention, the invention resides in the claims hereinafter appended. | A device used to secure a section of cable while one or more fiber is broken out from the cable. The device includes spaced apart clamp assemblies that hold a cable during the splicing process to protect the fairly delicate fibers within the sheathing. The disclosure also relates to a method of splicing using a clamp assembly. | 8 |
FIELD OF THE INVENTION
[0001] The present invention relates generally to digital communication systems and more specifically to reducing the temperature in such systems.
BACKGROUND OF THE INVENTION
[0002] In semiconductor technology, both the sizing and geometry of integrated circuits have consistently become smaller and smaller over the years, causing more hardware circuitry to be packed within each chip package or die. As a result of integrating more functionality and power amplifiers within each unit area, operating temperatures of many integrated circuits have become exceedingly high resulting in system instability and failure.
[0003] One approach to resolving the issue of high temperature integrated circuitry is the addition of a heat sink on the integrated circuit package. However, this solution substantially increases the manufacturing costs.
[0004] A second approach to reducing the integrated circuit temperature is to reduce the transmitter output power of the communication system. However, this method also decreases the wireless transmission range of the communication system.
[0005] Accordingly, what is needed is a method and system for reducing the temperature in an integrated circuit board. The method and system should be cost effective, easily implemented and adaptable to existing environments. The present invention addresses such a need.
SUMMARY OF THE INVENTION
[0006] The present invention satisfies this need, and presents a method and system for reducing the temperature of an integrated circuit. To achieve the above object, the present method is described as detecting a temperature of a communication system. The method and system further includes providing a signal based upon the detected temperature, and determining a desired idle time between transmit packets based upon the signal. Finally, the method and system includes sending the desired idle time between transmit packets to the communication system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The various features of the present invention and the manner of attaining them will be described in greater detail with reference to the following description, claims, and drawings, wherein reference numerals are reused, where appropriate, to indicate a correspondence between the referenced items, and wherein:
[0008] FIG. 1 is an illustration of a communication temperature control scheme in accordance with an embodiment.
[0009] FIG. 2 illustrates a first embodiment of an algorithm used to implement the idle time decision block.
[0010] FIG. 3 illustrates the use of dual temperature threshold values in a second embodiment of an algorithm.
[0011] FIG. 4 is a block diagram of a RF transmitter system that utilizes the temperature control scheme in accordance with an embodiment.
DETAILED DESCRIPTION
[0012] The present invention relates generally to digital communication systems and more specifically to reducing the temperature in such systems.
[0013] The following description is presented to enable one of ordinary skill in the art to make and use the invention and is provided in the context of a patent application and its requirements. Various modifications to the preferred embodiments and the generic principles and features described herein will be readily apparent to those skilled in the art. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features described herein.
[0014] A method and system in accordance with the present invention uses a temperature control scheme to detect the temperature of either an integrated circuit or of the communication system itself. Once the temperature is detected, the temperature information is sent to and idle time decision block where an idle time between transmit packets is determined and later sent to a communication system. In doing so, both reliability and efficiency of the communication system are improved because lower temperatures are sustained while consuming less overall system power. The temperature control scheme in accordance with the present invention can take the form of a computer program product accessible from a computer-usable or computer-readable medium providing program code for use by or in connection with a computer or any instruction execution system. For the purposes of this description, a computer-usable or computer-readable medium can be any apparatus that can contain, store, communicate, propagate, or transport the program for use by or in connection with the instruction execution system, apparatus, or device. The temperature control scheme in accordance with the present invention can also be implemented in hardware or application specific integrated circuits (ASIC).
[0015] The medium can be an electronic, magnetic, optical, electromagnetic, infrared, or a semiconductor system (or apparatus or device) or a propagation medium. Examples of a computer-readable medium include a semiconductor or solid state memory, magnetic tape, a removable computer diskette, a random access memory (RAM), a read-only memory (ROM), a rigid magnetic disk, and an optical disk. Current examples of optical disks include DVD, compact disk-read-only memory (CD-ROM), and compact disk—read/write (CD-R/W). To describe the features of the present invention in more detail, refer now to the following description in conjunction with the accompanying Figures.
[0016] FIG. 1 is an illustration of a communication temperature control scheme 100 in accordance with an embodiment. The temperature control scheme 100 is shown within the context of an Open System Interconnection Reference Model (OSI Model) Communication System, 102 . The illustrated OSI Model 102 comprises a plurality of layers including: a physical layer 104 , a data link layer 106 , a network layer 108 , a transport layer 110 , a session layer 112 , a presentation layer 114 , and an application layer 116 . Each of these layers provides services to its upper layer while receiving services from the layer immediately below it. For example, the data link layer 106 may provide services to the “upper” network layer 108 , while simultaneously receiving services from the “lower” physical layer 104 .
[0017] On this embodiment, a temperature sensor block 118 detects the temperature of the communication system 102 , and sends the information to an idle time decision block (ITDB) 120 . Based on the temperature received by the temperature sensor 118 , an ITDB 120 calculates a desired idle time between transmit packets. If the temperature has risen, the idle time is increased by the idle time block 120 in order to reduce the transmit duty cycle, and hence the temperature. If the temperature has fallen, the idle time is decreased by the ITDB 120 in order to increase the data throughput. The desired idle time between transmit packets is then sent to any of the seven layers of the OSI model communication system 102 , although in FIG. 1 (by example) it is sent to the network layer 108 . The ITDB 120 can be implemented in either software or hardware.
[0018] A key feature of the present invention is the ITDB 120 can be implemented in accordance with one or more algorithms. Two of these algorithms will be discussed further. FIG. 2 illustrates a first embodiment of an algorithm 200 used to implement the ITDB 120 using a single temperature threshold value T t0 . A temperature signal threshold value T t0 ( 202 ) is evaluated against a temperature signal obtained from the temperature sensor 118 via decision block 201 . The detected temperature signal can be any signal such as voltage, current, temperature, displacement, stress, or strain, as long as the detected signal provides the temperature information.
[0019] For example, in this embodiment, if the temperature from the temperature sensor 118 is more than the threshold value T t0 ( 202 ), the idle time will be increased between packets. However, if the temperature from the temperature sensor 118 is less than the signal threshold value T t0 ( 202 ), the idle time will be decreased between the packets. In so doing, the temperature of the device can be effectively controlled. Although this system works effectively, it has a disadvantage in some environments where the temperature fluctuates around the threshold value which may require the idle time to be adjusted frequently.
[0020] Therefore, to address this issue, another possible approach to implementing the ITDB 120 involves the use of dual temperature threshold values. FIG. 3 illustrates the use of dual temperature threshold values T t1 and T t2 in a second embodiment of an algorithm 300 . In this embodiment, the first threshold value T t1 ( 302 ) may be larger than the second threshold value T t2 ( 304 ). Both temperature threshold values T t1 ( 302 ) and T t2 ( 304 ) are evaluated against a temperature signal obtained from the temperature sensor ( 306 ). For example, in this embodiment, if the temperature signal from the temperature sensor 306 is larger than T t1 ( 302 ), the algorithm 300 sends a signal 308 to the network layer 108 to increase the idle time. If the temperature signal 310 from the temperature sensor 118 is smaller than T t2 ( 304 ), the algorithm 300 sends a signal to the network layer 108 to decrease the idle time. If the temperature signal is found to be within the range of T t1 ( 302 ) and T t2 ( 304 ), the algorithm 300 either sends no signal, or in the alternative, may send a signal 312 indicating no actions are required. This embodiment illustrates the advantage of using two threshold values because the need to make frequent adjustments to the idle time is greatly reduced.
[0021] A method and system in accordance with the present invention can be utilized in a variety of environments. FIG. 4 is a block diagram of a RF transmitter system 400 that utilizes the temperature control scheme 100 in accordance with an embodiment. The RF transmitter system 400 includes a software device driver 404 , coupled to a media access controller (MAC) 406 .
[0022] A baseband processor (BBP) 408 is coupled to a RF transmitter 410 , and a power amplifier 412 . The temperature sensor block 118 detects the temperature of the integrated circuit or the system. Though in FIG. 4 the temperature control scheme 100 is coupled to the software device driver 404 , it can also be coupled to the MAC 406 or the baseband processor 408 . Based on the temperature information, the ITDB 120 calculates the desired idle time between transmit packets. If the detected temperature information indicates that the temperature has risen, the idle time is increased in order to reduced the transmit duty cycle, and hence the temperature. If the detected temperature information indicates that the temperature has fallen, the idle time is decreased in order to increase the data throughput. The desired idle time between transmit packets is then sent to the software device driver 404 . In addition to being implemented as a separate block, the ITDB 120 can be implemented as part of the software device driver 404 , or within the MAC 406 . As before mentioned an ITDB 120 can be implemented in a variety of ways including but not limited to those disclosed in FIGS. 2 and 3 .
[0023] One advantage of a system and method in accordance with the present invention is improved system reliability and performance because less power is consumed in the operation of the overall communication system.
[0024] A second advantage of a system and method in accordance with the present invention is the reduced overall operating cost since less power is consumed in the operation of the overall communication system.
[0025] A third advantage of a system and method in accordance with the present invention is the ability to operate the communication system with reduced temperatures without affecting the wireless transmission range since the transmitter output power does not need to be reduced.
[0026] A fourth advantage is the elimination of the need of a head sink and/or an expensive IC package which would increase both the overall communication system cost and form factor.
[0027] Although the present invention has been described in accordance with the embodiments shown, one of ordinary skill in the art will readily recognize that there could be variations to the embodiments and those variations would be within the sprit and scope of the present invention. Accordingly, many modifications may be made by one of ordinary skill in the art without departing from the spirit and scope of the appended claims. | A method and system for reducing the temperature of a communication system are disclosed. The method and system comprise detecting a temperature of the communication system. The method and system further includes providing a signal based upon the detected temperature, and determining a desired idle time between transmit packets based upon the signal. Finally, the method and system includes sending the desired idle time between transmit packets to the communication system. | 8 |
BACKGROUND
[0001] 1. Field of the Invention
[0002] This invention relates to the construction of buildings and other structures, and more particularly to apparatus and methods for insulating and imparting desired architecture styles to buildings and other structures.
[0003] 2. Background of the Invention
[0004] Modern-day buildings and structures can take on a wide variety of different forms and appearances. Some aspects of a building's form or appearance are functional in nature. Other aspects are purely for aesthetic purposes. Yet other aspects serve both functional and aesthetic purposes. Whether for functional or aesthetic purposes, a significant amount of effort and resources are frequently dedicated to achieving a desired outward form or appearance for a building or structure. Such outward forms and appearances may be based on different architectural designs or styles, such as Gothic, Renaissance, Baroque, Neoclassical, Early Modern, Postmodern, Colonial, Contemporary, or similar designs or styles, to name just a few. Many of these designs or styles use different building materials and architectural elements to achieve their characteristic appearance.
[0005] As alluded to above, a large part of the cost of a building or structure may be attributed to achieving a desired appearance. For example, significant time and resources may be dedicated to adding architectural elements to the exterior of a building, or covering the building with overlay materials such as stone, brick, wood, or the like. These architectural elements and overlay materials are frequently applied to buildings in an inefficient and archaic manner. For example, architectural elements and overlay materials may be delivered to a construction site and then manually transported and applied to the outside of a building using scaffolds and other relatively primitive tools. Unfortunately, such techniques fail to take advantage of modern construction and assembly techniques that have driven down prices for many industrial and consumer products, such as cars, machinery, clothing, electronics, and the like.
[0006] In view of the foregoing, what are needed are improved construction techniques and building materials for applying architectural elements, overlay materials, and other desired elements to a building or structure. Ideally, such construction techniques and building materials will take advantage of modern construction and assembly techniques commonly used to fabricate industrial and consumer products. Such construction techniques and building materials will also ideally enable a wide variety of different architectural designs and styles to be achieved for buildings and other structures, as well as provide a functional purpose, such as insulate and/or weatherproof buildings and other structures.
SUMMARY
[0007] The invention has been developed in response to the present state of the art and, in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available methods and apparatus. Accordingly, improved methods and apparatus have been developed to insulate and impart desired architectural styles to buildings and other structures. Features and advantages of different embodiments of the invention will become more fully apparent from the following description and appended claims, or may be learned by practice of the invention as set forth hereinafter.
[0008] Consistent with the foregoing, a method for insulating and imparting a desired architectural style to a building or other structure is disclosed. In one embodiment, such a method includes providing a facade comprising an insulating panel and a decorative layer coupled to a front side of the insulating panel. The facade has a substantially planar surface on a back side thereof. The front side of the facade may be non-planar to provide a desired architectural contour to the facade. The method further provides an attachment mechanism on at least one of: (1) the back side of the facade, and (2) an exposed face of a building or other structure. The method attaches the back side of the facade to the exposed face of the building or other structure using the attachment mechanism. A corresponding apparatus and overall assembly are also disclosed and claimed herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered limiting of its scope, the invention will be described and explained with additional specificity and detail through use of the accompanying drawings, in which:
[0010] FIG. 1 is a perspective view of one embodiment of modular insulated facade for application to a building or other structure;
[0011] FIG. 2 is a perspective view showing a bottom panel of the modular insulated facade of FIG. 1 applied to a building or other structure;
[0012] FIG. 3 is a perspective view showing both bottom and top panels of the modular insulated facade of FIG. 1 applied to a building or other structure;
[0013] FIG. 4 is a close-up exploded perspective view of the modular insulated facade of FIG. 1 ;
[0014] FIG. 5 shows one example of a modular insulated facade in accordance with the invention being installed on a building or other structure;
[0015] FIG. 6 shows one example of a simple or standardized building, such as a glass and/or concrete building, prior to applying a modular insulated facade in accordance with the invention;
[0016] FIG. 7 shows a first example of a modular insulated facade applied to the building of FIG. 6 ;
[0017] FIG. 8 shows a second example of a modular insulated facade applied to the building of FIG. 6 ;
[0018] FIG. 9 shows a third example of a modular insulated facade applied to the building of FIG. 6 ;
[0019] FIG. 10 shows a fourth example of a modular insulated facade applied to the building of FIG. 6 ;
[0020] FIG. 11 shows a fifth example of a modular insulated facade applied to the building of FIG. 6 ;
[0021] FIG. 12 shows one example of modular insulated facades used on interior walls and a ceiling of a building;
[0022] FIG. 13 shows another example of modular insulated facades used on interior walls and a ceiling of a building; and
[0023] FIG. 14 shows an example of a modular insulated facade used as or on a roof of a building.
DETAILED DESCRIPTION
[0024] 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 invention, as represented in the Figures, is not intended to limit the scope of the invention, as claimed, but is merely representative of certain examples of presently contemplated embodiments in accordance with the invention. The presently described embodiments will be best understood by reference to the drawings, wherein like parts are designated by like numerals throughout.
[0025] Referring to FIG. 1 , a perspective view of one embodiment of a modular insulated facade 100 in accordance with the invention is illustrated. As shown, the modular insulated facade 100 is designed to be applied to a building 102 or other physical structure 102 to impart a desired architectural style thereto. In one embodiment, the modular insulated facade 100 is implemented in the form of modular panels 100 a, 100 b for attachment to a building 102 or structure 102 . For example, FIG. 2 shows the modular insulated facade 100 with a top panel 100 a and bottom panel 100 b, with the bottom panel 100 b attached to the building 102 or structure 102 . FIG. 3 shows both the top panel 100 a and bottom panel 100 b attached to the building 102 or structure 102 .
[0026] In certain embodiments, the panels 100 a, 100 b are sized to facilitate transport and delivery to a construction site. For example, the panels 100 a, 100 b may be sized to fit on a typical semi trailer, railroad car, or other vehicle to facilitate transport. The panels 100 a, 100 b may also be sized so that they are easily manipulated and installed on buildings 102 or structures 102 by cranes or other equipment, as shown in FIG. 5 , or exclusively using manpower. The size of the modular panels 100 a, 100 b may vary in accordance with a project's needs, desired ease of installation, transport restrictions, aesthetic design, and/or the like. The orientation of the modular panels 100 a, 100 b may also vary in different embodiments. For example, the horizontally aligned modular panels 100 a, 100 b illustrated in FIGS. 1 through 3 may be replaced by vertically aligned modular panels 100 a, 100 b, such as modular panels 100 a, 100 b extending from top to bottom of a building 102 . Joints between the modular panels 100 a, 100 b may be placed at any suitable location, such as at floor level, corners, or natural seams or lines in a building 102 or structure 102 , in order to reduce their conspicuousness.
[0027] Referring to FIG. 4 , while continuing to refer generally to FIGS. 1 through 3 , the modular panels 100 a, 100 b discussed above may be generally applied to concrete, metal, wood, and/or glass buildings with substantially planar sides, primarily in applications where the modular panels 100 a, 100 b are not required to provide any structural support. In certain embodiments, the modular panels 100 a, 100 b are fabricated from insulating panels 400 such as expanded polystyrene (EPS) panels 400 or other insulating foam panels 400 . The insulating panels 400 may be solid blocks or may be constructed from multiple blocks that are glued or welded together. A back side 406 of the insulating panels 400 may be substantially flat or planar to interface with a substantially flat or planar building 102 or structure 102 . A front side 404 of the insulating panels 400 may be shaped to provide a desired architectural style. This shape may be achieved by milling the insulating panels 400 using a CNC mill or other milling equipment. It is also contemplated that the shape may be achieved using a mold or a 3-D printer configured to lay down insulating material in a desired shape or pattern.
[0028] The insulating panels 400 may be coated or covered with one or more layers (collectively referred to herein as a “decorative layer” 402 ). In certain embodiments, the decorative layer 402 includes a base layer such as glass-fiber reinforced concrete, fiberglass, epoxy, plastic, polymers (e.g., polyurethane), stucco, or the like. The base layer may be applied to the insulating panels 400 by spraying, brushing, rolling, dipping, or using various deposition techniques. The base layer may provide one or more of impact resistance, corrosion resistance, rigidity, a barrier to moisture/weather, as well as provide a layer onto which other layers may be adhered. A finish layer, such as paint or stain may be applied onto or over the base layer. This finish layer may also be applied by spraying, brushing, rolling, dipping, or using various deposition techniques. Various intermediate layers (e.g., primers, etc.) may be used between the base layer and the finish layer.
[0029] Overlay materials, such as stone, brick, wood, vinyl, metal, moldings, castings, architectural elements, or the like, may be applied over the base layer. Ideally, such overlay materials, particularly weighty overlay materials, are applied thinly to keep the modular insulated facade 100 as light weight as possible while still providing a desired appearance. Although insulating materials such as EPS foam are typically very lightweight, coatings, finishes, and overlay materials can add a significant amount of weight to the modular panels 100 a, 100 b. Thus, these coatings, finishes, and overlay materials may be kept as thin and lightweight as possible to minimize the additional weight. Intermediate layers, such as vapor barriers, wind/moisture barriers, sheathing, metal lath or mesh, mortar scratch coats, mortar setting beds, felt paper, and/or the like, may be used depending on the application.
[0030] As mentioned above, a back side 406 of the modular insulated facade 100 may be substantially flat or planar to facilitate installation on a wide variety of buildings 102 or structures 102 . All that is needed is a substantially flat exposed surface on the building 102 or structure 102 to install the modular insulated facade 100 . Because the modular insulated facade 100 is designed to be lightweight, the modular insulated facade 100 may, in certain embodiments, be coupled to a building 102 or other structure 104 with nothing more than an adhesive. In certain embodiments, an adhesive is applied to the modular insulated facade 100 at the factory and covered with a paper cover seal. This paper cover seal may be removed at the construction site and the modular insulated facade 100 may be adhered to the building 102 or structure 102 . Alternatively, or additionally, an adhesive may be applied to the modular insulated facade 100 and/or the building 102 or structure 102 at the construction site.
[0031] Attachment of the modular insulated facade 100 to a building 102 or structure 102 is not limited to adhesives. In certain embodiments, mechanical fasteners, such as screws, bolts, hooks, rivets, brackets, or the like may be used on their own or in conjunction with an adhesive to attach the modular insulated facade 100 to a building 102 or structure 102 . In other embodiments, an overhang or lip may be provided at or near a top of the modular panels 100 a, 100 b. This overhang or lip may hook onto or rest on a top edge of a building 102 or structure 102 , or hook onto or rest on a rail attached to a building 102 or structure 102 . Other types of mechanical attachments are possible and within the scope of the invention. Mechanical attachments such as fasteners may be attached to the modular panels 100 a, 100 b at the factory or installed at the construction site.
[0032] In certain embodiments, an attachment mechanism may be selected to facilitate removal of the modular insulated facade 100 . For example, where an adhesive is used, a hot wire may be used to cut or melt the adhesive to enable removal of the modular insulated facade 100 from a building 102 or structure 102 . Mechanical fasteners may also be selected that are removable or capable of releasing their mechanical attachment. In certain cases, a modular insulated facade 100 may be removed from a building 102 or structure 102 so that it can be replaced with another modular insulated facade 100 either of the same or a different architectural style. A modular insulated facade 100 may also be removed from a building 102 or structure 102 to facilitate repair and reinstallation.
[0033] As shown in FIGS. 1 through 3 , in certain embodiments, a modular insulated facade 100 in accordance with the invention may include openings such as windows or doors. Modular panels 100 a, 100 b that include window openings may, in certain embodiments, be applied to glass walls or panels on a building 102 or structure 102 . The instant inventors have found that glass is one of the most cost-effective building materials with which to construct the walls of a building 102 or structure 102 . Installing modular panels 100 a, 100 b with window openings over glass or transparent walls may be used to create different types, shapes, and styles of windows. Window shapes, styles, and sizes may be changed by replacing a modular insulated facade 100 with another modular insulated facade 100 having different window openings. The glass, which is part of the building 102 or structure 102 as opposed to the modular insulated facade 100 , may be used with different types and styles of modular insulated facades 100 . The modular insulated facade 100 may control which portions and areas of glass are exposed to the exterior of the building 102 or structure 102 . In addition to allowing a wide variety of window designs to be achieved, implementing windows using the modular insulated facade 100 advantageously eliminates or substantially reduces cracks, leaks, and/or drafts associated with traditional windows (since the glass is a continuous panel from floor to ceiling as opposed to a number of discrete panels), potentially increasing the energy efficiency of a building 102 or structure 102 .
[0034] As previously explained, the modular panels 100 a, 100 b may be fabricated from insulating panels 400 . Thus, the modular insulated facade 100 may provide thermal insulation for a building 102 or structure 102 in addition to providing a desired aesthetic appearance. This eliminates or reduces the need to separately insulate the building 102 or structure 102 . In certain embodiments, the thickness and material of the insulating panels 400 may be selected to provide a desired R-value. For example, common residential code requires exterior walls to be a minimum R-21. One type of EPS foam that may be used as an insulating panel 400 is rated at R-5 per inch. Using this type of foam, the minimum thickness for the foam would be just over four inches.
[0035] Due to the modular design of the panels 100 a, 100 b, modern construction and assembly technique may be used to reduce the cost of a building 102 or structure 102 . For example, the modular panels 100 a, 100 b may be constructed in a factory and transported to a construction site ready for installation. Among other benefits, this construction method may reduce CO 2 emissions resulting from transporting materials and workers to and from a construction site, reduce emissions and environmental impacts from construction operations, minimize waste materials that may be reused and recycled in a factory setting, improve scheduling required to complete a building 102 or structure 102 , improve worker safety, improve quality of the finished product, etc. All of the efficiencies, cost-savings, and benefits associated with factory-based fabrication may help to reduce the overall cost and environmental impact of a building 102 or structure 102 .
[0036] In certain embodiments, structural members may be incorporated into the modular insulated facade 100 to impart additional rigidity, strength, or impact resistance thereto. For example corners or edges of the insulating panels 400 , or architectural elements on or attached to the insulating panels 400 , may be covered with or lined with metal or plastic beads to prevent dents, dings, or other damage. In other embodiments, metal studs or other structural members may be incorporated into the insulating panels 400 or into architectural shapes or elements on the insulating panels 400 to provide additional rigidity or strength to the insulating panels 400 and/or elements attached thereto. These studs or structural members may be incorporated into grooves or channels formed in the insulating panels 400 , or embedded in the insulating foam of the panels 400 at the time of creation.
[0037] After the modular panels 100 a, 100 b are installed on a building 102 or structure 102 , edges or seams between the modular panels 100 a, 100 b may be caulked or sealed, such as with expanding polyurethane-based insulating foam or other sealing agents. This will ideally provide an air- and/or water-tight seal between the modular panels 100 a, 100 b and/or between the modular panels 100 a, 100 b and the building 102 or structure 102 . This will ideally improve the overall thermal insulation and energy efficiency of the building 102 or structure 102 and reduce paths for insects, water, etc. The instant inventors anticipate a clearance gap of approximately ⅛ inch between modular panels 100 a, 100 b, a gap that may be filled with various types of caulks and sealants.
[0038] As can be appreciated, a wide variety of different architectural styles are possible using the disclosed modular insulated facade system, various examples of which are illustrated in FIGS. 7 through 11 . The disclosed modular insulated facade system may be used to transform a comparatively simple or standardized building, such as the building 102 illustrated in FIG. 6 , into any of the buildings 102 illustrated in FIGS. 7 through 11 . The modular insulated facade system may enable the styling of a building 102 to change by simply removing the previous modular insulated facade 100 and replacing it with a new modular insulated facade 100 having a desired architectural style. The modular insulated facade 100 also has the potential to significantly reduce the costs of constructing buildings 102 and other structures 102 . For example, instead of designing a building 102 from scratch, a basic or standardized concrete and/or glass building may be transformed into a building 102 with a distinct architectural style.
[0039] Using the disclosed modular insulated facade system, a wide variety of different architectural elements are possible. For example, the disclosed modular insulated facade system may be used to replicate columns, arches, crown molding, siding, cornices, gables, posts, pilasters, eaves, soffits, windows, and dormers, to name just a few. The surface of the modular insulated facade 100 may also be shaped, textured, and/or colored to look like brick, stone, logs, wood, or other materials. In addition to being useful in the construction of buildings 102 such as residential dwellings, commercial buildings, government buildings, public buildings, schools, multi-purpose units, and the like, the disclosed modular insulated facade system may be equally useful in the construction of movie sets, theme parks, stage backdrops, sound walls, landscaping, and the like.
[0040] The disclosed modular insulated facade 100 is not limited to covering exterior walls of a building 102 or structure 102 . In certain embodiments, the same type of system may be used to cover interior walls, ceilings, and even roofs of buildings 102 or structures 102 . FIG. 12 shows one example of a modular insulated facade 100 a used on interior walls of a building 102 . As shown, the modular insulated facade 100 a includes window and door opening that align with corresponding window and door openings of an exterior modular insulated facade 100 . In the illustrated embodiment, a glass panel 1200 resides between the interior modular insulated facade 100 a and the exterior modular insulated facade 100 . The interior and exterior modular insulated facades 100 , 100 a control which portions and areas of the glass panel 1200 are exposed to the inside and outside of the building, respectively. As also shown in FIG. 12 , the interior modular insulated facade 100 a includes architectural elements, namely crown molding 1202 , an arched window and door 1204 , window and door trim 1206 , chair rail 1208 , and panels/baseboards 1210 beneath the chair rail 1208 . These represent just a few examples of architectural elements that are possible using the disclosed modular insulated facade 100 . Other architectural elements are possible and within the scope of the invention.
[0041] As further shown in FIG. 12 , a modular insulated facade 100 b in accordance with the invention may, in certain embodiments, also be used in ceiling panels. A large number of different designs and architectural styles are possible. The light-weight construction of the modular insulated facade 100 b may be particularly useful for ceiling panels since the panels would be suspended and any attachment mechanism must hold their full weight. The light-weight construction of the modular insulated facade 100 b may reduce the robustness required for the attachment mechanism and may improve safety for those passing under the panels. FIG. 13 shows another example of modular insulated facades 100 a, 100 b used on interior walls and ceiling panels.
[0042] In other embodiments, a modular insulated facade 100 c in accordance with the invention may be used as a roof 1400 of a building 102 or structure 102 . In certain embodiments, additional structural members may be incorporated into the modular insulated facade 100 c to provide necessary strength and rigidity in roof applications. Various types of roofing materials may be overlaid on the modular insulated facade 100 to provide a desired appearance and/or protection from natural elements such as wind, water, etc.
[0043] The apparatus and methods disclosed herein may be embodied in other specific forms without departing from their 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. | A method for insulating and imparting a desired architectural style to a building or other structure is disclosed. In one embodiment, such a method includes providing a facade comprising an insulating panel and a decorative layer coupled to a front side of the insulating panel. The facade has a substantially planar surface on a back side thereof. The front side of the facade may be non-planar to provide a desired architectural contour to the facade. The method further provides an attachment mechanism on at least one of: (1) the back side of the facade, and (2) an exposed face of a building or other structure. The method attaches the back side of the facade to the exposed face of the building or other structure using the attachment mechanism. A corresponding apparatus and overall assembly are also disclosed herein. | 4 |
BACKGROUND OF THE INVENTION
[0001] 1. Technical Field of the Invention
[0002] The present invention relates to a remarkably improved method for producing disodium 5′-guanylate (i.e., 5′-guanylic acid disodium salt, being hereinafter often abbreviated as “5′-GMP2Na”) and disodium 5′-inosinate (i.e., 5′-inosinic acid disodium salt, being hereinafter often abbreviated as “5′-IMP2Na”), both being known to be important as seasonings, drugs and the like in the form of mixed crystals, not a mere mixture thereof.
[0003] 2. Related Art
[0004] 5′-GMP2Na and 5′-IMP2Na, as has been described above, are important in the fields of seasonings or condiments, drugs and the like. However, when they need to be used in combination, it is extremely difficult to prepare a mixture with a given mixed ratio by simply powder-mixing their crystals together, due to differences in the properties and powder characteristics of the two kinds of crystals. In addition, handling of such a mixture involves a variety of difficulties.
[0005] Meanwhile, there have been known as methods for producing 5′-GMP2Na and 5′-IMP2Na in the form of mixed crystals, the following three methods: I.e., a 1st one is a method (as disclosed in Japanese Patent Publication No. 12914/1965) comprising the steps of dissolving 5′-GMP2Na and 5′-IMP2Na in an aqueous solution containing an organic solvent such as methanol or the like and obtaining mixed crystals (being hereinafter often abbreviated as “I+G mixed crystals”) of 5′-GMP2Na and 5′-IMP2Na from the resulting solution, a 2nd one is a method (as disclosed in Japanese Patent Publications Nos. 16582/1979 and 4787/80) comprising the steps of dissolving 5′-GMP2Na and 5′-IMP2Na in water and obtaining I+G mixed crystals from the resulting solution by means of crystallization by cooling or concentrating, and a 3rd one is a method (as disclosed in Japanese Patent Publication No. 215494/1991 and Japanese Patent No. 2,770,470) in which a 5′-IMP2Na-containing aqueous solution is gradually added to a 5′-GMP2Na slurry solution at precipitating 5′-GMP2Na, whereby I+G mixed crystals are formed.
[0006] Incidentally, 5′-GMP2Na and 5′-IMP2Na are known to form a mixed crystal in such a manner that 5′-GMP2Na is incorporated into a crystal lattice of 5′-IMP2Na in an aqueous solution containing an organic solvent such as methanol or the like or a mere aqueous solution. An X-ray diffraction pattern of the mixed crystal is almost the same as that of 5′-IMP2Na. It is considered that 5′-GMP2Na having a similar chemical structure to that of 5′-IMP2Na enters a lattice of 5′-IMP2Na, and they maintain a stable condition by means of hydrogen bonding. A crystal of 5′-IMP2Na has a good crystal form, and an I+G mixed crystal having the same lattice has almost the same crystal form.
[0007] In order to obtain I+G mixed crystals by crystallization, although the above 1st method can achieve crystallization at a high recovery rate, it has the problem that it requires expensive explosion-proof facilities on an industrial scale because it uses an organic solvent, and therefore production costs increase. Further, in order to obtain a product (mixed crystals) having a desirable weight ratio of 5′-IMP2Na to 5′-GMP2Na (being hereinafter often abbreviated as “I/G ratio”) by the above 2nd method, concentrated drains and feed liquids must be controlled, and conditions for setting temperatures, pressures and like must be strictly controlled in the case of crystallization by concentrating, while in the case of crystallization by cooling, the composition of a crystallization solution (i.e., a solution (to be) subjected to crystallization) must be controlled more strictly because the composition of the crystallization solution tends to change continuously, and therefore, both cases have the problem that devices and control of processes become complicated. In the case of the above 3rd method, the starting raw materials, 5′-IMP2Na and 5′-GMP2Na, must be kept separate from each other, and there is the problem that the number of facilities increases in order to prevent 5′-IMP2Na and 5′-GMP2Na from mixing with each other before crystallization.
SUMMARY OF THE INVENTION
[0008] [Problems to be Solved by the Invention]
[0009] It is an object of the present invention to provide a method for producing 5′-GMP2Na which is difficult to handle due to the properties and powder characteristic of its crystals in particular and 5′-IMP2Na, in the form of crystals which are easy to handle, that is, I+G mixed crystals having a given I/G ratio, under simple process control and with inexpensive facilities with the I/G ratio being controlled easily.
[0010] [Means to Solve the Problem]
[0011] The present inventors have made extensive and intensive studies to improve conventionally known crystallization methods of I+G mixed crystals, which methods involve complicated or intricate control and processes. Consequently, they have found that I+G mixed crystals with a given I/G ratio and stable quality can be deposited or precipitated by carrying out crystallization under constant temperature conditions that are industrially easy to control, more specifically, that the above object can be achieved by feeding a mixed feed solution of 5 ′-IMP2Na and 5′-GMP2Na with a high concentration which will become supersaturated at the temperature of the solution charged in the below-described crystallization bath (in the present specification, the term “charged solution” or “solution charged” is used in such a sense that it includes “charged slurry” or “slurry charged” (in the broad sense)) into the crystallization bath (lower-temperature bath) kept at a constant temperature which is lower than the temperature of the mixed feed solution, whereby I+G mixed crystals are deposited from the mixed solution of 5′-IMP2Na and 5′-GMP2Na due to the difference in solubility which is, in turn, ascribable to the difference in temperature. The present invention has been completed based on these findings.
[0012] Accordingly, the present invention relates to a method for producing mixed crystals of disodium 5′-guanylate and disodium 5′-inosinate which comprises feeding a mixed solution of disodium 5′-guanylate and disodium 5′-inosinate which solution will become supersaturated at the below-mentioned constant temperature, to a solution or slurry of disodium 5′-guanylate and disodium 5′-inosinate charged in a crystallization bath (lower-temperature bath) and kept at a constant temperature, whereby mixed crystals of disodium 5′-guanylate and disodium 5′-inosinate are deposited from the mixed solution of disodium 5′-guanylate and disodium 5′-inosinate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] [0013]FIG. 1 gives a diagram showing the change of composition of a mother liquor during crystallization of mixed crystals (Example 1).
[0014] [0014]FIG. 2 gives a diagram showing I/G ratios for various particle size levels of the mixed crystals (Example 1).
[0015] [0015]FIG. 3 gives a diagram showing I/G ratios for various particle size levels of mixed crystals (Comparative Example 1).
[0016] [0016]FIG. 4 gives a diagram showing the relationship between a feed temperature and an I/G ratio of deposited mixed crystals (Example 2).
DETAILED DESCRIPTION OF THE INVENTION
[0017] The present invention will be described in detail hereinafter.
[0018] Firstly, a mixed solution (mixed feed solution) of 5′-IMP2Na and 5′-GMP2Na to be used as a feed solution according to the production method of the present invention will be described.
[0019] This feed solution can be prepared not only from product crystals of 5′-IMP2Na and those of 5′-GMP2Na using water or an aqueous solution containing an organic solvent as a solvent but also from, for example, I+G mixed crystals having an I/G ratio out of a predetermined range or crude crystals of 5′-IMP2Na and those 5′-GMP2Na in the course of production process by means of a method such as a fermentation method, organic synthesis method or the like. However, it is needless to say that the amount of the impurities is limited to such degree that they do not affect the solubility or crystal growth rate of target I+G mixed crystals. The proportion of the 5′-IMP2Na and the 5′-GMP2Na in a dissolved solution (mixed feed solution) can be set arbitrarily within a range of 5 to 40% in accord with the I/G ratio of the target I+G mixed crystals, and is preferably 8 to 25%. Further, the concentrations of 5′-IMP2Na and 5′-GMP2Na in a mixed feed solution need to be at least equal to the common solubility of 5′-IMP2Na and 5′-GMP2Na at a set temperature of the lower-temperature bath. Furthermore, in order to obtain I+G mixed crystals having an I/G ratio of 1.0, the I/G ratio of the dissolved solution must fall within a range of 0.82 to 0.95.
[0020] In addition, it is effective in improving a crystallization yield to add about 5 to 20%, preferably about 8 to 15%, based on solubility, of a salt such as NaCl, Na 2 SO 4 , (NH 4 ) 2 SO 4 , NH 4 Cl, Na 2 HPO 4 or the like to a mixed feed solution and carry out crystallization where the solubility of each component of the target mixed crystals is low due to the salting-out effects by these salts.
[0021] Next, a solution or slurry charged in a lower-temperature bath and kept at a constant temperature which is lower than that of a mixed feed solution to cause the mixed feed solution to become supersaturated so as to deposit I+G mixed crystals, will be described.
[0022] As such a charged solution or charged slurry, there may be mentioned a crystallization slurry which has been prepared from the same mixed solution as the feed solution, a mixed solution of 5′-IMP2Na and 5′-GMP2Na which has been prepared by use of water, an aqueous solution containing an organic solvent, or the like, as the solvent, and the like. Although the composition thereof is not particularly limited, a slurry of I+G mixed crystals having an I/G ratio of 0.8 to 1.5, having a slurry concentration of about 10 to 20% (ratio indicated in % of the amount of mixed crystals of 5′-IMP2Na and 5′-GMP2Na (solid) to the amount of the mixed solution inclusive of the solid mixed crystals), and having a temperature of about 30 to 50° C., is preferred, in consideration of improving the physical properties of I+G mixed crystals obtained by feeding a mixed feed solution, as compared with those of each component of I+G mixed crystals, particularly 5′-GMP2Na, and securing stability in controlling the I/G ratio. The amount of the slurry is preferably about 10 to 30% based on the amount of the feed solution to be added. As a method for preparing such a slurry, there may be employed any crystallization method such as cooling crystallization, concentrating crystallization, crystallization involving addition of an auxiliary (such as an inorganic salt, an organic solvent, or the like) or the like. In every case, although a slurry may be formed by spontaneous crystallization, it is preferably prepared by adding, as seed crystals, 5′-IMP2Na crystals or I+G mixed crystals in an amount of about 5 to 20% based on the total amount of the 5′-IMP2Na and 5′-GMP2Na present in the charged solution. Further, such a slurry may be also prepared by adding existing 5′-IMP2Na crystals or I+G mixed crystals into water in an amount exceeding the solubility thereof, without resorting to crystallization. Incidentally, 5′-GMP2Na crystals are not appropriate as seed crystals due to the properties and powder characteristics of the crystals.
[0023] A solution or slurry charged in a lower-temperature bath must be kept at a constant temperature. Thereby, the composition of the mother solution becomes stable in the course of crystallization, and I+G mixed crystals deposited during the crystallization has a fixed I/G ratio, accordingly.
[0024] Finally, crystallization manipulations will be described.
[0025] As for a pH at which crystallization is carried out, when it is within a pH range of each disodium salt of 5′-IMP2Na and 5′-GMP2Na, i.e., a pH range of 6 to 10, on the phase diagram, I+G mixed crystals can be obtained. It is preferred that the feed solution and charged solution or charged slurry have all a pH of about 6 to 8.
[0026] Upon feeding a feed solution into a lower-temperature bath, it is preferably added as slowly as possible, preferably over a period of three hours, whereby crystals deposited by growth of seed crystals or spontaneous crystallization in the bath are kept in good shape. Further, it is also preferable that stirring be maintained in good condition so that the fed solution can be diffused quickly.
[0027] After completion of feed of the feed solution, solid-liquid separation can be performed directly. However, it is also possible to carry out a cooling operation to some extent, whereby the yield is improved. In this case as well, about 80% of the deposited crystals has been deposited in the course of feeding, and the I/G ratio of the I+G mixed crystals becomes more stable than when cooling crystallization is carried out from the start.
EXAMPLES
[0028] The present invention will be further described with reference to examples hereinafter.
Example 1
[0029] No Seed Crystals Added, Constant Temperature Feed-Type Crystallization
[0030] 63 g of an aqueous solution containing 1.1 g of 5′-IMP2Na, 3.2 g of 5′-GMP2Na and 6.5 g of NaCl was kept at 4° C. as a charged solution. 520 g of feed solution containing 52 g of 5′-IMP2Na, 64 g of 5′-GMP2Na and 52 g of NaCl was added to the charged solution over a period of three hours with stirring. As for the composition of the mother solution during addition, the concentration of 5′-IMP2Na increased at the initial stage but the composition of the mother solution was kept constant thereafter (FIG. 1).
[0031] After completion of the addition, the resulting slurry was cooled to 30° C., the crystals were separated by centrifuging, and the separated crystals (mixed crystals) were then dried. Solid-liquid separability at the time of separating the crystals was good.
[0032] The I/G ratios of the mixed crystals having different particle diameters were almost the same throughout the various particle size levels (FIG. 2). That is, the dried crystals were sieved by use of sieves having a mesh size of 44, 66, 88, 105, 149, 177 and 250 μm (In FIG. 2, size of particles passing through a sieve having a mesh size of 44 μm is indicated as 0 μm). After sieving, the I/G ratio of each sieved fraction of the crystals was measured. As a result, the I/G ratios were almost the same throughout all the fractions.
Comparative Example 1
[0033] No Seed Crystals Added, Cooling Crystallization
[0034] After 575 g of an aqueous solution containing 67 g of 5′-IMP2Na, 74 g of 5′-GMP2Na and 57 g of NaCl was cooled from 65° C. to 30° C. over a period of 5 hours, the crystals were separated by centrifuging, and the separated crystals were dried.
[0035] The I/G ratios of the dried crystals having different particle diameters were measured and compared with the I/G ratios of the crystals obtained in Example 1 (FIG. 3). That is, the two kinds of dried crystals, i.e., those obtained in Comparative Example 1 and those obtained in the same manner as in Example 1, were respectively sieved by use of sieves having a mesh size of 53, 106, 180, 215, 250 and 355 μm (In FIG. 3, size of particles passing through a sieve having a mesh size of 53 μm is indicated as 0 μm) . After sieving, the I/G ratio of each sieved fraction of the two kind of crystals was measured. As a result, unlike in the case of the constant temperature feed-type crystallization of Example 1, the I/G ratios of the crystals obtained by cooling crystallization of Comparative Example 1 were significantly different between the crystals having different particle diameters.
[0036] From the above results of Example 1 and Comparative Example 1, it was confirmed that the method of the present invention is a crystallization method which is capable of carrying out stable crystallization easily under given conditions and facilitating control of the composition (I/G ratio) of an I+G mixed crystal.
Example 2
[0037] No Seed Crystals Added, Constant Temperature Feed-Type Crystallization at Varied Temperatures
[0038] 63 g of an aqueous solution containing 1.1 g of 5′-IMP2Na, 3.2 g of 5′-GMP2Na and 6.5 g of NaCl was kept at 30, 40 or 50° C. as a charged solution. 520 g of feed solution containing 52 g of 5′-IMP2Na, 64 g of 5′-GMP2Na and 52 g of NaCl was added to the charged solution over a period of four hours with stirring. After completion of the addition, the crystals were separated by centrifuging, with the resulting slurry kept at the feed temperature, and the separated crystals were dried.
[0039] The I/G ratios of the three kinds of dried crystals were measured (FIG. 4). It is understood from FIG. 4 that mixed crystals having a target I/G ratio can be obtained easily by controlling the temperature.
Example 3
[0040] No Seed Crystals Added and Seed Crystals Added (Charged Slurry Used)
[0041] 65 g of a charged solution containing 7.6 g of 5′-IMP2Na, 8.5 g of 5′-GMP2Na and 6.5 g of NaCl was subjected to crystallization by cooling to 40° C. directly (no seed crystals added) or before 4 g of I+G mixed crystals or 5′-IMP2Na crystals was added thereto as seed crystals, whereby a charged slurry was formed. 575 g of feed solution containing 67 g of 5′-IMP2Na, 74 g of 5′-GMP2Na and 57 g of NaCl was added to the charged slurry over a period of four hours with stirring. After completion of the addition, the slurry was cooled to 30° C. Thereafter, the crystals were separated by centrifuging and the separated crystals were dried.
[0042] The powder characteristics (rough specific volume and angle of repose) of the three kinds of crystals obtained are shown in the following table 1.
TABLE 1 Effect of Adding Seed Crystals Rough Specific Angle of Seed Crystals Volume Repose (°) Not Added 1.9 49 I + G Mixed 1.6 46 Crystals IMP ( * ) 1.4 43
[0043] From the above results of Example 3, it was confirmed that addition of seed crystals improves powder characteristics.
Example 4
[0044] Seed Crystals Used—Charged Slurry Used
[0045] A feed solution having a composition shown in the following table 2 was continuously added with stirring over a period of 4 hours, to a charged slurry (crystals deposited in situ and contained in the slurry serving as seed crystals) obtained by subjecting a solution having the same composition to crystallization by cooling to 40° C. in each run. After completion of the addition, the slurry was cooled to 30° C., the crystals were separated by centrifuging, and the separated crystals were dried.
TABLE 2 Relationship between Composition of Feed Solution and Composition of I + G Mixed Crystals Composition of Feed Composition of Run Solution ( * 1) Deposited Crystals No. IMP ( * 2) GMP ( * 3) I/G ratio I/G ratio 1 9.9 12.2 0.81 0.89 2 9.7 11.5 0.84 1.02 3 10.6 11.6 0.91 1.03 4 10.2 11.1 0.92 1.04 5 9.1 12.8 0.71 0.87 6 12.1 9.8 1.23 1.88
[0046] In consideration of the above results of Examples 1 to 4 and Comparative Example 1 and preliminary tests if required, it could be understood that it is very easy for those skilled in the art to determine the composition of a feed solution suitable for depositing I+G mixed crystals having a target composition (I/G ratio).
[0047] [Effect of the Invention]
[0048] According to the present invention, the I/G ratio of mixed crystals of 5′-guanylic acid disodium salt and 5′-inosinic acid disodium salt can be controlled easily, and physical properties such as a specific volume, an angle of repose, and the like of crystals, particularly those of 5′-GMP2Na, can be improved easily. | Herein is disclosed a method for producing mixed crystals of disodium 5′-guanylate and disodium 5′-inosinate which comprises feeding a mixed solution of disodium 5′-guanylate and disodium 5′-inosinate which solution will become supersaturated at the below-mentioned constant temperature, to a solution or slurry of disodium 5′-guanylate and disodium 5′-inosinate charged in a crystallization bath (lower-temperature bath) and kept at a constant temperature, whereby mixed crystals of disodium 5′-guanylate and disodium 5′-inosinate are deposited from the mixed solution of disodium 5′-guanylate and disodium 5′-inosinate, according to which method 5′-GMP2Na which is difficult to handle due to the properties and powder characteristic of its crystals in particular and 5′-IMP2Na, in the form of crystals which are easy to handle, that is, I+G mixed crystals having a given I/G ratio, can be produced under simple process control and with inexpensive facilities, with the I/G ratio being controlled easily. | 2 |
FIELD OF THE INVENTION
The present invention generally relates to the processing of digital signals for generating signals with bit orders or patterns modified from those of the supplied binary signals. More particularly, the present invention relates to a method of generating binary signals with the orders or patterns of bits re-arranged or shuffled on the basis of, typically, a fast Fourier transform algorithm and also to a bit-order modifiable signal processor circuit adapted to put such a method into practice.
BACKGROUND OF THE INVENTION
Digital signal processors (DSPs) are finding increasingly expanding practical applications in converting supplied analog signals into digital versions and further converting the resultant digital signals back into analog ones after the processing of the digital signals is complete. Such practical applications of digital signal processors include the processing of signals in high-speed modem circuitries for communication systems and equipment, compression of data for the analysis and synthesis of sound information using linear prediction coding technologies, analysis of signal waveforms in sound recognition systems, execution of fast Fourier transform algorithms generation and modification of signals required for various computer-aided operation control systems, and processing of data for use n computer graphics technologies.
Among these various practical applications of digital signal processing technologies, those using the fast Fourier transform algorithms outweigh other applications. One of the important demands in using the fast Fourier transform algorithms is to effectively reduce the number of addressing cycles required for the execution of the programs to carry out the algorithms. A prime object of the present invention is to meet such a demand.
SUMMARY OF THE INVENTION
In accordance with one outstanding aspect of the present invention, there is provided a method of generating binary signals comprising, (a) storing in first memory means a binary index signal consisting of a sequence of a predetermined number of bits, (b) storing in second memory means a binary base signal consisting of a sequence of the predetermined number of bits, (c) adding together the index signal and the base signal for producing an initial output signal representative of the arithmetic sum of the index and base signals during an initial cycle of signal generating operation, (d) tentatively storing the initial output signal in the second memory means and adding the initial output signal to the index signal for producing an output signal differing in bit pattern from the initial output signal during the cycle of signal generating operation immediately subsequent to the initial cycle and tentatively storing the last named output signal in the second memory means, and (e) thereafter adding together the index signal from the first memory means and the output signal produced during each of the successive cycles of signal generating operation for producing another output signal differing in bit pattern from each of the output signals produced during the immediately preceding cycle of signal generating operation, (f) the arithmetic sum being produced by carrying out a forward arithmetic addition from the least significant bits forward or a reverse arithmetic addition from the most significant bits backward.
In accordance with another outstanding aspect of the present invention, there is provided a bit-order modifiable signal generator circuit, comprising (a) an adder circuit comprising the combination of a binary multi-stage adder/subtractor and a forward-reverse selective carry propagation network, the multi-stage adder/subtractor having functions to carry out both a forward arithmetic addition from the least significant bits forward and a reverse arithmetic addition from the most significant bits backward selectively under the control of the forward/reverse selective carry propagation network, (b) an index register operable for having programmably yet fixedly stored therein a binary index signal consisting of a sequence of a predetermined number of bits, and (c) a signal register operable for having programmably yet fixedly stored therein a binary base signal consisting of a sequence of the predetermined number of bits, (d) the adder circuit being responsive to the index signal output from the index register and to a binary signal output from the signal register for producing an output signal representative of the arithmetic sum of the index signal and the signal output from the signal register during each cycle of signal generating operation, (e) the signal register being responsive to the output signal from the adder circuit for tentatively storing the output signal from the adder circuit and feeding back the signal to the adder circuit for being arithmetically added to the index signal during each cycle of signal generating operation.
BRIEF DESCRIPTION OF THE DRAWINGS
The drawbacks of the prior-art bit-order reversible address generator circuit and the features and advantages of a method according to the present invention and of a bit-order modifiable signal processor circuit to put the method into practice will be more clearly understood from the following description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a block diagram showing the general circuit arrangement of a prior-art bit-order reversible address generator circuit provided on a DSP semiconductor chip;
FIG. 2 is a circuit diagram schematically showing an example a bit-order reversible multiplexer network which forms part of the prior-art address generator circuit shown in FIG. 1;
FIG. 3 is a block diagram showing the general circuit arrangement of a carry propagation network incorporated in a binary adder circuit of a bit-order reversible address generator embodying one aspect of the present invention;
FIG. 4 is a block diagram similar to FIG. 3 but shows an alternative form of carry propagation network which may be incorporated in a binary adder circuit of the bit-order reversible address generator embodying one aspect of the present invention;
FIG. 5 is a view showing an example of the MOSFET circuit arrangement operable as a carry-over circuit in the carry propagation network shown in FIG. 4;
FIG. 6 is a circuit diagram schematically showing the detailed circuit arrangement of the carry propagation network shown in FIG. 4, viz., the arrangement in which the bidirectional carry propagator forming part of the network is used in combination with the carry-over circuit illustrated in FIG. 5;
FIG. 7 is a circuit diagram showing a MOSFET transfer-gate circuit which may implement the carry-kill selector included in the bidirectional carry propagator shown in FIG. 6;
FIG. 8 is a block diagram schematically showing a bit-order reversible address generator circuit embodying the present invention, the circuit using the forward-reverse selective carry propagation network of FIG. 3 or FIG. 4;
FIGS. 9a and 9b are views showing the forward-carry and reverse-carry binary addition rules, respectively, which are used in producing modified address signals in the bit-order reversible address generator circuit shown in FIG. 8;
FIG. 10a is a view showing an example of the procedure to perform a succession of forward-carry binary additions for each interaction of the successive cycles of address generating operation in the address generator circuit shown in FIG. 8; and
FIG. 10b is a view showing an example of the procedure to perform a succession of reverse-carry binary additions for each interaction of the successive cycles of address generating operation in the address generator circuit shown in FIG. 8.
DESCRIPTION OF THE PRIOR ART
Table 1 below shows a scheme in accordance with which a bit-order reversible address generation technique based on an 8-point radix-two fast Fourier transform algorithm (hereinafter referred to as FFT algorithm) is to be executed for data vectors or bit sequences x(k) of three-bit length wherein k=0, 1, 2, . . . 7. In carrying out the 8-point FFT algorithm, address signals expressed in the form of three-bit sequences x(k) with normal bit orders on, for example, a time axis are converted into address signals of reversed bit orders on a frequency axis by the reversal of the order in which the bits of each of the given bit sequences in terms of time. Table 2 shows a similar scheme for bit sequences x(k) of four-bit length which are to be reversed in bit order in executing a 16-point radix-two FFT algorithm wherein k=0, 1, 2, . . . 15.
TABLE 1______________________________________x(k) X(k)______________________________________x(0 = 000) -- X(0 = 000)x(1 = 001) -- X(4 = 100)x(2 = 010) -- X(2 = 010). .. .. .x(5 = 101) -- X(5 = 101)x(6 = 110) -- X(3 = 011)x(7 = 111) -- X(7 = 111)______________________________________
TABLE 2______________________________________x(k) X(k)______________________________________x(0 = 0000) -- X(0 = 0000)x(1 = 0001) -- X(8 = 1000)x(2 = 0010) -- X(4 = 0100). .. .. .x(13 = 1101) -- X(11 = 1011)x(14 = 1110) -- X(7 = 0111)x(15 = 1111) -- X(15 = 1111)______________________________________
Each of these bit-order reversible address generation techniques may be realized by having recourse to software approaches encompassing the algorithm of Table 1 or Table 2 on a general-purpose DSP semiconductor chip. Alternatively, such address generation techniques may be realized by means of hardware configurations incorporating the circuit arrangements of FIGS. 1 and 2 on a special-purpose DSP semiconductor chip. The circuit arrangements herein shown are assumed to be operable for the reversal of the bit orders of three-bit address signals on the basis of an 8-point radix-two FFT algorithm.
The circuit shown in FIG. 1 includes an index counter 10 for supplying normal bit-order three-bit address signals x(k) to a three-input, three-output bit-order reversible multiplexer 12. When the bit-order reversible multiplexer 12 is operative in a bit-order reversing mode, each of the normal bit-order address signals x(k) can thus be reversed in the order of bits by means of the bit-order reversible multiplexer 12. The resultant signals X(k) with reversed bit orders are supplied to a binary adder circuit 14. To this adder circuit 14 is also supplied from an address register 16 a base address signal provided by, for example, the starting normal bit-order address signal x(0). In response to this normal bit-order base address signal x(0) from the address register 16, the adder circuit 14 outputs a reversed bit-order address signal for access to a certain location of the memory array (not shown). FIG. 2 schematically shows a typical circuit topology of the bit-order reversible multiplexer 12.
As shown in FIG. 2, the bit-order reversible multiplexer 12 consists of three logic-signal steering sections 12a, 12b and 12c each having two inputs and one output. One input to the first steering section 12a and one input to the third steering section 12c are jointly connected to an input line 18a for the most significant bit (MSB) and, likewise, the other input to the first steering section 12a and the other input to the third steering section 12c are jointly connected to an input line 18c for the least significant bit (LSB) of the supplied normal bit-order data signal x(k). Both of the two inputs to the second steering section 12b are connected to a line 18b for the bit intervening between the most and least significant bits of the address signal x(k). The outputs of the first and third steering sections 12a and 12c are connected to output lines 20a and 20c for the most and least significant bits, respectively, of the output signal X(k). The output of the second steering section 12b is connected to an output line 20b for the non-reversed intermediate bit of the address signal X(k).
Whether a software approach or a hardware approach may be used, problems are encountered in conventional bit-order reversed address generation techniques, as follows:
(1) Where a software approach is relied upon for the generation of bit-order reversed address signals on a general-purpose DSP semiconductor chip, large amounts of time and labor are inevitably required for the building of the program to carry out the algorithm for the address generation. Also required is the disproportionately large amount of machine time for the generation of the bit-order reversed address signals.
(2) Difficulties are experienced in fabricating a special-purpose hardware structure on a general-purpose DSP semiconductor chip because of the requirement for the provision of the real estate for the accommodation of such an additional circuit as the bit-order reversible multiplexer of, for example, the configuration illustrated in FIG. 2.
(3) Such a bit-order reversible multiplexer could be used on a special-purpose DSP semiconductor chip but is operable merely for the reversal of data of a fixed bit length and not for the handling of data with any desired number of bits.
(4) A known bit-order reversible multiplexer represented by the multiplexer shown in FIG. 2 requires a large wiring and interconnect area on the semiconductor chip, which therefore could not be designed and fabricated with the design rules used for the fabrication of large-scale integrated (LSI) circuits.
The present invention contemplates provision of a novel method of generating address signals selectively having modified or non-modified bit orders and a bit-order modifiable address generator circuit to put the method into practice on, for example, a general-purpose DSP semiconductor chip. Such a novel address generation technique and the circuit to carry out the technique in accordance with the present invention method will make it possible to have any binary signals or sequences of bits modified into any desired bit patterns such as, for example, bit-order reversed sequences of bits fast and programmably without having recourse to the use of any extra special-purpose signal modifying means.
It should thus be borne in mind that, although the present invention will be hereinafter described as being applied to the generation of address signals providing access to various locations of a semiconductor memory array, the improvements achievable by the present invention may be exploited in generating any other forms of signals for use in microprocessors or in any other forms of signal processing circuits.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 shows a forward/reverse selective carry propagation network which may form part of a bit-order reversible address generator circuit embodying the present invention. As shown, the carry propagation network, designated in its entirety by reference numeral 22, comprises two, forward and reverse, signal carry chains 24 and 26 arranged separately of each other. The forward-carry chain 24 extends from a carry-in line C IN (f) to a carry-out line C OUT (f) through a forward-carry propagator 28 having two control terminals. Similarly, the reverse-carry chain 26 extends from a carry-in line C IN (r) to a carry-out line C OUT (r) through a reverse-carry propagator 30 having two control terminals. One of the control terminals of the forward-carry propagator 28 and one of the control terminals of the reverse-carry propagator 30 are jointly connected to a first input line A, and the other control terminals of the forward-carry and reverse-carry propagators 28 and 30 are jointly connected to a second input line B.
The carry propagation network 22 shown in FIG. 3 further comprises a forward-carry/reverse-carry selector 32 which is operative to provide a choice between the carry-forward and carry-reverse modes of operation in the address generator circuit embodying the present invention. As will be understood more clearly as the description proceeds, bits of suitable operands such as an addend and an augend for the generation of a modified address signal are to be supplied through the first and second input lines A and B, respectively.
In the presence of logic "0" bits on both of these first and second input lines A and B, there will be neither a forward carry toward the most significant stage nor a reverse carry toward the least significant stage of the address generator circuit, thus establishing a carry-kill mode of operation in the shown carry propagation network 22. On the other hand, the presence of a logic "0" bit on one of the first and second input lines A and B and a logic "1" bit on the other input line results in a forward carry to the immediately upper stage or a reverse carry to the immediately lower stage of the address generator circuit. A carry is thus propagated from a less significant bit to a more significant bit or conversely from a more significant bit to a less significant bit in the address signal to be generated, thus establishing a carry-propagate mode of operation in the carry-propagation network 22. In the presence of logic "1" bits on both of the first and second input lines A and B, there will be a forward carry toward or to the most significant stage or a reverse carry toward or to the least significant stage of the address generator circuit, thus producing a precharge mode of operation in the carry-propagation network 22. Each of the signal carry chains 24 and 26 is precharged during the precharge mode of operation thus produced in the carry-propagation network 22. Table 3 below is the truth table showing the results of the logic operations which thus proceed in the shown carry propagation network 22. Represented by C in FIG. 3 is a carry-over signal which dictates the forward or reverse carry in the more significant or less significant bit or stage of the circuit.
TABLE 3______________________________________A 0 0 1 1B 0 1 0 1C.sub.IN 0 1 0 1 0 1 0 1C.sub.OUT 0 0 0 1 0 1 1 1______________________________________
In FIG. 4 is shown another form of forward/reverse selective carry propagation network 34 which may also form part of a bit-order reversible address generator circuit according to the present invention. The carry propagation network 34 herein shown features a single carry chain which is operable for both carry-forward and carry-reverse modes of operation. The single carry chain extends through a bidirectional carry propagator 36 provided between carry lines 40 and 42 respectively leading rearwardly and forwardly from the carry propagator 36. The bidirectional carry propagator 36 has two control terminals, one of which is connected to a first input line A and the other of which is connected to a second input line B. A forward-carry/reverse-carry selector 38 is connected across the bidirectional carry propagator 36 through the lines 40 and 42 and is operative to select the direction in which a carry is to be propagated through the carry propagation network 34. Carry-in and carry-out lines are thus provided by the reverse-directed carry line 40 and forward-directed carry line 42, respectively, when a forward carry mode of operation is selected by the selector 38. Conversely, carry-in and carry-out lines are provided by the forward-directed carry line 42 and reverse-directed carry line 40, respectively, when a reverse carry mode of operation is selected by the selector 38.
Each of the forward/reverse selective carry propagation networks 22 and 34 hereinbefore described with reference to FIGS. 3 and 4 can be implemented by a transistor circuitry of metal-oxide-semiconductor field-effect transistor (MOSFET) configuration advantageously for its potential high-speed performance and to enable the memory system to operate efficiently. Thus, the carry propagation network 22 of the type shown in FIG. 3 can be implemented readily by fabricating the forward-carry/reverse-carry selector 32 in the form of a MOSFET circuit combined with known carry propagators used as the forward-carry and reverse-carry propagators 28 and 30 of the carry propagation network 22. Each of the bidirectional carry propagator 36 and the forward-carry/reverse-carry selector 38 of the carry propagation network 34 shown in FIG. 4 can also be easily realized by a combination of MOSFET devices. A MOSFET device is an inherently bi-directional device with the direction of current being dependent upon the relationship between the magnitudes of the voltages applied to the two source/drain diffusion regions of the device.
FIG. 5 shows an example of a carry-over circuit of MOSFET configuration for use in the carry propagation network 34 shown in FIG. 4. The carry-over circuit, represented in its entirety by reference numeral 44, is well known in the art as Manchester carry chain and extends through a pass transistor 46 from a carry-in line C IN to a carry-out line C OUT . The pass transistor 46 has its gate connected through a line 48 to a supply source of a carry-propagate signal P (=A*B). The carry-propagate signal P is effective in creating the carry-propagate mode of operation in the address generator circuit under consideration. On the other hand, the carry-out line C OUT is connected to a ground line across a carry-kill control transistor 50 having its gate connected to a supply source of a carry-kill signal K=(A*B) through a line 52. The carry-kill signal K is effective in creating the carry-kill mode of operation and is thus exclusive in effect to the carry-propagate signal P. In the presence of the carry-propagate signal P on the gate of the pass transistor 46, a carry forward to the immediately upper bit or backward to the immediately lower bit is allowed to pass through the pass transistor 46. The carry-kill signal K, when present at the gate of the carry-kill control transistor 50, is predominant over a carry toward the most significant bit or a carry toward the least significant bit.
FIG. 6 shows an example of the MOSFET circuit arrangement operable as the bidirectional carry propagator 24 with which the carry-over circuit 44 thus constructed may be used together to form the carry propagation network 34 shown in FIG. 4. The bidirectional carry propagator 36 comprises a parallel combination of a two-input logic exclusive-OR gate 54 and a two-input logic NOR gate 56, each has its two inputs connected to input lines A and B. The logic exclusive-OR gate 54 has its output connected to the gate of a pass transistor 58 provided between the forward-carry and reverse-carry lines F and R of the bidirectional carry chain shown in FIG. 4. The pass transistor 58 has one of its source/drain terminals connected to the reverse-directed carry line 40 and the other of the source/drain terminals connected to the forward-directed carry line 42. The transistor 58 receives a carry-propagate signal P in the presence of a logic "1" bit on one input terminal of the exclusive-OR gate 54 and a logic "0" bit on the other input terminal of the gate 54. On the other hand, the logic NOR gate 56 has its output connected to one control terminal of a carry-kill selector 60 which has output terminal connected to the gate of a carry-kill control transistor 62. The carry-kill control transistor 62 is shown having its source/drain terminals connected between the forward-directed carry line 42 and ground and receives a carry-kill signal K in the presence of logic "0" bits concurrently on both of the two input terminals of the NOR gate 56. The two input terminals of the carry-kill selector 60 which include the input terminal connected to the output of the NOR gate 56 are connected to carry-kill control lines 64 and 66 as shown. Though not shown in the drawings, the carry-kill control line 64 leads to the input terminal of the carry-kill selector of the lower bit or stage of the circuit and the carry-kill control line 66 leads to the input terminal of the carry-kill selector of the upper bit or stage of the circuit.
In the circuit arrangement shown in FIG. 6, the forward-carry/reverse-carry selector 38 has its input terminals connected to the signal carry chain across the pass transistor 58. The pass transistor 58 on the signal carry chain has its gate connected, to one input terminal of a two-input logic exclusive-OR gate 68, and the other input terminal of which is connected to the carry selector 38.
Each of the forward-carry/reverse-carry and carry-kill selectors 38 and 60 forming part of the bidirectional carry propagator 36 are constructed and arranged as hereinbefore described by a MOSFET transfer-gate circuit, the simplified circuit topology of which is shown in FIG. 7. The transfer-gate circuit of FIG. 7 comprises first and second transistors 70 and 72 each having its source/drain terminals connected between a common node 74 and lines 76 and 78, respectively. The gates of the transistors 70 and 72 are connected to the first and second input lines A and B as in that the logic signals to appear on the lines 76 and 78 are exclusive to each other so that either the first input line A or the second input line B is selected to be active depending upon the logical relationship between the signals to be applied to the lines 76 and 78.
FIG. 8 shows the general circuit topology of a bit-order reversible address generator circuit embodying the present invention. The address generator circuit herein shown is assumed to be operable for generating four-bit address signals and may use either of the forward/reverse selective carry propagation networks 22 and 34 shown in FIG. 3 and FIG. 4, respectively. As shown, the address generator circuit comprises a bit-order reversible binary adder circuit 80 which is, by way of example, assumed to be provided by the combination of a known type of multi-stage adder/subtractor (not shown) used in a conventional bit-order reversible address generator and the forward/reverse selective carry propagation network 22 or 34 of FIG. 3 or FIG. 4. It is in this instance important that the multi-stage adder/subtractor herein used have functions to carry out both a forward arithmetic addition from the least significant bits forward and a reverse arithmetic addition from the most significant bits backward. The forward/reverse selective carry propagation network 22 or 34 selects one of these two modes of addition. The binary adder circuit 80 is connected on its input side to output terminals of a four-bit index register 82 through bus lines A and on its output side to input terminals of a four-bit address register 84. The address register 84 in turn is operative to provide a bit-order reversed or non-reversed address signal as an output signal of the address generator circuit herein shown. The bit-order reversed or non-reversed address signal thus output from the address register 84 is fed back to and referenced by the adder circuit 80 through bus lines B. The bus lines A and B herein shown correspond to the input and output lines A and B, respectively, which have been shown in FIGS. 3, 4, 6 and 7. The index signal from the index register 82 and the address signal generated by the address register 84 and fed back to the adder circuit 80 thus correspond to the previously mentioned addend and augend for the generation of a modified address signal. The adder circuit 80 is operative to supply an output address signal to the address register 84 as the output from the exclusive-OR gate 68 of the circuit shown in FIG. 6.
Description will now be made regarding the different modes of operation of the bit-order reversible address generator circuit thus constructed and arranged in accordance with the present invention. For convenience of description it will be assumed that bit sequences X(k) of four-bit length with normal bit orders on a time axis are used as data vectors in carrying out a 16-point radix-two FFT algorithm.
Prior to the start of the address generating operation, a data vector or bit sequence (0000) representative of the decimal number "1" is loaded as a modifier index address into the index register 82 while a suitable base address such as for example the starting address (0000="0") is loaded into the address register 84. The forward-carry/reverse-carry selector 32 of the network 22 shown in FIG. 3 or the forward-carry/reverse-carry selector 38 of the network 34 shown in FIG. 4 is first assumed to be conditioned to select the forward carry for performing a succession of binary arithmetic additions from the least significant adder stage or bit onward as exemplified in FIG. 9a.
The starting address X(0=0000) loaded into the address register 84 is fed back to the bit-order reversible adder circuit 80, which therefore produces the sum (0001="1") of the starting address and the modifier index address (0001) from the index register 82 as indicated in FIG. 10a. The result of the arithmetic addition is provided as the second address X(1=0001) at the output terminal of the address register 84 and is fed back to the adder circuit 80. The adder circuit 80 now produces the sum (0010="2") of the index address (0001) from the index register 82 and the second address X(1=0001) fed back from the address register 84. Such additions proceed successively as shown in FIG. 10a until an iteration of a total of sixteen arithmetic additions is complete with the generation of the sixteenth address X(15=1111) as the result of the addition between the index address (0001) from the index register 82 and the fifteenth address X(14=1110) fed back from the address register 84 as shown in FIG. 10a.
To perform the bit-order reversed address generation thereafter, a modifier index address representative of the decimal number corresponding to one half of the number of the sample points set in the FFT algorithm in use is loaded into the index register 82. The sample points of the FFT algorithm herein being herein assumed to be 16 in number, the bit sequence (1000) representative of the decimal number "8" is loaded as a fixed modifier index address into the index register 82. In the address register 84 is maintained the base address provided by the starting address (0000="0"). The forward-carry/reverse-carry selector 22 of the network 22 shown in FIG. 3 or the forward-carry/reverse-carry selector 38 of the network 34 shown in FIG. 4 is now conditioned to select the reverse carry for performing a succession of binary arithmetic additions from the most significant adder stage or bit downward as exemplified in FIG. 9b.
The starting address X(0=0000) loaded into the address register 84 is fed back to the bit-order reversible adder circuit 80, which therefore produces the sum (1000="8") of the starting address and the modifier index address (1000) from the index register 82 as indicated in FIG. 10b. The result of the arithmetic addition is provided as the second address X(8=1000) at the output terminal of the address register 84 and is fed back to the adder circuit 80. The adder circuit 80 now produces the sum (0100="4") of the index address (1000) from the index register 82 and the second address X(8=1000) fed back from the address register 84. The successive add operations proceed as shown in FIG. 10b until an iteration of sixteen arithmetic additions is complete with the generation of the sixteenth address X(15=1111) as the result of the addition of the index address (1000) from the index register 82 and the fifteenth address X(7=0111) fed back from the address register 84 as shown in FIG. 10b.
As will have been understood from the foregoing description the address generation techniques proposed by the present invention are characterized inter alia in the following respects:
(1) The bit-order reversible adder circuit 80 of the address generator circuit can be realized by mere addition of the forward/reverse selective carry propagation network 22 or 34 of FIG. 3 or FIG. 4 to a known type of adder/subtractor configuration which forms part of a conventional general-purpose address generator circuit.
(2) Such a bit-order reversible adder circuit 80 is operable for the generation of both bit-order reversed and non-reversed addresses by iterations of simple arithmetic additions according to ordinary forward or backward binary addition rules. Generation of the bit-order reversed or non-reversed addresses is effected selectively under the control of the forward-carry/reverse-carry selector 32 forming part of the network 22 shown in FIG. 3 or the forward-carry/reverse-carry selector 38 included in the network 34 shown in FIG. 4.
(3) The bit-order reversed addresses can be generated quickly and efficiently simply by feeding back the address output from the address register 84 to the binary adder circuit 80 during each cycle of address generating operation.
(4) The modifier index address to be loaded into the index register 82 and used as the addend in the arithmetic addition can be selected arbitrarily from among the various candidates which are equal in number to the sample points set in the FFT algorithm used. Where a 16-point FFT algorithm is to be used as in the described embodiment of the invention, the index address to be loaded into the index register 82 can thus be selected from among the total of sixteen candidates (0000), (0001), (0010), (1111) for the generation of both the bit-order reversed addresses and nonreversed addresses. The bit patterns of the address signals can therefore be programmably modified by selection of any of the sixteen index addresses without having recourse to the provision of any extra hardware configurations.
(5) The number of the candidates available for the selection of the index address is dictated merely by the number of the sample points to be used in the FFT algorithm to be executed. The number of the bits to form each of the address signals to be generated by the address generation circuit embodying the present invention can be selected arbitrarily by selection of the sample points to be used in the FFT algorithm.
In this connection it has been described that the index address to be used in performing the bit-order reversed address generation is selected to be representative of the decimal number corresponding to one half of the number of the sample points set in the FFT algorithm to be used. Such an index address may however be substituted by an address selected depending upon the used rules of allocation of the data to the memory array. Where, for example, two-word data signals such as those representative of complex numbers are to be processed, one first (1/1) of the number of the sample points of the FFT algorithm used, viz., the point number of the FFT algorithm per se may be used as the decimal number to represent the modifier index address.
(6) The improved address generation techniques according to the present invention can b implemented readily and economically by a hardware structure which may be composed of a sufficiently small number of semiconductor devices on, typically, a general-purpose DSP chip. | A method of and a circuit for generating address signals, wherein a binary index signal and a binary base address signal are stored in index and address registers, respectively, whereupon the index signal and the base address signal are added together to produce an initial output address signal representative of the arithmetic sum of the index and base address signals during an initial cycle of signal generating operation. The initial output address signal is tentatively storing in the address register and is added to the index signal to produce an output address signal differing in bit pattern from the initial output address signal during the cycle of signal generating operation immediately subsequent to the initial cycle. This output signal is likewise tentatively storing in the signal register and thereafter the index signal from the index register and the output address signal produced during each of the successive cycles of signal generating operation are added together to produce another output address signal differing in bit pattern from each of the output address signals produced during the immediately preceding cycle of signal generating operation, wherein the arithmetic sum is produced by carrying out a forward arithmetic addition from the least significant bits forward or a reverse arithmetic addition from the most significant bits backward. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application Ser. No. 60/630,036, filed on Nov. 23, 2004, and entitled “FILTERING EXTRACTED PERSONAL NAMES,” the entire contents of the prior application being incorporated herein in their entirety for all purposes.
TECHNICAL FIELD
[0002] This disclosure relates to name recognition.
BACKGROUND
[0003] Various products are available for extracting names from unstructured text. Products are also available for comparing potential names against known names in a database.
SUMMARY
[0004] A particular implementation combines a name extraction algorithm and a post-extraction filtering algorithm. The name extraction algorithm may be configured to provide extract more potential names given that the post-extraction filtering algorithm may be able to eliminate some of the non-names that are erroneously extracted. Further, however, by extracting more potential names, some real names may be extracted that might not have been extracted without the reconfiguration. Thus, recall may be improved without too adverse an impact on precision. In certain implementations, both recall and precision may be improved.
[0005] According to a general aspect, a method includes accessing a source of text that includes names, and providing the source of text as an input for a name extraction algorithm. The method extracts a set of potential names from the source of text using the name extraction algorithm, and provides the set of potential names as an input for a post-extraction filtering algorithm. The method produces a set of filtered names by filtering the set of potential names against a database of names using the post-extraction filtering algorithm. The method provides the set of filtered names to one or more destinations or users.
[0006] Implementations may include one or more of the following features. For example, the method may adjust the name extraction algorithm to emphasize recall and to deemphasize precision so as to provide a larger set of potential names to the post-extraction filtering algorithm than would be provided without the adjustment. The name extraction algorithm may include a rule for automatically identifying names from within the source of text. Adjusting the name extraction algorithm may include broadening the rule so that more text strings satisfy the rule. Broadening the rule may include rewriting the rule so that an occurrence of two consecutive names within the source is extracted as a potential name. Adjusting the name extraction algorithm to emphasize recall and to deemphasize precision may include adding a rule to the name extraction algorithm for automatically identifying names from within the source of text, wherein the addition of the rule results in the name extraction algorithm being able to extract more text strings as potential names.
[0007] The set of filtered names may provide improved recall and improved precision compared with the set of potential names. The source of text may include a source of unstructured text. The source of text need not identify text as being a name. The database might not be used in the extracting of the set of potential names.
[0008] Implementations may include hardware, a method or process, and/or code (software or firmware, for example) on a computer-accessible or processor-accessible medium. The hardware and/or the code may be configured or programmed to perform a method or process.
[0009] The details of one or more implementations are set forth in the accompanying drawings and the description below. Other features are apparent from the description and drawings, and from the claims.
DETAILED DESCRIPTION
[0010] We now describe a particular implementation, and we include a description of a significant number of details to provide clarity in the description. All or most of the description below focuses on the particular implementation. That implementation may be expanded in various ways, all of which are not explicitly described below. However, one of ordinary skill in the art will readily understand and appreciate that various other implementations are both enabled and contemplated by this disclosure. By focusing on a particular implementation, the features are hopefully better described. However, such a focus does not limit the disclosure to just that implementation. Any language that might otherwise appear to be closed or limiting should generally be construed as being open and non-limiting, for example, by being construed to be referring to a specific implementation and not to be foreclosing other implementations.
[0011] The exploding amount of intelligence information available from unstructured text sources increasingly demands the use of automated information extraction tools to detect the names of persons, organizations, and locations. Despite incredible improvements in the performance of named entity extraction engines since the mid-1980s, detecting legitimate entities in unstructured text using either human-generated patterns or statistical and probabilistic techniques is still inexact. Users must usually accept a trade-off between valuing recall, in which more entities are extracted but at the cost of precision, or valuing precision, in which results are more correct but at the cost of detecting fewer entities. In addition, the sheer volume of extracted entities often makes it difficult or impossible for human evaluation of extraction output, resulting in databases populated with spurious information, or even textual garbage, containing no actionable intelligence value. A system that could automatically detect and purge spurious extracted entities would make it possible to favor extraction approaches that increase recall without the need to consider any concomitant reduction in precision. In this paper, we describe such a system for improving the recall and precision of extracted personal named entities using a Language Analysis Systems (LAS) product for generating name statistics, such as NameStats™, in conjunction with the LAS name data archive.
[0012] The LAS name data archive contains over 800 million personal names from almost every country on earth. Each name is classified according to the country of birth of its bearer, along with country of citizenship and gender. Having such a large store of attested personal names has allowed LAS to create a range of products for classifying, searching, genderizing, and parsing personal names. LAS NameStats™ is one such product that provides information about the statistical occurrence of name tokens both as given names and surnames. These occurrence statistics make it possible to predict the likelihood that a string extracted as a personal named entity by an extraction engine is indeed a personal name. We show how this information can be used to increase extraction precision, and we demonstrate its value for improving the performance of extraction recall.
[0013] Experiments to improve precision were carried out using two information extraction systems: (1) Alias-i's LingPipe, a freeware program that uses a statistical model trained to extract named entities from journalistic and genomic texts, 1 and (2) Lockheed Martin's AeroText™, a commercially available software suite that employs human-generated patterns for extracting named entities from a variety of texts.2 The extraction exercise used two corpora from the Message Understanding Conferences (MUC) held in the 1990s: MUC-6 and MUC-7. These texts were chosen for several reasons: (1) they are widely recognized within the information extraction community, since many of the improvements in information extraction were generated through the MUC conferences; (2) they ship with tagged keys, greatly reducing the amount of work needed to gauge changes in recall and precision; and (3) they are available at reasonable cost.3 Both LingPipe and AeroText™ were trained on these corpora, however, such that recall and precision scores were already fairly high for these texts. In each case, the corpus employed for the experiment was the one for which the extraction engine obtained the lower precision score: MUC-6 in the case of LingPipe and MUC-7 in the case of AeroText™. A lower precision score allows for a clearer demonstration of the benefits of post-extraction filtering. Initial extraction scores for personal named entities for each of the engines are presented in Table 1: 1 LingPipe can be trained on other types of texts using its Java API. More information is available at http://www.alias-i.com/lingpipe. 2 More information is available at http://www.aerotext.com. 3 The two corpora are available for purchase from the Linguistic Data Consortium at http://www.ldc.upenn.edu.
TABLE 1 Initial Extraction Scores for Personal Named Entities AeroText ™ LingPipe (on MUC-6) (on MUC-7) Recall 70.09% 89.78% Precision 62.60% 78.63% F-Measure 66.13% 83.84% Spurious Entities 147 215
[0014] The extraction results from each engine were then filtered using the LAS NameStats™ product and some logic relying on the occurrence counts of the potential name tokens to determine when an entity should be retained or filtered out:
[0015] (1) For one-token entities: If the token count (determined by NameStats™) passed a configurable threshold, or if it had been seen as part of a multi-token extracted entity, the entity was retained;
(2) For two-token entities: If the token count for one of the tokens passed a configurable threshold, or if the first token was an initial (e.g., a middle initial), the entity was retained; (3) For three-token entities: If the token count for two of the tokens was greater than a configurable threshold and the third token count was not zero, or if the middle token was an initial, the entity was retained. (4) For multi-token entities: All.entities consisting of more than three tokens were filtered out.4 4 Such an approach may not be acceptable in an enterprise version of this type of name filtering, particularly when dealing with non-Anglo names that don't follow a simple first-middle-last name pattern. NameStats is able to recognize that certain tokens are actually a part of a compound name (e.g., Al Shehri is treated as one token), making it feasible to restrict the filtering logic to three tokens for this experiment.
[0019] Filtering spurious entities would not be expedient if it also filtered out legitimate personal names, resulting in a significant reduction in recall. The application of this filtering process, however, resulted in a significant reduction in the number of spurious entities with almost no effect whatsoever on recall. The scores are presented in Table 2:
TABLE 2 Filtered Extraction Scores for Personal Named Entities AeroText ™ LingPipe (on MUC-6) (on MUC-7) Recall 70.09% 89.44% Precision 73.00% 82.43% F-Measure 71.51% 85.79% Spurious Entities 91 168
[0020] The number of spurious entities obtained from the LingPipe extraction from the MUC-6 corpus was reduced by 38.10%, resulting in a 16.61% relative improvement in precision for this corpus. This was achieved with no reduction in recall at all. The number of spurious entities obtained from the AeroText™ extraction from the MUC-7 corpus was reduced by 21.86%, resulting in a 4.83% improvement in precision. This was achieved with only a 0.38% reduction in recall. In both examples, applying this type of filtering process to the output of the extraction results in data sets that are significantly cleaned of extraneous information or textual junk.
[0021] For information extraction systems, such as AeroText™, which rely on human-adjudicated patterns, or rules, to recognize named entities in unstructured text, one approach to maximize recall is to create rules that are as broad as possible. For example, a typical rule might extract as a person entity two or more unknown tokens following a title term, e.g.,
[ Secretary General ] Title [ Kofi ] Unk [ Annan ] Unk -> [ Secretary General ] Title [ Kofi Annan ] Person
[0022] This rule could be made broader by removing the requirement that a title term precede the unknown tokens. Such a rule would inevitably retrieve a greater number of person entities, but the penalty in loss of precision could be significant. In many cases, the trade-off would be so great that the increase in recall is not sufficient to justify the loss of precision. Using name data stores as post-extraction filters, however, will permit such an increase in the expansiveness of extraction patterns since the reduction in precision can be mitigated by the filters. Such an approach makes it easier for an information extraction project to favor maximum recall without being subject to an excessive and intolerable increase in the number of spurious entities extracted.
[0023] To demonstrate the effectiveness of this approach, all 243 occurrences of personal names in the first chapter of the 911 Commission Report were tagged by hand using AeroText's built-in Key Editor.5 This text was chosen for three reasons: (1) it contains enough personal named entities to provide a reliable measure of any improvement in recall or precision; (2) it contains many names of non-Anglo origin, likely to be treated by AeroText™ as unknown tokens; and (3) it is widely and freely available. Results from the experiment with this text indicate that significant increases in both recall and precision can be achieved with the filtering approach described above. 5 Names that are part of an organization or facility, such as Kennedy in Kennedy International Airport, were not tagged as names, since AeroText™ extracts the name as part of the organization entity.
[0024] The document was initially processed with no changes to the person entity extraction rules provided by the sample project that ships with AeroText™. AeroText™ extracted 223 person entities; many of these, however, were either partially correct (i.e., only a portion of a name was correctly extracted or a string longer than the actual name was extracted) or spurious. Recall and precision figures for this base run are provided in Table 3:
TABLE 3 911 Commission Report Base Run Recall 66.26% Precision 69.10% F-Measure 67.65% Spurious Entities 72 Missed Entities 82
[0025] An independent scoring algorithm was employed so as not to reflect any credit for partially correct extractions. For example, if AeroText™ extracted Shehri as a person while Mohand al Shehri is the actual entity, Shehri is treated as spurious and the correct entity is judged to have been missed. While this scoring approach may not accord the extraction engine its due for partially identifying entities, it allows for a much more straightforward evaluation of the benefits of post-extraction filtering.
[0026] Before attempting to broaden the AeroText™ person extraction rules, the initial output was filtered to confirm the positive outcome obtained for the MUC corpora described above and to establish a baseline against which to measure any further improvement in recall and precision. Establishing a baseline here is important, since some improvement in recall and precision obtained through filtering might initially seem surprising. This unexpected behavior is actually attributable to the restriction imposed on the scoring algorithm in not allowing credit for partial matches. This is explained below, following the presentation of the scores for the filtered initial run of the 911 Commission corpus in Table 4:
TABLE 4 911 Commission Report Filtered Base Run Recall 69.14% Precision 75.37% F-Measure 72.12% Spurious Entities 55 Missed Entities 75
[0027] First, note that the filtering procedure resulted in a 23.61% reduction in the number of spurious entities, which for this corpus amounts to a 9.07% increase in precision. What is surprising here is that as precision improves, recall should be expected to remain fairly steady. If it changes, it should decrease rather than increase as it has in this case. The increase here is due to the fact that the filtering algorithm also strips names of recognized titles, e.g., AeroText™ extracted Secretary Rumsfield, while only Rumsfield was keyed as a personal name. Stripping the title moved the Rumsfield entities in the base run from missing to correct, resulting in an improved recall score.
[0028] The AeroText™ knowledge base was then enhanced by the addition of a single rule that allowed two or three consecutive possible personal names to be extracted as a name. The internal elements and features that allow AeroText™ to determine that something is a possible personal name are too complicated to discuss here. What is important is that this rule is sufficiently broad that it will capture many true names that were initially missed, along with numerous spurious hits. The results of processing the 911 Commission corpus with the broader rule are presented in Table 5:
TABLE 5 911 Commission Report Broad Run Recall 77.37% Precision 74.31% F-Measure 75.81% Spurious Entities 65 Missed Entities 55
[0029] As expected, adding the broader rule increased the number of person entities correctly extracted (out of the 243 possible) by nearly 17% over the base run. In this case, we would expect a decrease in precision, but the elimination of partially extracted entities as described above actually resulted in a 7.54% increase. The 74.31% precision rate for the broad run is still slightly below the figure.obtained by filtering the base run, however.
[0030] The person entities extracted from the broad run were then subjected to the filtering process, using the LAS NameStats™ product. Results are presented in Table 6:
TABLE 6 911 Commission Report Filtered Broad Run Recall 80.25% Precision 82.63% F-Measure 81.42% Spurious Entities 41 Missed Entities 48
[0031] These figures demonstrate that filtering results derived from less specific extraction rules for personal named entities can result in significant improvements in both recall and precision. In this case, adding a single broad rule, followed by filtering, results in an increase in recall of 21.11% over the base and a reduction in the number of spurious entities by 43.05%, which amounts to a 19.58% increase in precision for this data set.
[0032] Although automated named entity extraction makes it possible to utilize much more of the exploding information available to intelligence analysts today, it also means that a certain number of significant entities will be overlooked, while a certain number of spurious entities will find their way into persistent databases. In this paper, we have demonstrated that using large name data stores with appropriate filtering logic can significantly reduce the number of spurious personal name entities extracted by an extraction system without having any consequential impact on recall. This type of filtering also makes it possible for knowledge workers to create broader rules that will extract a larger number of entities without having to tolerate a significant decrease in precision. Filters using large name data stores should therefore be considered as a valuable tool in improving the overall goal of extracting intelligence from unstructured text.
[0033] A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made. For example, a variety of different name extraction algorithms, databases, and filtering algorithms may be used, alone or in conjunction. Further, various different rules may be added to, or modified within, either a name extraction algorithm or a filtering algorithm, for example. Accordingly, other implementations are within the scope of the following claims. | A particular implementation includes accessing a source of text that includes names, and providing the source of text as an input for a name extraction algorithm. A set of potential names is extracted from the source of text using the name extraction algorithm, and the set of potential names is provided as an input for a post-extraction filtering algorithm. A set of filtered names is produced by filtering the set of potential names against a database of names using the post-extraction filtering algorithm, and the set of filtered names is provided to one or more destinations or users. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a division of U.S. application Ser. No. 13/734,350 filed Jan. 4, 2013, which is a continuation-in-part of U.S. application Ser. No. 12/435,781 filed May 5, 2009, abandoned, which is a continuation-in-part of U.S. application Ser. No. 12/363,383 filed Jan. 30, 2009, abandoned, which is a division of U.S. application Ser. No. 10/953,513 filed Sep. 30, 2004, U.S. Pat. No. 7,504,110, which is a continuation-in-part of International application no. PCT/IL2003/000271 filed Apr. 1, 2003, which claims the benefit of U.S. provisional application No. 60/368,981 filed Apr. 2, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to vaccine compositions and methods for protecting against infection with Streptococcus pneumoniae . More specifically, the present invention provides vaccine compositions comprising S. pneumoniae cell wall or cell membrane proteins associated with an age-dependent immune response.
BACKGROUND OF THE INVENTION
[0003] The Gram-positive bacterium Streptococcus pneumoniae is a major cause of disease, suffering and death worldwide. Diseases caused by infection with this agent include otitis media, pneumonia, bacteremia, sepsis and meningitis. In some cases, infected individuals may become asymptomatic carriers of S. pneumoniae , thereby readily allowing the rapid spread of this infective agent throughout the population. In view of the serious consequences of infection with S. pneumoniae , as well as its rapid spread within and between populations, there is an urgent need for safe, effective vaccination regimes. Current methods of vaccination are based on inoculation of the subject with polysaccharides obtained from the capsules of S. pneumoniae . While these polysaccharide-based vaccine preparations have been found to be reasonably efficacious when used to prevent infection in adult populations, they are significantly less useful in the treatment of young children (under two years of age) and the elderly. One commonly-used capsular polysaccharide 23-valent vaccine, for example, has been found to be only 60% effective in preventing S. pneumoniae invasive disease in elderly subjects and completely incapable of yielding neither long-term memory (Hammitt et al., 2011, Vaccine 29:2287-2295) nor clinically-useful antibody responses in the under-two age group (Shapiro E. D. et al., 1991, N. Engl. J. Med. 325: 1453-1460).
[0004] In an attempt to increase the immunogenicity of these vaccines, various compositions comprising capsular polysaccharides that have been conjugated with various carrier proteins and combined with adjuvant have been used. The resulting so-called conjugate vaccines (CV) currently include 10-13 serotypes. Although vaccines of this type constitute an improvement in relation to the un-conjugated polysaccharide vaccines, they have not overcome the problem of coverage, since they are effective against only about 10% of the 92 known capsular serotypes. Consequently, upon vaccination, pneumococcal carriage and repopulation with serotypes not present in the vaccine occurs (Dagan, 2009, Vaccine 27 Suppl 3:C22-24).
[0005] In the cases of certain other bacteria of pathogenic importance for human and other mammalian species, vaccines comprising immunogenic virulence proteins are currently being developed. Such protein-based vaccines should be of particular value in the case of vulnerable subjects such as very young children, in view of the fact that such subjects are able to produce antibodies against foreign proteins. Unfortunately, very little is known of the molecular details of the life cycle of S. pneumoniae , or of the nature of role of the various virulence factors which are known or thought to be involved in targeting and infection of susceptible hosts.
[0006] Several publications describe and characterize specific S. pneumoniae proteins. For example, U.S. Pat. No. 5,958,734, U.S. Pat. No. 5,976,840, U.S. Pat. No. 6,165,760 and U.S. Pat. No. 6,300,119 disclose S. pneumoniae GtS polypeptides of various lengths, polynucleotides encoding them and methods for producing such polypeptides by recombinant techniques. WO 02/077021 the sequences of about 2,500 S. pneumoniae genes and their corresponding amino acid sequences from type 4 strain that were identified in silico. U.S. Pat. No. 6,699,703 and its counterparts discloses about 2600 S. pneumoniae polypeptides and methods for producing such polypeptides by recombinant techniques, compositions comprising same and methods of use in the preparation of a vaccine. WO 98/23631 relates to 111 Streptococcal polynucleotides identified as having a GUG start codon, which encodes a Val residue, to polypeptides encoded by such polynucleotides, and to their production and uses. WO 02/083833 discloses 376 S. pneumoniae polypeptide antigens which are surface localized, membrane associated, secreted or exposed on the bacteria, for preparation of a diagnostic kit and or vaccine. Although suggested in part of the publications, no working examples for the use of the proteins as antigens in the production of a vaccine were provided. Furthermore, none of these references disclose or suggest that use of selected protein antigens which do no elicit immune response in infants and in elderly, improve the outcome of vaccination against S. pneumoniae.
[0007] Phosphoenolpyruvate protein phosphotransferase (PPP, also known as PtsA) is an intracellular protein that belongs to the sugar phosphotransferase system (PTS) and is also localized to the bacterial cell wall. In the cytoplasm PPP belongs to the group of phosphtransferase systems (PTS) responsible for carbohydrate internalization, which occurs concurrently with their phosphorylation. The phosphorylation of the membrane-spanning enzyme is dependent upon a group of proteins that sequentially transfer a phosphate group to this enzyme. PPP is a cytoplasmic protein that catalyzes the initial step in this process by transferring a phosphate group from phosphoenolpyruvate to a histidine in another enzyme, HrP in this system (Saier, M. H., Jr. & Reizer, J., 1992, J Bacteriol 174:1433-1438).
[0008] There is an unmet need to provide protein-based vaccine compositions which overcome the problems and drawbacks of currently available vaccines, by being effective against a wide range of different S. pneumoniae serotypes, and capable of protecting all age groups including infants and elderly.
SUMMARY OF THE INVENTION
[0009] It has now been found that it is possible to protect individuals against infection with S. pneumoniae by means of administering to said individuals a vaccine composition comprising one or more proteins isolated from the outer layers of the aforementioned bacteria and/or one or more immunonologically-active fragments, derivatives or modifications thereof. Unexpectedly, it was found that a defined set of proteins, associated with age-dependent immunity, are effective in vaccine compositions against a wide range of different S. pneumoniae serotypes, and in all age groups, including those age groups that do not produce anti- S. pneumoniae antibodies following vaccination with polysaccharide-based compositions, or those resulting in a shift in serotype distribution towards those pneumococcal capsular polysaccharides that are not present in the vaccine. These age groups include infants aged 0-4 years and elderly. Thus, the use of the set of antigens in accordance with the principle of the invention overcomes the disadvantages of known vaccines.
[0010] It is now disclosed that the antibody response to S. pneumoniae proteins increases with age in infants and this increase correlates negatively with morbidity. Antibodies to S. pneumoniae protein antigens develop in humans during the asymptomatic carriage and invasive disease. Infants below two years of age who are at most risk from pneumococcal infections do not respond efficiently to currently available polysaccharide-based vaccination. It is now unexpectedly shown, using sera longitudinally collected from healthy children, exposed to bacterial infections that there is an age-dependent enhancement of the antibody response to certain S. pneumoniae surface protein antigens, while in most other proteins there is no enhancement of immunogenicity during the checked time period. This enhancement, with age, of antibody responses against a set of specific pneumococcal surface proteins is implicated in the development of natural immunity and was used in the present invention to identify candidate antigens (herein “age dependent proteins”) for use in improved vaccine compositions effective in all age groups, including infants, immunocompromized subjects and elderly.
[0011] In elderly subjects capsular polysaccharide based vaccines are only 60% effective in preventing S. pneumoniae invasive disease. An elderly subject should be vaccinated at least once in five years and the vaccination efficacy is reduced in each repeated vaccination. The protein-based vaccines of the present invention, which are T-cell dependent antigens, are expected to be more effective than the polysaccharide-based vaccines in elderly subjects.
[0012] The present invention provides a method for protecting individuals against infection with S. pneumoniae by the use of a protein-based vaccine.
[0013] The present invention further provides a protein-based vaccine that is prepared from at least one of a specific set of immunogenic cell wall and/or cell membrane proteins of S. pneumoniae , having age-dependent immune responses, or from one or more immunologically-active fragments, derivatives or modifications thereof.
[0014] According to one aspect of the present invention, a vaccine composition comprises as an active ingredient one or more isolated proteins selected from one or more S. pneumoniae cell wall or cell membrane proteins or immunologically-active protein fragments, derivatives or modifications thereof, which are associated with an age-dependent immune response. According to preferred embodiments, this aspect of the invention said the age-dependent S. pneumoniae cell wall and/or cell membrane protein is selected from the group consisting of: phosphoenolpyruvate protein phosphotransferase (Accession No. NP — 345645, SEQ ID NO: 4); phosphoglucomutase/phosphomannomutase family protein (Accession No. NP — 346006, SEQ ID NO:5); trigger factor (Accession No. NP — 344923, SEQ ID NO: 6); elongation factor G/tetracycline resistance protein (tetO), (Accession No. NP — 344811, SEQ ID NO: 7); NADH oxidase (Accession No. NP — 345923, SEQ ID NO: 8); Aspartyl/glutamyl-tRNA amidotransferase subunit C (Accession No. NP — 344960, SEQ ID NO: 9); cell division protein FtsZ (Accession No. NP — 346105, SEQ ID NO: 10); L-lactate dehydrogenase (Accession No. NP — 345686, SEQ ID NO: 11); glyceraldehyde 3-phosphate dehydrogenase (GAPDH), (Accession No. NP — 346439, SEQ ID NO: 12); fructose-bisphosphate aldolase (Accession No. NP — 345117, SEQ ID NO: 13); UDP-glucose 4-epimerase (Accession No. NP — 346261, SEQ ID NO: 14); elongation factor Tu family protein (Accession No. NP — 358192, SEQ ID NO: 15); Bifunctional GMP synthase/glutamine amidotransferase protein (Accession No. NP — 345899, SEQ ID NO: 16); glutamyl-tRNA synthetase (Accession No. NP — 346492, SEQ ID NO: 17); glutamate dehydrogenase (Accession No. NP — 345769, SEQ ID NO: 18); Elongation factor TS (Accession No. NP — 346622, SEQ ID NO: 19); phosphoglycerate kinase (TIGR4) (Accession No. AAK74657, SEQ ID NO: 20); 30S ribosomal protein 51 (Accession No. NP — 345350, SEQ ID NO: 21); 6-phosphogluconate dehydrogenase (Accession No. NP — 357929, SEQ ID NO: 22); aminopeptidase C (Accession No. NP — 344819, SEQ ID NO: 23); carbamoyl-phosphate synthase (large subunit) (Accession No. NP — 345739, SEQ ID NO: 24); PTS system, mannose-specific IIAB components (Accession No. NP — 344822, SEQ ID NO: 25); 30S ribosomal protein S2 (Accession No. NP — 346623, SEQ ID NO: 26); dihydroorotate dehydrogenase 1B (Accession No. NP — 358460, SEQ ID NO: 27); aspartate carbamoyltransferase catalytic subunit (Accession No. NP — 345741, SEQ ID NO: 28); elongation factor Tu (Accession No. NP — 345941, SEQ ID NO: 29); Pneumococcal surface immunogenic protein A (PsipA) (Accession No. NP — 344634, SEQ ID NO: 30); phosphoglycerate kinase (R6) (Accession No. NP — 358035, SEQ ID NO: 31); ABC transporter substrate-binding protein (Accession No. NP — 344690, SEQ ID NO: 32); endopeptidase 0 (Accession No. NP — 346087, SEQ ID NO: 33); Pneumococcal surface immunogenic protein B (PsipB) (Accession No. NP — 358083, SEQ ID NO: 34); Pneumococcal surface immunogenic protein C (PsipC) (Accession No. NP — 345081, SEQ ID NO: 35).
[0015] According to a particular embodiment, the vaccine composition comprises the age-dependent protein phosphoenolpyruvate protein phosphotransferase (PPP or rPtsA) of Accession No. NP — 345645, set forth in SEQ ID NO: 4, or a fragment or modification thereof wherein such fragment or modification is capable of eliciting an immune response against S. pneumoniae.
[0016] According to other embodiments, the vaccine composition comprises at least one age-dependent protein selected from the group consisting of: phosphoenolpyruvate protein phosphotransferase (PPP, Accession No. NP — 345644, SEQ ID NO: 4); Fructose-bisphosphate aldolase (NP 345117, SEQ ID NO: 13); Aminopeptidase C (NP — 344819, SEQ ID NO: 23); NADH oxidase (NOX, NP — 345923, SEQ ID NO: 8) and ABC transporter substrate-binding protein (Accession No. NP — 344690, SEQ ID NO: 32).
[0017] According to some embodiments the one or more bacterial proteins of the vaccine are effective in all age groups, including those age groups that do not produce anti- S. pneumoniae antibodies following vaccination with polysaccharide-based vaccines; or exposure to the bacteria.
[0018] According to one embodiment the age group comprises infants less than four years of age. According to another embodiment the age group comprises infants less than two years of age.
[0019] According to one embodiment the age group comprises elderly subjects. According to yet another embodiment the age group comprises children older the 4 years of age and adult subjects.
[0020] According to another embodiment the age group comprises immunocompromised subjects.
[0021] The vaccine compositions of the present invention may also contain other, non-immunologically-specific additives, diluents and excipients. For example, in many cases, the vaccine compositions of the present invention may contain, in addition to the S. pneumoniae cell-wall and/or cell-membrane protein(s), one or more adjuvants.
[0022] Pharmaceutically acceptable adjuvants include, but are not limited to water in oil emulsion, lipid emulsion, and liposomes. According to specific embodiments the adjuvant is selected from the group consisting of: Montanide®, alum, muramyl dipeptide, Gelvac®, chitin microparticles, chitosan, cholera toxin subunit B, labile toxin, AS21A, ASO2V, Intralipid®, Lipofundin, Monophosphoryl lipid A; RIBI: monophosphoryl lipid A with Mycobacterial cell wall components (muramy tri peptide), ISCOMs Immune stimulating complexes, CpG, and DNA vaccines such as pVAC. Also included are immune enhancers such as cytokines.
[0023] In some embodiments the vaccine composition is formulated for intramuscular, intranasal, oral, intraperitoneal, subcutaneous, topical, intradermal and transdermal delivery. In some embodiments the vaccine is formulated for intramuscular administration. In other embodiments the vaccine is formulated for oral administration. In yet other embodiments the vaccine is formulated for intranasal administration.
[0024] In one particularly preferred embodiment, the method of the present invention for protection of mammalian subjects against infection with S. pneumoniae comprises administering to a subject in need of such protection an effective amount of at least one cell wall and/or cell membrane proteins associated with age-related immune response, and/or immunogenically-active fragments, derivatives or modifications thereof, wherein said at least one protein is selected from the group consisting of: fructose-bisphosphate aldolase (FBA, NP — 345117, SEQ ID NO:13), Phosphoenolpyruvate protein phosphotransferase (PPP) NP — 345645 (SEQ ID NO:4), Glutamyl tRNA synthetase (GtS, NP — 346492, SEQ ID NO:17), NADH oxidase (NOX, NP — 345923, SEQ ID NO:8), Pneumococcal surface immunogenic protein B (PsipB; NP — 358083, SEQ ID NO:34), trigger factor (TF, NP — 344923, SEQ ID NO:6), FtsZ cell division protein (NP — 346105, SEQ ID NO:10), PTS system, mannose-specific IIAB components (PTS, NP — 344822, SEQ ID NO:25), and Elongation factor G (EFG, NP344811, SEQ ID NO:7).
[0025] According to a particular embodiment, the method comprises administration of the protein phosphoenolpyruvate protein phosphotransferase (PPP or rPtsA) of Accession No. NP — 345645, set forth in SEQ ID NO: 4, or a fragment or modification thereof wherein such fragment or modification is capable of eliciting an immune response against S. pneumoniae.
[0026] According to some embodiments at least one protein of the vaccine composition is an enzyme involved in glycolysis. According to a specific embodiment the at least one protein involved in glycolysis is selected from the group consisting of: L-lactate dehydrogenase (SEQ ID NO: 11), UDP-glucose 4-epimerase (SEQ ID NO: 14), fructose-bisphosphate aldolase (SEQ ID NO: 13), glyceraldehyde-3-phosphate dehydrogenase (SEQ ID NO: 12), phosphoglycerate kinase (SEQ ID NO: 31) and 6-phosphoglutamate dehydrogenase (SEQ ID NO: 22).
[0027] According to another embodiment at least one protein of the vaccine composition is an enzyme involved in protein synthesis. According to a specific embodiment the protein involved in protein synthesis is glutamyl-tRNA amidotransferase (SEQ ID NO: 16) or glutamyl-tRNA synthetase (SEQ ID NO: 17).
[0028] According to other embodiments at least one protein of the vaccine composition is an enzyme belonging to the other physiological pathways selected from: NADP glutamate dehydrogenase (NP — 345769), aminopeptidase C (Accession No. NP — 344819, SEQ ID NO: 23), carbamoylphosphate synthase (Accession No. NP — 345739, SEQ ID NO: 24), aspartate carbamoyltransferase (Accession No. NP — 345741, SEQ ID NO: 28), NADH oxidase (NOX, Accession No. NP — 345923, SEQ ID NO: 8), Pneumococcal surface immunogenic protein B (PsipB, Accession No. NP — 358083, SEQ ID NO: 34); and pyruvate oxidase.
[0029] In some embodiments the cell wall and/or cell membrane proteins are lectins. According to specific embodiments the lectin proteins are selected from the group consisting of: Fructose-bisphosphate aldolase (NP 345117, SEQ ID NO:13); Aminopeptidase C (NP — 344819, SEQ ID NO:23).
[0030] According to some embodiments the S. pneumoniae proteins and/or fragments, derivatives or modifications thereof are lectins and the vaccine compositions comprising them are particularly efficacious in the prevention of localized S. pneumoniae infections. In one preferred embodiment, the localized infections are infections of mucosal tissue, particularly of nasal and other respiratory mucosa.
[0031] In alternative embodiments of the method of the invention, the cell wall and/or cell membrane proteins are non-lectins.
[0032] In specific embodiments the non-lectin proteins are selected from the group consisting of: Phosphomannomutase (NP 346006, SEQ ID NO:5); Trigger factor (NP 344923, SEQ ID NO:6); NADH oxidase (NP 345923, SEQ ID NO:8); L-lactate dehydrogenase (NP 345686, SEQ ID NO:11); Glutamyl-tRNA synthetase (NP 346492, SEQ ID NO:17).
[0033] According to other embodiments the S. pneumoniae proteins and/or their fragments, derivatives or modifications used in the aforementioned methods, compositions and vaccines are non-lectins, and the vaccine compositions are particularly efficacious in the prevention of systemic S. pneumoniae infections.
[0034] In another preferred embodiment of the method of the invention, vaccine composition comprises at least one lectin protein and at least one non-lectin protein.
[0035] The present invention is directed according to another aspect to a method for preventing infection of mammalian subjects with S. pneumoniae , wherein said method comprises administering to a subject in need of such treatment an effective amount of one or more S. pneumoniae cell wall and/or cell membrane proteins associated with age-related immune response, and/or immunogenically-active fragments, derivatives or modifications thereof, wherein said proteins are selected from the group consisting of: phosphoenolpyruvate protein phosphotransferase (Accession No. NP — 345645, SEQ ID NO:4); phosphoglucomutase/phosphomannomutase family protein (Accession No. NP — 346006, SEQ ID NO:5); trigger factor (Accession No. NP — 344923, SEQ ID NO:6); elongation factor G/tetracycline resistance protein (tetO), (Accession No. NP — 344811, SEQ ID NO:7); NADH oxidase (Accession No. NP — 345923, SEQ ID NO:8); Aspartyl/glutamyl-tRNA amidotransferase subunit C (Accession No. NP — 344960, SEQ ID NO:9); cell division protein FtsZ (Accession No. NP — 346105, SEQ ID NO:10); L-lactate dehydrogenase (Accession No. NP — 345686, SEQ ID NO:11); glyceraldehyde 3-phosphate dehydrogenase (GAPDH), (Accession No. NP — 346439, SEQ ID NO:12); fructose-bisphosphate aldolase (Accession No. NP — 345117, SEQ ID NO:13); UDP-glucose 4-epimerase (Accession No. NP — 346261, SEQ ID NO:14); elongation factor Tu family protein (Accession No. NP — 358192, SEQ ID NO:15); Bifunctional GMP synthase/glutamine amidotransferase protein (Accession No. NP — 345899, SEQ ID NO:16); glutamyl-tRNA synthetase (Accession No. NP — 346492, SEQ ID NO:17); glutamate dehydrogenase (Accession No. NP — 345769, SEQ ID NO:18); Elongation factor TS (Accession No. NP — 346622, SEQ ID NO:19); phosphoglycerate kinase (TIGR4) (Accession No. AAK74657, SEQ ID NO:20); 30S ribosomal protein 51 (Accession No. NP — 345350, SEQ ID NO:21); 6-phosphogluconate dehydrogenase (Accession No. NP — 357929, SEQ ID NO:22); aminopeptidase C (Accession No. NP — 344819, SEQ ID NO:23); carbamoyl-phosphate synthase (large subunit) (Accession No. NP — 345739, SEQ ID NO:24); PTS system, mannose-specific IIAB components (Accession No. NP — 344822, SEQ ID NO:25); 30S ribosomal protein S2 (Accession No. NP — 346623, SEQ ID NO:26); dihydroorotate dehydrogenase 1B (Accession No. NP — 358460, SEQ ID NO:27); aspartate carbamoyltransferase catalytic subunit (Accession No. NP — 345741, SEQ ID NO:28); elongation factor Tu (Accession No. NP — 345941, SEQ ID NO:29); Pneumococcal surface immunogenic protein A (PsipA) (Accession No. NP — 344634, SEQ ID NO:30); phosphoglycerate kinase (R6) (Accession No. NP — 358035, SEQ ID NO:31); ABC transporter substrate-binding protein (Accession No. NP — 344690, SEQ ID NO:32); endopeptidase 0 (Accession No. NP — 346087, SEQ ID NO:33); Pneumococcal surface immunogenic protein B (PsipB) (Accession No. NP — 358083, SEQ ID NO:34); Pneumococcal surface immunogenic protein C (PsipC) (Accession No. NP 345081, SEQ ID NO:35).
[0036] Vaccine compositions of the present invention can be administered to a subject in need thereof, prior to, during or after occurrence of infection or inoculation with S. pneumoniae.
[0037] The vaccine compositions of the present invention are administered, according to one embodiment by means of injection. According to some embodiments the injection route is selected from the group consisting of: intramuscular, intradermal or subcutaneous. According to other embodiments the injection route is selected from intravenous and intraperitoneal. According to yet other embodiments the vaccine compositions of the present invention are administered by nasal or oral routes.
[0038] According to some embodiments the S. pneumoniae proteins and/or fragments, derivatives or modifications thereof are lectins and the vaccine compositions comprising them are particularly efficacious in the prevention of localized S. pneumoniae infections. In one preferred embodiment, the localized infections are infections of mucosal tissue, particularly of nasal and other respiratory mucosa.
[0039] According to other embodiments the S. pneumoniae proteins and/or their fragments, derivatives or modifications used in the aforementioned methods, compositions and vaccines are non-lectins, and the vaccine compositions are particularly efficacious in the prevention of systemic S. pneumoniae infections.
[0040] In another preferred embodiment of the method of the invention, vaccine composition comprises at least one lectin protein and at least one non-lectin protein.
[0041] In one preferred embodiment of the method of the invention, the mammalian subject is a human subject.
[0042] The aforementioned vaccine compositions may clearly be used for preventing infection of the mammalian subjects by S. pneumoniae . However, said vaccine composition is not restricted to this use alone. Rather it may be usefully employed to prevent infection by any infectious agent whose viability or proliferation may be inhibited by the antibodies generated by a host in response to the inoculation therein of the one or more S. pneumoniae proteins provided in said composition.
[0043] According to some embodiments the vaccine compositions of the present invention inhibit S. pneumoniae adhesion to cells, for example to human lung cells.
[0044] DNA vaccines comprising at least one polynucleotide sequence encoding age-dependent bacterial proteins according to the invention are also within the scope of the present invention, as well as methods for protecting a mammalian subject against infection with S. pneumoniae comprising administering such polynucleotide sequence to a subject. According to one embodiment the present invention provides a vaccine composition comprising at least one polynucleotide sequence encoding a protein selected from one or more S. pneumoniae cell wall or cell membrane proteins or immunogenically-active protein fragments, derivatives or modifications thereof, which is associated with an age-dependent immune response. According to some embodiments the DNA vaccine composition further comprises at least one polynucleotide sequence encoding an adjuvant peptide or protein. According to a preferred embodiment a DNA vaccine according to the invention is administered by intramuscular injection.
[0045] The present invention discloses, according to yet a further aspect, a method for identifying bacterial proteins having age-dependent immunogenicity. Identified age-dependent proteins can be used in vaccine compositions against pathogens expressing said proteins.
[0046] According to certain embodiments, a method for identifying a bacterial protein having age-dependent immunogenicity is provided the method comprises the steps of: providing an extract of the cell wall and/or cell membrane of the pathogen; separating the extract by 2D-electrophoresis or micro-chromatography; blotting the protein extract to a matrix; probing the blots with sera collected longitudinally from children at different ages; identifying the protein spots having intensity increasing with age; thereby identifying a protein having age-dependent immunogenicity.
[0047] According to some embodiments the protein extract is blotted onto a paper. According to other embodiments the proteins are identified using Matrix Assisted Laser Desorption/Ionization mass spectrometry (MALDI-MS) technique.
[0048] According to some embodiments the pathogen is a bacterium. According to specific embodiments the bacterium is S. pneumoniae and the sera are collected from children aged 18, 30 and 42 months. According to another embodiment the pathogen is Streptococcus pyogenes.
[0049] All of the above and other characteristics and advantages of the present invention will be further understood from the following illustrative and non-limitative examples of preferred embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
[0050] FIG. 1 is a photograph of a Western blot in which the sera of mice immunized with (A) recombinant GAPDH and (B) recombinant fructose-bisphosphate aldolase are seen to recognize the corresponding native proteins (CW) (in an electrophoretically-separated total cell wall protein preparation), and the corresponding recombinant protein (R).
[0051] FIG. 2 is a photograph of a Western blot in which the sera of mice immunized with pVAC constructs containing the cDNA of S. pneumoniae fructose-bipshosphate aldolase (A) and GAPDH (B) are seen to recognize the corresponding native proteins from electrophoretically-separated total cell wall protein preparation. Sera obtained following immunization with the pVAC parental plasmid did not recognize either of the two proteins (C).
[0052] FIGS. 3A and 3B each shows a graph describing the ability of recombinant GAPDH ( 3 B) and fructose-bisphosphate aldolase ( 3 A) to elicit a protective immune response to intraperitoneal and intranasal challenge with a lethal dose of S. pneumoniae in the mouse model system.
[0053] FIG. 4 is a photograph of a gel depicting the 297 base pair ALDO 1-containing fragment of S. pneumoniae fructose bisphosphate aldolase.
[0054] FIG. 5 depicts an agarose gel separation of ALDO 1 and the pHAT vector after restriction by Kpn1 and SacI enzymes.
[0055] FIG. 6 is a photograph of an agarose gel showing the 297 by PCR amplification product (comprising ALDO 1) obtained from colonies transformed with the pHAT/ALDO 1 construct.
[0056] FIG. 7A-E describes the vaccine potential of PPP. BALB/c mice were immunized SC with rPPP formulated with CFA (day 0) and IFA (days 14 & 28), and followed for colonization ( 7 A- 7 D) or mortality ( 7 E) following IN inoculation. ( 7 A) strain WU2, 3 h (p<0.01), ( 7 B) strain WU2 48 h (p<0.05), ( 7 C) Strain D39, NP, 48 h (p<0.001), ( 7 D) Strain D39, lung, 48 h (p<0.007), ( 7 E) Strain WU2, 7 days of observation for mortality (p<0.05).
[0057] FIG. 8 depicts the increased survival of mice following a lethal intranasal inoculation of mice following immunization with recombinant Glutamyl tRNA synthetase (rGtS).
[0058] FIG. 9 describes survival of mice following active immunization with recombinant NADH oxidase (rNOX).
[0059] FIG. 10 survival of mice after passive IP immunization with: anti-rPsipB antiserum, control preimmune serum, or anti-non-lectin protein mixture (NL) serum. The mice were inoculated intraperitonealy with the antiserum 24 and 3 hours prior to bacterial challenge.
[0060] FIG. 11 active immunization of mice with Trigger factor (TF) using CFA/IFA/IFA immunization protocol in comparison to control (adjuvant) immunized animals.
[0061] FIG. 12 survival of mice following IP challenge with S. pneumoniae after 1 hour neutralization with anti-FtsZ cell division protein (FtsZ) antiserum, preimmune serum or anti NL serum.
[0062] FIG. 13 survival of mice following IP challenge with S. pneumoniae neutralized with anti-PTS system, mannose-specific IIAB components (PTS) antiserum, preimmune serum or NL serum.
[0063] FIG. 14 mice survival after active immunization with Elongation factor G (EFG) with Alum adjuvant in comparison to mice injected with adjuvant only as control.
[0064] FIG. 15 reconfirms the age dependent recognition of GtS by sera obtained longitudinally from children attending day care centers and a serum obtained from an adult subject.
[0065] FIG. 16 reconfirms the age dependent recognition of NOX, using rNOX, by sera obtained longitudinally from children attending day care centers.
[0066] FIG. 17A-B demonstrates surface expression and conservation of PPP in different strains. 17 A. Membrane and cell-wall (CW) protein fractions from four clinical isolates were immunoblotted with mouse anti-PtsA antibodies; rPtsA positive control (upper lane). The membrane was immunoblotted with pre-immune serum as negative control (lower lane). 17 B. CW and cytoplasmic protein fractions immunoblotted with rabbit anti-FabD antibodies.
[0067] FIG. 18 reconfirms the age dependent immunogenicity of PPP. rPPP was immunoblotted with sera obtained from infants attending day care centers at ( 18 A) 7, ( 18 B) 12, ( 18 C) 24, and (D) 38 months of age.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0068] As disclosed herein for the first time, specific pneumococcal surface proteins that exhibit age-dependent immunogenicity, which coincide with the development of natural protective immunity. Proteins identified using antibodies against these proteins, present in infant sera, elicit a protective response against S. pneumoniae and can be used for protection against infection with the bacteria. It is now shown that proteins identified as exhibiting age-dependent immune response in infants, or antibodies to such proteins were able to protect mice against infection with S. pneumoniae.
[0069] Vaccine compositions according to the present invention may be used for preventing infection of the mammalian subjects by S. pneumoniae . However, said vaccine compositions may be also usefully employed to prevent adhesion of the bacteria to cells and to inhibit and reduce bacterial load and bacterial carriage. It was shown (Daniely et al., 2006, Clin. Exp. Immunol. 144, 254-263; Mizrachi Nebenzahl et al., 2007, J. Infectious Diseases 196:945-53), that antibodies to proteins identified in the present application as possessing age-dependent immunogenicity are capable of inhibiting S. pneumoniae adhesion to human lung cells.
[0070] The immunologically variant capsular polysaccharides of S. pneumoniae are used widely for the typing of clinical isolates. There are more than 90 capsular serotypes and their prevalence among human isolates varies with age, disease type and to some extent geographical origin. A 23-valent capsular polysaccharide-based vaccine is licensed for use in adults, but it does not elicit an efficient antibody response or protection in children under 2 years of age and immunocompromised patients. To overcome this lack of responsiveness to the T cell independent polysaccharide antigens in young children the conjugate pneumococcal vaccines were developed. These vaccines consist of 7 to 13 of the most prevalent S. pneumoniae capsular polysaccharides covalently linked to a protein carrier to stimulate T cell responses to the vaccine. These vaccines are highly effective in preventing invasive pneumococcal disease in infants but there are some drawbacks associated with the complexity of the manufacturing process that increase costs and the limited number of various capsular polysaccharides that can be included in the vaccine. Vaccination with conjugate pneumococcal vaccines has recently been shown to result in a shift in serotype distribution toward those pneumococcal capsular polysaccharides that are not present in the vaccine. In addition, geographical variations in the prevalence of clinically important serotypes of S. pneumoniae were described. These concerns combined with the increasing antibiotic resistance are driving research efforts to develop a wide range pneumococcal vaccine that is immunogenic in all age groups and broadly cross-protective against all or most serotypes. In addition proteins are T cell dependent antigen and are more likely to induce long lasting immunological memory.
[0071] The reasons to longitudinally start collecting sera from day-care children who are frequently exposed to S. pneumoniae , aiming to identify protein antigens involved in the development of natural immunity to S. pneumoniae , at 18 months of age were:
[0000] i. During gestation maternal IgG antibodies cross the placenta and in the initial months of life these maternal antibodies are protecting the infants.
ii. Starting at 6 months of age the levels of the maternal antibodies decline and a gradual increase in the infants' antibodies start to appear.
iii. Children are most susceptible to S. pneumoniae infections between 5-35 months of age. The first decrease in their susceptibility can be observed at between 12-23 months of age however the most significant decrease occurs between 24-35 months of age. It is assumed that natural strong immune response to a protein (for example Pyruvate oxidase and Enolase table 2), preceding this time period is not sufficient to protect children from S. pneumoniae infections. Therefore these proteins which did not elicit natural protection against the bacteria although an immune response against them is high in young infants are not age-dependent.
[0072] Immunodeficiency comprises a highly variable group of diseases. While primary immunodeficiency result from genetic alteration in genes affecting the immune response, acquired immunodeficiency result from infection with pathogens that affects the immune system (such as HIV-1). Other conditions that may cause diminution of the immune response and increase susceptibility to infections include malnutrition and diseases such as cancer. Most of the immunocompromised patients have acquired immunodeficiency. Malfunction of the immune system may stem from either lack of or the existence of dysfunctional B cells or T cells or macrophages. In other cases immunodeficiency may result in loss of immune memory cells. Antibody deficiencies comprise the most common types of primary immune deficiencies in human subjects. Such patients are highly susceptible to encapsulated bacterial infections. For example, patients that have B cell immunodeficiency could benefit from vaccination with the proteins of the present invention, which are T cell dependent antigens. Patients that demonstrated loss of immune memory, including HIV-1 patients, could also benefit from vaccination with the compositions of the present invention.
[0073] Thus it was suspected that the most significant development of natural immunity occurs after two years of age and it was chosen to encompass this period in the attempt to identify proteins that the immune responses to them increase with age during this period.
[0074] Vaccination of infants in the first year of age with the age-dependent bacterial proteins of the invention is expected to elicit protective immune responses to the bacteria, simulating the development of natural protective immunity that occurs at an older age.
[0075] Vaccination protects individuals (and by extension, populations) from the harmful effects of pathogenic agents, such as bacteria, by inducing a specific immunological response to said pathogenic agents in the vaccinated subject.
[0076] Vaccines are generally, but not exclusively, administered by means of injection, generally by way of the intramuscular, intradermal or subcutaneous routes. Some vaccines may also be administered by the intravenous, intraperitoneal, nasal or oral routes.
[0077] The S. pneumoniae -protein containing preparations of the invention can be administered as either single or multiple doses of an effective amount of said protein. The term “effective amount” is used herein to indicate that the vaccine is administered in an amount sufficient to induce or boost a specific immune response, such that measurable amounts (or an increase in the measurable amounts) of one or more antibodies directed against the S. pneumoniae proteins used may be detected in the serum or plasma of the vaccinated subject. The precise weight of protein or proteins that constitutes an “effective amount” will depend upon many factors including the age, weight and physical condition of the subject to be vaccinated. The precise quantity also depends upon the capacity of the subject's immune system to produce antibodies, and the degree of protection desired. Effective dosages can be readily established by one of ordinary skill in the art through routine trials establishing dose response curves. However, for the purposes of the present invention, effective amounts of the compositions of the invention can vary from 0.01-1,000 μg/ml per dose, more preferably 0.1-500 μg/ml per dose, wherein the usual dose size is 1 ml.
[0078] The vaccine compositions of the present invention, capable of protecting subject from infection or inoculation with S. pneumoniae can be administered to a subject in need thereof, prior to, during or after occurrence of infection or inoculation with the bacteria.
[0079] In general, the vaccines of the present invention would normally be administered parenterally, by the intramuscular, intravenous, intradermal or subcutaneous routes, either by injection or by a rapid infusion method. Compositions for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions, and emulsions. Examples of non-aqueous solvents are propylene glycol, polyethylene glycol, vegetable oils such as olive oil, and injectable organic esters such as ethyl oleate. Besides the abovementioned inert diluents and solvents, the vaccine compositions of the invention can also include adjuvants, wetting agents, emulsifying and suspending agents, or sweetening, flavoring, or perfuming agents.
[0080] The vaccines of the present invention will generally comprise an effective amount of one or more S. pneumoniae proteins as the active component, suspended in an appropriate vehicle. In the case of intranasal formulations, for example, said formulations may include vehicles that neither cause irritation to the nasal mucosa nor significantly disturb ciliary function. Diluents such as water, aqueous saline may also be added. The nasal formulations may also contain preservatives including, but not limited to, chlorobutanol and benzalkonium chloride. A surfactant may be present to enhance absorption of the subject proteins by the nasal mucosa. An additional mode of antigen delivery may include an encapsulation technique, which involves complex coacervation of gelatin and chondroitin sulfate (Azhari R, Leong K W. 1991. Complex coacervation of chondroitin sulfate and gelatin and its use for encapsulation and slow release of a model protein. Proc. Symp. Control. Rel. 18: 617; Brown K E, Leong K, Huang C H, Dalal R, Green G D, Haimes H B, Jimenez P A, Bathon J. 1998. Gelatin chondroitin 6-sulfate microspheres for delivery of therapeutic proteins to the joint. Arthritis Rheum 41: 2185-2195).
DEFINITIONS
[0081] The term “immunologically-active” is used herein in ordinary sense to refer to an entity (such as a protein or its fragment or derivative) that is capable of eliciting an immune response when introduced into a host subject.
[0082] The term “immunogenic protein” according to the present invention denotes a bacterial protein that was identified by antibodies present in human sera. “Antigenicity” refers to the ability of the bacterial protein to produce antibodies against it in the host. The term “age-related immune response” or “age dependent protein” (as used throughout this application) indicates that the ability of subjects to produce antibodies to the bacterial protein or proteins, causing said immune response, increases with age. In the case of human subjects, said ability is measured over a time scale beginning with neonates and ending at approximately four years of age and adults. In non-human mammalian subjects, the “age-related immune response” is measured over an age range extending from neonates to an age at which the immune system of the young mammal is at a stage of development comparable to that of a pre-puberty human child and adults.
[0083] It is to be noted that in the context of the present invention, the terms “fragments”, “derivatives” and “modifications” are to be understood as follows:
[0084] “Fragment”: a less than full length portion, or linked portions, of the native sequence of the protein in question, wherein the sequence of said portion is essentially unchanged as compared to the relevant part of the sequence of the native protein.
[0085] “Derivative”: a full length, and a less than full length portion of the native sequence of the protein in question, wherein either the sequence further comprises (at its termini and/or within said sequence itself) non-native amino acid sequences, i.e. sequences which do not form part of the native protein in question. The term “derivative” also includes within its scope molecular species produced by conjugating chemical groups to the amino residue side chains of the native proteins or fragments thereof, wherein said chemical groups do not form part of the naturally-occurring amino acid residues present in said native proteins.
[0086] “Modification”: a full length protein or less than full length portion thereof comprising at least one amino acid residue which is not natively present in the same location in the sequence of said protein, which have been introduced as a consequence of mutation of the native sequence (by either random or site-directed processes), by chemical modification or by chemical synthesis.
[0087] The term “infection” as used herein in the present application refers to a state in which disease-causing S. pneumoniae have invaded, colonized, spread, adhered, disseminated or multiplied in body cells or tissues. This term encompass the term “inoculation”, namely the state in which the bacteria colonized the nasopharynx but there are no infection symptoms yet.
[0088] The term “lectins” is used hereinabove and hereinbelow to indicate proteins having the ability to bind specifically to polysaccharides or oligosaccharides. Conversely, the term “non-lectins” is used to refer to proteins lacking the aforementioned saccharide-binding property, or to proteins which do not bind the saccharides tested in the present application.
Vaccine Formulation
[0089] The vaccines of the present invention comprise at least one bacterial protein exhibiting an age-dependent increase antibody response in infants, fragment, derivative or modification of said bacterial protein, and optionally, an adjuvant. Formulation can contain a variety of additives, such as adjuvant, excipient, stabilizers, buffers, or preservatives. The vaccine can be formulated for administration in one of many different modes.
[0090] In preferred embodiment, the vaccine is formulated for parenteral administration, for example intramuscular administration. According to yet another embodiment the administration is orally.
[0091] According to yet another embodiment the administration is intradermal. Needles specifically designed to deposit the vaccine intradermally are known in the art as disclosed for example in 6,843,781 and 7,250,036 among others. According to other embodiments the administration is performed with a needleless injector.
[0092] According to one embodiment of the invention, the vaccine is administered intranasally. The vaccine formulation may be applied to the lymphatic tissue of the nose in any convenient manner. However, it is preferred to apply it as a liquid stream or liquid droplets to the walls of the nasal passage. The intranasal composition can be formulated, for example, in liquid form as nose drops, spray, or suitable for inhalation, as powder, as cream, or as emulsion.
[0093] In another embodiment of the invention, administration is oral and the vaccine may be presented, for example, in the form of a tablet or encased in a gelatin capsule or a microcapsule.
[0094] The formulation of these modalities is general knowledge to those with skill in the art.
[0095] Liposomes provide another delivery system for antigen delivery and presentation. Liposomes are bilayered vesicles composed of phospholipids and other sterols surrounding a typically aqueous center where antigens or other products can be encapsulated. The liposome structure is highly versatile with many types range in nanometer to micrometer sizes, from about 25 nm to about 500 μm. Liposomes have been found to be effective in delivering therapeutic agents to dermal and mucosal surfaces. Liposomes can be further modified for targeted delivery by for example, incorporating specific antibodies into the surface membrane, or altered to encapsulate bacteria, viruses or parasites. The average survival time or half life of the intact liposome structure can be extended with the inclusion of certain polymers, for example polyethylene glycol, allowing for prolonged release in vivo. Liposomes may be unilamellar or multilamellar.
[0096] The vaccine composition may be formulated by: encapsulating an antigen or an antigen/adjuvant complex in liposomes to form liposome-encapsulated antigen and mixing the liposome-encapsulated antigen with a carrier comprising a continuous phase of a hydrophobic substance. If an antigen/adjuvant complex is not used in the first step, a suitable adjuvant may be added to the liposome-encapsulated antigen, to the mixture of liposome-encapsulated antigen and carrier, or to the carrier before the carrier is mixed with the liposome-encapsulated antigen. The order of the process may depend on the type of adjuvant used. Typically, when an adjuvant like alum is used, the adjuvant and the antigen are mixed first to form an antigen/adjuvant complex followed by encapsulation of the antigen/adjuvant complex with liposomes. The resulting liposome-encapsulated antigen is then mixed with the carrier. The term “liposome-encapsulated antigen” may refer to encapsulation of the antigen alone or to the encapsulation of the antigen/adjuvant complex depending on the context. This promotes intimate contact between the adjuvant and the antigen and may, at least in part, account for the immune response when alum is used as the adjuvant. When another is used, the antigen may be first encapsulated in liposomes and the resulting liposome-encapsulated antigen is then mixed into the adjuvant in a hydrophobic substance.
[0097] In formulating a vaccine composition that is substantially free of water, antigen or antigen/adjuvant complex is encapsulated with liposomes and mixed with a hydrophobic substance. In formulating a vaccine in an emulsion of water-in-a hydrophobic substance, the antigen or antigen/adjuvant complex is encapsulated with liposomes in an aqueous medium followed by the mixing of the aqueous medium with a hydrophobic substance. In the case of the emulsion, to maintain the hydrophobic substance in the continuous phase, the aqueous medium containing the liposomes may be added in aliquots with mixing to the hydrophobic substance.
[0098] In all methods of formulation, the liposome-encapsulated antigen may be freeze-dried before being mixed with the hydrophobic substance or with the aqueous medium as the case may be. In some instances, an antigen/adjuvant complex may be encapsulated by liposomes followed by freeze-drying. In other instances, the antigen may be encapsulated by liposomes followed by the addition of adjuvant then freeze-drying to form a freeze-dried liposome-encapsulated antigen with external adjuvant. In yet another instance, the antigen may be encapsulated by liposomes followed by freeze-drying before the addition of adjuvant. Freeze-drying may promote better interaction between the adjuvant and the antigen resulting in a more efficacious vaccine.
[0099] Formulation of the liposome-encapsulated antigen into a hydrophobic substance may also involve the use of an emulsifier to promote more even distribution of the liposomes in the hydrophobic substance. Typical emulsifiers are well-known in the art and include mannide oleate (Arlacel™ A), lecithin, Tween™ 80, Spans™ 20, 80, 83 and 85. The emulsifier is used in an amount effective to promote even distribution of the liposomes. Typically, the volume ratio (v/v) of hydrophobic substance to emulsifier is in the range of about 5:1 to about 15:1.
[0100] Microparticles and nanoparticles employ small biodegradable spheres which act as depots for vaccine delivery. The major advantage that polymer microspheres possess over other depot-effecting adjuvants is that they are extremely safe and have been approved by the Food and Drug Administration in the US for use in human medicine as suitable sutures and for use as a biodegradable drug delivery system (Langer R. Science. 1990; 249(4976):1527-33). The rates of copolymer hydrolysis are very well characterized, which in turn allows for the manufacture of microparticles with sustained antigen release over prolonged periods of time (O'Hagen, et al., Vaccine, 1993; 11:965-9).
[0101] Parenteral administration of microparticles elicits long-lasting immunity, especially if they incorporate prolonged release characteristics. The rate of release can be modulated by the mixture of polymers and their relative molecular weights, which will hydrolyze over varying periods of time. Without wishing to be bound to theory, the formulation of different sized particles (1 μm to 200 μm) may also contribute to long-lasting immunological responses since large particles must be broken down into smaller particles before being available for macrophage uptake. In this manner a single-injection vaccine could be developed by integrating various particle sizes, thereby prolonging antigen presentation and greatly benefiting livestock producers.
[0102] In some applications an adjuvant or excipient may be included in the vaccine formulation. Montanide™ (Incomplete Freund's adjuvant) and alum for example, are preferred adjuvants for human use. The choice of the adjuvant will be determined in part by the mode of administration of the vaccine. A preferred mode of administration is intramuscular administration. Another preferred mode of administration is intranasal administration. Non-limiting examples of intranasal adjuvants include chitosan powder, PLA and PLG microspheres, QS-21, ASO2A, calcium phosphate nanoparticles (CAP); mCTA/LTB (mutant cholera toxin E112K with pentameric B subunit of heat labile enterotoxin), and detoxified E. Coli derived labile toxin.
[0103] The adjuvant used may also be, theoretically, any of the adjuvants known for peptide- or protein-based vaccines. For example: inorganic adjuvants in gel form (aluminium hydroxide/aluminium phosphate, Warren et al., 1986; calcium phosphate, Relyvelt, 1986); bacterial adjuvants such as monophosphoryl lipid A (Ribi, 1984; Baker et al., 1988) and muramyl peptides (Ellouz et al., 1974; Allison and Byars, 1991; Waters et al., 1986); particulate adjuvants such as the so-called ISCOMS (“immunostimulatory complexes”, Mowat and Donachie, 1991; Takahashi et al., 1990; Thapar et al., 1991), liposomes (Mbawuike et al. 1990; Abraham, 1992; Phillips and Emili, 1992; Gregoriadis, 1990) and biodegradable microspheres (Marx et al., 1993); adjuvants based on oil emulsions and emulsifiers such as IFA (“Incomplete Freund's adjuvant” (Stuart-Harris, 1969; Warren et al., 1986), SAF (Allison and Byars, 1991), saponines (such as QS-21; Newman et al., 1992), squalene/squalane (Allison and Byars, 1991); synthetic adjuvants such as non-ionic block copolymers (Hunter et al., 1991), muramyl peptide analogs (Azuma, 1992), synthetic lipid A (Warren et al., 1986; Azuma, 1992), synthetic polynucleotides (Harrington et al., 1978) and polycationic adjuvants (WO 97/30721).
[0104] Adjuvants for use with immunogens of the present invention include aluminum or calcium salts (for example hydroxide or phosphate salts). A particularly preferred adjuvant for use herein is an aluminum hydroxide gel such as Alhydrogel™. Calcium phosphate nanoparticles (CAP) is an adjuvant being developed by Biosante, Inc (Lincolnshire, Ill.). The immunogen of interest can be either coated to the outside of particles, or encapsulated inside on the inside (He et al., 2000, Clin. Diagn. Lab. Immunol., 7, 899-903).
[0105] Another adjuvant for use with an immunogen of the present invention is an emulsion. A contemplated emulsion can be an oil-in-water emulsion or a water-in-oil emulsion. In addition to the immunogenic chimer protein particles, such emulsions comprise an oil phase of squalene, squalane, peanut oil or the like as are well known, and a dispersing agent. Non-ionic dispersing agents are preferred and such materials include mono- and di-C 12 -C 24 -fatty acid esters of sorbitan and mannide such as sorbitan mono-stearate, sorbitan mono-oleate and mannide mono-oleate.
[0106] Such emulsions are for example water-in-oil emulsions that comprise squalene, glycerol and a surfactant such as mannide mono-oleate (Arlacel™ A), optionally with squalane, emulsified with the chimer protein particles in an aqueous phase. Alternative components of the oil-phase include alpha-tocopherol, mixed-chain di- and tri-glycerides, and sorbitan esters. Well-known examples of such emulsions include Montanide™ ISA-720, and Montanide™ ISA 703 (Seppic, Castres, France. Other oil-in-water emulsion adjuvants include those disclosed in WO 95/17210 and EP 0 399 843.
[0107] The use of small molecule adjuvants is also contemplated herein. One type of small molecule adjuvant useful herein is a 7-substituted-8-oxo- or 8-sulfo-guanosine derivative described in U.S. Pat. No. 4,539,205, U.S. Pat. No. 4,643,992, U.S. Pat. No. 5,011,828 and U.S. Pat. No. 5,093,318. 7-allyl-8-oxoguanosine(loxoribine) has been shown to be particularly effective in inducing an antigen-(immunogen-) specific response.
[0108] A useful adjuvant includes monophosphoryl lipid A (MPL®), 3-deacyl monophosphoryl lipid A (3D-MPL®), a well-known adjuvant manufactured by Corixa Corp. of Seattle, formerly Ribi Immunochem, Hamilton, Mont. The adjuvant contains three components extracted from bacteria: monophosphoryl lipid (MPL) A, trehalose dimycolate (TDM) and cell wall skeleton (CWS) (MPL+TDM+CWS) in a 2% squalene/Tween™ 80 emulsion. This adjuvant can be prepared by the methods taught in GB 2122204B.
[0109] Other compounds are structurally related to MPL® adjuvant called aminoalkyl glucosamide phosphates (AGPs) such as those available from Corixa Corp under the designation RC-529™ adjuvant {2-[(R)-3-tetra-decanoyloxytetradecanoylamino]-ethyl-2-deoxy-4-O-phosphon-o-3-O—[(R)-3-tetradecanoyloxytetra-decanoyl]-2-[(R)-3-tetra-decanoyloxytet-radecanoyl-amino]-p-D-glucopyranoside triethylammonium salt}. An RC-529 adjuvant is available in a squalene emulsion sold as RC-529SE and in an aqueous formulation as RC-529AF available from Corixa Corp. (see, U.S. Pat. No. 6,355,257 and U.S. Pat. No. 6,303,347; U.S. Pat. No. 6,113,918; and U.S. Publication No. 03-0092643).
[0110] Further contemplated adjuvants include synthetic oligonucleotide adjuvants containing the CpG nucleotide motif one or more times (plus flanking sequences) available from Coley Pharmaceutical Group. The adjuvant designated QS21, available from Aquila Biopharmaceuticals, Inc., is an immunologically active saponin fractions having adjuvant activity derived from the bark of the South American tree Quillaja Saponaria Molina (e.g. Quil™ A), and the method of its production is disclosed in U.S. Pat. No. 5,057,540. Derivatives of Quil™ A, for example QS21 (an HPLC purified fraction derivative of Quil™ A also known as QA21), and other fractions such as QA17 are also disclosed. Semi-synthetic and synthetic derivatives of Quillaja Saponaria Molina saponins are also useful, such as those described in U.S. Pat. No. 5,977,081 and U.S. Pat. No. 6,080,725. The adjuvant denominated MF59 available from Chiron Corp. is described in U.S. Pat. No. 5,709,879 and U.S. Pat. No. 6,086,901.
[0111] Muramyl dipeptide adjuvants are also contemplated and include N-acetyl-muramyl-L-threonyl-D-isoglutamine (thur-MDP), N-acetyl-nor-muramyl-L-alanyl-D-isoglutamine (CGP 11637, referred to as nor-MDP), and N-acetylmuramyl-L-alanyl-D-isoglutaminyl-L-alanine-2-(1′-2′-dipalmityol-s-n-glycero-3-hydroxyphosphoryloxy) ethylamine ((CGP) 1983A, referred to as MTP-PE). The so-called muramyl dipeptide analogues are described in U.S. Pat. No. 4,767,842.
[0112] Other adjuvant mixtures include combinations of 3D-MPL and QS21 (EP 0 671 948 B1), oil-in-water emulsions comprising 3D-MPL and QS21 (WO 95/17210, PCT/EP98/05714), 3D-MPL formulated with other carriers (EP 0 689 454 B1), QS21 formulated in cholesterol-containing liposomes (WO 96/33739), or immunostimulatory oligonucleotides (WO 96/02555). Adjuvant SBAS2 (now AS02) available from SKB (now Glaxo-SmithKline) contains QS21 and MPL in an oil-in-water emulsion is also useful. Alternative adjuvants include those described in WO 99/52549 and non-particulate suspensions of polyoxyethylene ether (UK Patent Application No. 9807805.8).
[0113] The use of an adjuvant that contains one or more agonists for toll-like receptor-4 (TLR-4) such as an MPL® adjuvant or a structurally related compound such as an RC-529® adjuvant or a Lipid A mimetic, alone or along with an agonist for TLR-9 such as a non-methylated oligo deoxynucleotide-containing the CpG motif is also optional.
[0114] Another type of adjuvant mixture comprises a stable water-in-oil emulsion further containing aminoalkyl glucosamine phosphates such as described in U.S. Pat. No. 6,113,918. Of the aminoalkyl glucosamine phosphates the molecule known as RC-529 {(2-[(R)-3-tetradecanoyloxytetradecanoylamino]ethyl 2-deoxy-4-O-phosphono-3-O—[(R)-3-tetradecanoyloxy-tetradecanoyl]-2-[(R)-3-tetradecanoyloxytetra-decanoylamino]-p-D-glucopyranoside triethylammonium salt.)} is preferred. One particular water-in-oil emulsion is described in WO 99/56776.
[0115] Adjuvants are utilized in an adjuvant amount, which can vary with the adjuvant, host animal and immunogen. Typical amounts can vary from about 1 μg to about 1 mg per immunization. Those skilled in the art know that appropriate concentrations or amounts can be readily determined.
[0116] Vaccine compositions comprising an adjuvant based on oil in water emulsion is also included within the scope of the present invention. The water in oil emulsion may comprise a metabolisable oil and a saponin, such as for example as described in U.S. Pat. No. 7,323,182.
[0117] According to several embodiments, the vaccine compositions according to the present invention may contain one or more adjuvants, characterized in that it is present as a solution or emulsion which is substantially free from inorganic salt ions, wherein said solution or emulsion contains one or more water soluble or water-emulsifiable substances which is capable of making the vaccine isotonic or hypotonic. The water soluble or water-emulsifiable substances may be, for example, selected from the group consisting of: maltose; fructose; galactose; saccharose; sugar alcohol; lipid; and combinations thereof.
[0118] The compositions of the present invention comprise according to several specific embodiments a proteosome adjuvant. The proteosome adjuvant comprises a purified preparation of outer membrane proteins of meningococci and similar preparations from other bacteria. These proteins are highly hydrophobic, reflecting their role as transmembrane proteins and porins. Due to their hydrophobic protein-protein interactions, when appropriately isolated, the proteins form multi-molecular structures consisting of about 60-100 nm diameter whole or fragmented membrane vesicles. This liposome-like physical state allows the proteosome adjuvant to act as a protein carrier and also to act as an adjuvant.
[0119] The use of proteosome adjuvant has been described in the prior art and is reviewed by Lowell GH in “New Generation Vaccines”, Second Edition, Marcel Dekker Inc, New York, Basel, Hong Kong (1997) pages 193-206. Proteosome adjuvant vesicles are described as comparable in size to certain viruses which are hydrophobic and safe for human use. The review describes formulation of compositions comprising non-covalent complexes between various antigens and proteosome adjuvant vesicles which are formed when solubilizing detergent is selectably removed using exhaustive dialysis technology.
[0120] The present invention also encompasses within its scope the preparation and use of DNA vaccines. Vaccination methods and compositions of this type are well known in the art and are comprehensively described in many different articles, monographs and books (see, for example, chapter 11 of “Molecular Biotechnology: principles and applications of recombinant DNA” eds. B. R. Glick & J. J. Pasternak, ASM Press, Washington, D.C., 2 nd edition, 1998). In principle, DNA vaccination is achieved by cloning the cDNAs for the desired immunogen into a suitable DNA vaccine vector, such as the pVAC vector (Invivogen), using codons optimized for expression in human. In the case of pVAC, the desired immunogenic proteins are targeted and anchored to the cell surface by cloning the gene of interest in frame between the IL2 signal sequence and the C-terminal transmembrane anchoring domain of human placental alkaline phosphatase. The use of other immune enhancers, including adjuvants or cloning in frame other immune enhancing cytokines, together with the DNA vaccines is also within the scope of the present invention. Such DNA vaccine vectors are specifically designed to stimulate humoral immune responses by intramuscular injection. The antigenic peptide produced on the surface of muscle cells is taken up by antigen presenting cells (APCs), processed and presented to the immune system T helper cells through the major histocompatibility complex (MHC) class II molecules.
[0121] Oral liquid preparations may be in the form of, for example, aqueous or oily suspension, solutions, emulsions, syrups or elixirs, or may be presented dry in tablet form or a product for reconstitution with water or other suitable vehicle before use. Such liquid preparations may contain conventional additives such as suspending agents, emulsifying agents, non-aqueous vehicles (which may include edible oils), or preservative.
[0122] The aforementioned adjuvants are substances that can be used to augment a specific immune response. Normally, the adjuvant and the composition are mixed prior to presentation to the immune system, or presented separately, but into the same site of the subject being vaccinated. Adjuvants that may be usefully employed in the preparation of vaccines include: oil adjuvants (for example, Freund's complete and incomplete adjuvants, that will be used in animal experiments only and is forbidden from use in humans), mineral salts, alum, silica, kaolin, and carbon, polynucleotides and certain natural substances of microbial origin. An additional mode of antigen delivery may include an encapsulation technique, which involves complex coacervation of gelatin and chondroitin sulfate (Azhari R, Leong K W. 1991. Complex coacervation of chondroitin sulfate and gelatin and its use for encapsulation and slow release of a model protein. Proc. Symp. Control. Rel. 18: 617; Brown K E, Leong K, Huang C H, Dalal R, Green G D, Haimes H B, Jimenez P A, Bathon J. 1998. Gelatin/chondroitin 6-sulfate microspheres for delivery of therapeutic proteins to the joint. Arthritis Rheum 41: 2185-2195).
[0123] Further examples of materials and methods useful in the preparation of vaccine compositions are well known to those skilled in the art. In addition, further details may be gleaned from Remington's Pharmaceutical Sciences, Mack Publishing Co, Easton, Pa., USA, 20 th edition 2000.
[0124] The S. pneumoniae cell-wall and/or cell-membrane proteins for use in working the present invention may be obtained by directly purifying said proteins from cultures of S. pneumoniae by any of the standard techniques used to prepare and purify cell-surface proteins. Suitable methods are described in many biochemistry text-books, review articles and laboratory guides, including inter alia “Protein Structure: a practical approach” ed. T. E. Creighton, IRL Press, Oxford, UK (1989).
[0125] However, it is to be noted that such an approach suffers many practical limitations that present obstacles for producing commercially-viable quantities of the desired proteins. The S. pneumoniae proteins of the present invention may therefore be more conveniently prepared by means of recombinant biotechnological means, whereby the gene for the S. pneumoniae protein of interest is isolated and inserted into an appropriate expression vector system (such as a plasmid or phage), which is then introduced into a host cell that will permit large-scale production of said protein by means of, for example, overexpression.
[0126] As a first stage, the location of the genes of interest within the S. pneumoniae genome may be determined by reference to a complete-genome database such as the TIGR database that is maintained by the Institute for Genomic Research. The selected sequence may, where appropriate, be isolated directly by the use of appropriate restriction endonucleases, or more effectively by means of PCR amplification. Suitable techniques are described in, for example, U.S. Pat. Nos. 4,683,195, 4,683,202, 4,800,159, 4,965,188, as well as in Innis et al. eds., PCR Protocols: A guide to method and applications. Alternatively, the gene may be chemically synthesized with codons optimized to the expression system actually used (i.e. E. coli ). For DNA vaccines, codons are optimized for expression in human.
[0127] Following amplification and/or restriction endonuclease digestion, the desired gene or gene fragment is ligated either initially into a cloning vector, or directly into an expression vector that is appropriate for the chosen host cell type. In the case of the S. pneumoniae proteins, Escherichia coli is the most useful expression host. However, many other cell types may be also be usefully employed including other bacteria, yeast cells, insect cells and mammalian cell systems known in the art.
[0128] High-level expression of the desired protein (as intact protein sequence, modified protein sequence, fragment of thereof), within the host cell may be achieved in several different ways (depending on the chosen expression vector) including expression as a fusion protein (e.g. with factor Xa or thrombin), expression as a His-tagged protein, dual vector systems, expression systems leading to incorporation of the recombinant protein inside inclusion bodies etc. The recombinant protein will then need to be isolated and purified from the cell membrane, interior cellular soluble fraction, inclusion body or (in the case of secreted proteins) the culture medium, by one of the many methods known in the art.
[0129] All of the above recombinant DNA and protein purification techniques are well known to all skilled artisans in the field, the details of said techniques being described in many standard works including “Molecular cloning: a laboratory manual” by Sambrook, J., Fritsch, E. F. & Maniatis, T., Cold Spring Harbor, N.Y., 2 nd ed., 1989, which is incorporated herein by reference in its entirety.
[0130] As disclosed and explained hereinabove, each of the abovementioned embodiments of the invention may be based on the use of one or more intact, full length, cell wall and/or cell membrane proteins or, in the alternative, or in addition thereto, fragments, derivatives and modifications of said full length proteins. Fragments may be obtained by means of recombinant expression of selected regions of the cell wall protein gene(s). Derivatives of the full length proteins or fragments thereof may be obtained by introducing non-native sequences within the DNA sequences encoding said proteins, followed by expression of said derivatized sequences. Derivatives may also be produced by conjugating non-native groups to the amino residue side chains of the cell wall proteins or protein fragments, using standard protein modification techniques. Modified cell wall proteins and protein fragments for use in the present invention may also be obtained by the use of site-directed mutagenesis techniques. Such techniques are well known in the art and are described, for example, in “Molecular cloning: a laboratory manual” by Sambrook, J., Fritsch, E. F. & Maniatis, T., Cold Spring Harbor, N.Y., 2 nd ed., 1989. Of particular interest is the use of one or more of the preceding techniques to create fragments or derivatives possessing the desired epitopic sites, but lacking other domains which are responsible for adverse effects such as suppression of cellular immune responses. It is to be emphasized that all of the immediately preceding discussion of fragments, derivatives and mutants of the cell wall proteins disclosed herein are to be considered as an integral part of the present invention.
[0131] S. pneumoniae infections are common in children under the five years of age mainly under two years of age. The infants' antibody production is known to be produced at 6 months of age. The present invention is based in part on a study performed with sera obtained longitudinally from children at 18, 30 and 42 months of age, attending day care centers, which are exposed to the bacteria. The children's sera were screened for change, with age, of the presence or amount of antibodies to specific cell wall/membrane proteins. Antibodies to specific proteins which were absent or low in sera of younger children and appear or increase with age identified proteins that now would be considered as candidate for vaccine development for protecting infants against S. pneumoniae . Without wishing to be bound to any theory it is suspected that the immune response of younger children to the proteins in the context of the bacterium is also not efficient. Since the increase in the response to these proteins is in reciprocal correlation with disease it was assumed that immunization with these proteins will elicit a protective immune response. Each of the proteins in the set disclosed for the first time in the present application as being associated with age-dependent immune response to the bacteria may elicit protective immune response against the bacteria at all ages to all subjects, including infants, elderly and immunocompromised subjects.
[0132] PPP enzymatic function occurs in the cytoplasm, however, it was found also to localize to the cell-wall and to the cytoplasmic membrane. FabD, an enzyme that is involved in lipid metabolism, could be found in the cytoplasm only but could not be found in the cell wall, further suggesting that under the experimental conditions used the cell-wall localization of PPP does not result from a non-specific leakage. Moreover, live unencapsulated bacteria could be stained with an anti-PPP monoclonal antibody, further suggesting that PPP is cell-wall localized. Membrane localization of PPP observed in immunoblots may result from its intracellular enzymatic activity in the PTS system, which occurs near to or at the inner leaflet of the cytoplasmic membrane.
[0133] The cell-wall residence, age-dependent immunogenicity, conservation among pneumococcal strains and adhesin activity support the vaccine potential of PPP. Immunization with rPPP reduced nasopharyngeal and lung colonization and reduced mortality upon challenge.
[0134] The observations that PPP resides in the cell-wall, demonstrates age-dependent antigenicity, and inhibits adhesion suggest that it could be a candidate vaccine antigen.
EXAMPLES
[0135] The following examples are provided for illustrative purposes and in order to more particularly explain and describe the present invention. The present invention, however, is not limited to the particular embodiments disclosed in the examples.
Example 1
[0136] Prevention of S. pneumoniae Infection in Mice by Inoculation with S. pneumoniae Cell Wall Protein Fractions
Methods:
[0137] Bacterial Cells: The bacterial strain used in this study was an S. pneumoniae serotype 3 strain and R6. The bacteria were plated onto tryptic soy agar supplemented with 5% sheep erythrocytes and incubated for 17-18 hours at 37° C. under anaerobic conditions. The bacterial cells were then transferred to Todd-Hewitt broth supplemented with 0-5% yeast extract and grown to mid-late log phase. Bacteria were harvested and the pellets were stored at −70° C.
[0138] Purification of Cell Wall Proteins: Bacterial pellets were resuspended in phosphate buffered saline (PBS). The resulting pellets were then treated with mutanolysin to release cell wall components. Supernatants containing the CW proteins were then harvested. Subsequently, the bacteria were sonicated, centrifuged and the resulting pellet containing the bacteria membranes (m) were lysed with 0.5% TRITON™ X-100.
[0139] Fractionation of the Cell Wall Protein Mixture: Cell wall protein-containing supernatants were allowed to adhere to fetuin (a highly glycosylated pan-lectin binding protein) that was covalently bound to a sepharose column. Non-adherent molecules, obtained from the flow-through fraction were predominantly non-lectin molecules, while the column-adherent lectins were eluted with 50 mM ammonium acetate at pH 3.5.
[0140] Experimental: S. pneumoniae cell wall (CW) proteins were separated into lectin (CW-L) and non-lectin (NL) fractions by fetuin affinity chromatography, as described hereinabove. C57BL/6 and BALB/c mice were vaccinated with S. pneumoniae total CW (CW-T), CW-L and CW-NL protein preparations mixed with Freund's adjuvant, by means of the following procedure: each mouse was primed with 25 micrograms of CW-T, CW-NL and CW-L protein preparations intramuscularly, with complete Freund's adjuvant (CFA) and boosted with incomplete Freund's adjuvant (IFA), 4 and 7 weeks following priming. Western blots of the abovementioned protein preparations were probed with sera obtained a week after the last immunization. Animals were then challenged intranasally (IN) or intraperitoneally (IP) with 10 8 cfu of S. pneumoniae serotype 3, that caused 100% mortality in control mice immunized with CFA and boosted with IFA only within 96 hours post-inoculation. Vaccination with CW-L elicited partial protection against S. pneumoniae IN and IP challenge (50% and 45% respectively). Vaccination with CW-T and CW-NL proteins elicited 70% and 65% protection against IP challenge, respectively. Vaccination with CW-T and CW-NL proteins elicited 85% and 50% protection against IN inoculation, respectively.
Example 2
Determination of Age-Related Immunoreactivity to S. pneumoniae Surface Proteins
[0141] The following study was carried out in order to investigate the age-related development of immunoreactivity to S. pneumoniae cell wall and cell membrane proteins.
[0142] Operating as described hereinabove in Example 1, a fraction containing cell wall proteins was obtained from a clinical isolate of S. pneumoniae . In addition, cell membrane proteins were recovered by solubilizing the membrane pellet in 0.5% TRITON™ X-100. The cell wall and cell membrane proteins were separated by means of two-dimensional gel electrophoresis, wherein the proteins were separated using polyacrylamide gel isoelectric focusing in one dimension, and sodium dodecyl sulfate polyacrylamide gel electrophoresis (SDS-PAGE) in the other dimension. The separated proteins were either transferred to a nitrocellulose membrane or directly stained with COOMASSIE BRILLIANT BLUE™.
[0143] Sera were collected longitudinally from healthy children attending day-care centers at 18, 30 and 42 months of age. Starting at 12 months of age, nasopharyngeal swabs were taken from the children on a bimonthly schedule over the 2.5 years of the study. Pneumococcal isolates were characterized by inhibition with optochin and a positive slide agglutination test (Phadebact, Pharmacia Diagnostics). In addition, sera were collected from healthy adults.
[0144] The ability of serum prepared from the above-mentioned blood samples to recognize the separated S. pneumoniae proteins was investigated by Western blot analysis according to the methods described by Rapola S. et al. (J. Infect. Dis., 2000, 182: 1146-52). Putative identification of the separated protein spots obtained following the 2D-electrophoresis was achieved by the use of the Matrix Assisted Laser Desorption/Ionization mass spectrometry (MALDI-MS). The results of the above analysis are summarized in the following table:
[0000]
TABLE 1
Age-dependent immunoreactivity to S. pneumoniae surface proteins
Spot
Proteins/
Age (years)
no.
spot
Homology to
1.5
2.5
3.5
adult
1
2
DNA K/phosphoenolpyruvate protein
*
*
*
*
Phosphoesterase
3
1
Trigger factor
*
*
*
*
4
2
60 KDa chaperonin (GroEl protein) Eleongation factor
**
*
**
***
G/tetracycline resistance protein teto (TET(O))
7
2
Glutamyl-tRNA amidotransferase subunit
*
**
* * *
A/N utilization sybstance protein protein A
11
2
Oligopeptide-binding protein amiA/aliA/aliB
precursor
Hypothetical zinc metalloproteinase in SCAA
5′ region (ORF 6)
12
1
Pneumolysin (thiol-activated cytolysin
*
*
**
13
1
L-lactate dehydrogenase
*
**
*
14
1
Glyceraldehyde 3-phosphate dehydrogenase
*
**
***
***
(GAPDH)
15
1
Fructose-bisphosphate aldolase
**
***
***
***
16
1
UDP-glucose 4-epimerase
**
*
17
2
Elongation factor G/tetracycline resistance
*
**
protein teto (TET(O))
18
1
Pyruvat oxidase
***
***
***
***
22
1
Glutamyl-tRNA synthetase
*
**
23
1
NADP-specific glutamate dehydrogenase
*
*
*
24
1
Glyceraldehydes 3-phosphate dehydrogenase
*
**
***
****
(GAPDH)
25
1
Enolase (2-phosphoglycerate dehydratase)
*
**
**
**
27
1
Phosphoglycerate kinase
*
**
**
**
29
1
Glucose-6-phosphate isomerase
*
*
**
30
2
40S ribosomal protein
S1/6-phosphogluconate dehydrogenase
31
1
Aminopeptidase C
33
Carbamoyl-phosphate synthase
*
**
***
57/65
Aspartate carbamoyltransferase
*
*
**
**
58
30S ribosomal protein S2
**
*
[0145] The data presented in the preceding table indicate that there is an age-dependent development of immunoreactivity to several S. pneumoniae cell wall and cell surface proteins.
[0146] Ling et al. (Clin. Exp. Immunol. 138:290-298, 2004) further describes identification of S. pneumoniae vaccine candidates. As shown in table 2, it was found that the antigenic proteins from the enriched cell wall extract fell into three groups. The first group comprised proteins with low immunogenicity. The second group consists of antigens for which the immunogenicity seemed to increase with age of children attending day-care centers, while the third group of proteins was highly antigenic with all sera tested. The existence of serum antibodies to a certain bacterial protein does not necessarily indicate their capacity to elicit protective immune response against the bacteria. However, the increase in the antibody response to bacterial proteins which coincides with the diminution in morbidity described in children encouraged to test these antigens for their ability to elicit protection against S. pneumoniae . It is concluded that the immunogenic enzymes with an age dependent increase in antigenicity of S. pneumoniae found in enriched cell wall and membrane extract may represent a novel class of vaccine candidates. As shown herein for the first time many of these identified proteins/enzymes elicit protective level immune responses in mice and afford significant protection against respiratory challenge with virulent S. pneumoniae .
[0000]
TABLE 2
Identification of S. pneumoniae surface proteins with age-dependent immunogenicity
Immunoreactivity
MALDI-TOF analysis
Age (months)
Spot
Homology
Acc. number
Mascot
MW
pI
1.5
2.5
3.5
Adult
Proteins with low immunogenicity
1
DNA K
NP_345035
173
64.8
4.6
*
*
23
NADP-specific
NP_345769
186
49
5.3
*
*
*
glutamate dehydrogenase
Proteins with increased immunogenicity
7
Glutamyl-tRNA
NP_344959
83
52
4.9
*
**
**
***
Amidotransferase subunit
A
13
L-lactate dehydrogenase
NP_345686
134
35.9
5.2
*
**
*
**
14
Glyceraldehyde 3-
NP_346439
350
37.1
5.7
*
**
***
***
phosphate dehydrogenase
15
Fructose-bisphosphate
NP_345117
106
31.5
5
**
***
***
***
aldolase
16
UDP-glucose 4-
NP_346051
116
37.5
4.8
**
*
*
**
epimerase
22
Glutamyl-tRNA
NP_346492
194
56
4.9
*
**
**
synthetase
27
Phosphoglycerate kinase
NP_345017
109
41.9
4.9
*
**
**
**
29
Glucose-6-phosphate
NP_346493
96
51.3
5.2
*
*
**
isomerase
30
6-phosphogluconate
NP_344902
58
53.7
4.9
**
**
dehydrogenase
31
Aminopeptidase C
NP_344819
120
33.7
4.8
**
**
x
Hypothetical protein
NP_358083
15
5.2
*
**
33
Carbamoyl-phosphate
NP_345739
230
116.5
4.8
*
**
***
synthase
65
Aspartate
NP_345741
44
34.7
5.1
*
*
**
**
carbamoyltransferase
Proteins with high immunogenicity
18
Pyruvate oxidase
NP_345231
168
65.3
5.1
***
***
***
***
25
Enolase (2-
NP_345598
215
47.1
4.7
**
**
**
**
phosphoglycerate
dehydratase)
[0147] The extent of surface protein recognition by the sera was determined by the optical density as measured by the imager used in our study (αInnotech). *Low; **intermediate; ***high
Example 3
Prevention of S. pneumoniae Infection in Mice with Recombinantly-Expressed S. pneumoniae Cell Surface Proteins
[0148] Glycolytic enzymes associated with the cell surface of Streptococcus pneumoniae are antigenic in humans and elicit protective immune responses in the mouse.
[0149] The glycolytic enzymes fructose-bisphosphate aldolase (FBA, NP — 345117, SEQ ID NO: 13), and Glyceraldehide 3 phosphate dehydrogenase (GAPDH, NP 346439, SEQ ID NO:12), which are associated with the cell surface of S. pneumoniae , were used to immunize mice against S. pneumonia as described in Ling et al., Clin. Exp. Immunol. 138:290-298. 2004. It was shown that both proteins, which are antigenic in humans, elicit cross-strain protective immunity in mice.
[0150] Cloning of Immunogenic S. pneumoniae Surface Proteins: S. pneumoniae fructose-bisphosphate aldolase (hereinafter referred to as “aldolase”) and GAPDH proteins were cloned into the pHAT expression vector (BD Biosciences Clontech, Palo Alto, Calif., USA; HAT Vectors encode polyhistidine epitope tag in which the 6 histidine are not consecutive: Lys Asp His Leu Ile His Asn Val His Lys Glu His Ala His Ala His Asn Lys (SEQ ID NO:36)), and expressed in E. coli BL21 cells (Promega Corp., USA) using standard laboratory procedures. Following lysis of the BL21 cells, recombinant proteins were purified by the use of immobilized metal affinity chromatography (IMAC) on Ni-NTA columns (Qiagen) and eluted with imidazole. In a separate set of experiments, S. pneumoniae aldolase cDNAs were cloned into the pVAC expression vector (Invivogen), a DNA vaccine vector specifically designed to stimulate a immune response by intramuscular injection. Antigenic proteins are targeted and anchored to the cell surface by cloning the gene of interest in frame between the IL2 signal sequence and the C-terminal transmembrane anchoring domain of human placental alkaline phosphatase. The antigenic peptide produced on the surface of muscle cells is taken up by antigen presenting cells (APCs) and processed to be presented to the T helper cells by the major histocompatibility complex (MHC) class II molecules.
[0151] Immunization: BALB/c and C57BL/6 mice (7 week old females) were intraperitonealy immunized with 25 micrograms of either recombinant aldolase or recombinant GAPDH proteins together with either Freund's complete adjuvant (CFA) or an alum adjuvant. In a separate set of experiments, mice of the aforementioned strains were intramuscularly immunized with 50 micrograms of the pVAC-aldolase or pVAC-GAPDH constructs that were described hereinabove.
[0152] Assessment of Immunogenicity: The immunogenicity of recombinant S. pneumoniae aldolase and GAPDH proteins was assessed by Western blot assay using serum of mice that had been immunized with either total cell wall proteins (CW-T) or with one of the recombinant proteins (as described hereinabove). The results obtained ( FIG. 1 ) indicate that the sera of the immunized animals recognized both recombinant GAPDH and aldolase proteins, and the native GAPDH and aldolase proteins present in the CW-T mixture.
[0153] In a separate set of experiments the serum of mice that had been immunized with DNA vaccines of pVAC-aldolase or pVAC-GAPDH constructs, as described above, was used to detect native aldolase and GAPDH, respectively in Western blots obtained from SDS-PAGE separations of CW-T proteins. The results obtained ( FIG. 2 ) indicate that inoculation with the DNA vaccines containing pVAC-based constructs is capable of eliciting an immune response. Sera of mice vaccinated with the parental pVAC plasmid (i.e. without insert) did not react with the CW-T proteins.
[0154] Protective Vaccination: Following immunization with the recombinant proteins as described hereinabove, the mice were challenged intranasally with a lethal dose of 10 8 CFU of S. pneumoniae serotype 3. Only 10% of the control animals (immunization with either CFA or alum only) survived the bacterial challenge. However, 40% of the animals immunized with the recombinant aldolase protein in CFA and 43% of the animals immunized with the same protein in alum survived the challenge. In contrast, immunization with the protein DNA K, having low immugenicity (table 2) did not elicit a protective immune response. Following immunization with the pVAC-aldolase construct, 33% of the animals survived. With regard to recombinant GAPDH, 36% of the animals immunized with this recombinant protein survived. Immunization with the pVAC-GAPDH construct, led to a survival rate of 40%, as shown in FIG. 3 .
Example 4
S. pneumoniae Immunogenic Proteins
[0155] Operating essentially as in Example 2, the ability of serum prepared from blood samples of children aged 1.5, 2.5 and 3.5 years and adults to recognize the separated S. pneumoniae proteins was investigated by Western blot analysis according to the methods described by Rapola S. et al. (J. Infect. Dis., 2000, 182: 1146-52).
[0156] Identification of the separated protein spots obtained following the 2D-electrophoresis was achieved by the use of the Matrix Assisted Laser Desorption/Ionization mass spectrometry (MALDI-MS) technique, and comparison of the partial amino acid sequences obtained thereby with the sequences contained in the TIGR4 and/or R6 databases (maintained by The Institute for Genomic Research).
[0157] The cell surface proteins found to be immunogenic (classified according to their cellular location—cell membrane or cell wall) are summarized in the following table:
[0000]
TABLE 3
list of immunogenic proteins
Accession
SEQ
Spot #
Protein name
No.
ID NO
1
phosphoenolpyruvate protein phosphotransferase
NP_345645
4
2
phosphoglucomutase/phosphomannomutase family
NP_346006
5
protein
3
trigger factor
NP_344923
6
4
elongation factor G/tetracycline resistance protein
NP_344811
7
(tetO)
6
NADH oxidase
NP_345923
8
7
Aspartyl/glutamyl-tRNA amidotransferase subunit C
NP_344960
9
8
cell division protein FtsZ
NP_346105
10
13
L-lactate dehydrogenase
NP_345686
11
14
glyceraldehyde 3-phosphate dehydrogenase (GAPDH)
NP_346439
12
15
fructose-bisphosphate aldolase
NP_345117
13
16
UDP-glucose 4-epimerase
NP_346261
14
elongation factor Tu family protein
NP_358192
15
21
Bifunctional GMP synthase/glutamine amidotransferase
NP_345899
16
protein
22
glutamyl-tRNA synthetase
NP_346492
17
23
glutamate dehydrogenase
NP_345769
18
26
Elongation factor TS
NP_346622
19
27
phosphoglycerate kinase (TIGR4)
AAK74657
20
30
30S ribosomal protein S1
NP_345350
21
6-phosphogluconate dehydrogenase
NP_357929
22
31
aminopeptidase C
NP_344819
23
33
carbamoyl-phosphate synthase (large subunit)
NP_345739
24
57
PTS system, mannose-specific IIAB components
NP_344822
25
58
30S ribosomal protein S2
NP_346623
26
62
dihydroorotate dehydrogenase 1B
NP_358460
27
65
aspartate carbamoyltransferase catalytic subunit
NP_345741
28
14
elongation factor Tu
NP_345941
29
19
Pneumococcal surface immunogenic protein A (PsipA)
NP_344634
30
22
phosphoglycerate kinase (R6)
NP_358035
31
40
ABC transporter substrate-binding protein
NP_344690
32
10
endopeptidase O
NP_346087
33
14
Pneumococcal surface immunogenic protein B (PsipB)
NP_358083
34
Pneumococcal surface immunogenic protein C (PsipC)
NP_345081
35
Example 5
Preparation of an S. pneumoniae Fructose Bisphosphate Aldolase Fragment
[0158] A peptide referred to as ALDO 1, corresponding to the first 294 nucleotides of the coding sequence of the fructose bisphosphate aldolase gene (SP0605 Streptococcus pneumoniae TIGR 4) (SEQ ID NO:1), was amplified from S. pneumoniae strain R6 genomic DNA by means of PCR with the following primers:
[0000]
(SEQ ID NO: 2)
3 Forward (5′-GGT ACC ATG GCA ATC GTT TCA GCA-3′),
(SEQ ID NO: 3)
Reverse (5′-GAG CTC ACC AAC TTC GAT ACA CTC AAG-3′).
[0159] The amplified product obtained thereby is shown in FIG. 4 .
[0160] The Forward and Reverse primers, constructed according to the TIGR4 sequence contain Kpn1 and SacI recognition sequences, respectively. The primers flank the entire open reading frames.
[0161] The primers were used to amplify the gene from S. pneumoniae serotype 3 strain WU2. The amplified and Kpn1-SacI (Takara Bio Inc, Shiga, Japan) digested DNA-fragments were cloned into the pHAT expression vector (BD Biosciences Clontech, Palo Alto, Calif., USA; as described in Example 3), as illustrated in FIG. 5 and transformed in DH5a UltraMAX ultracompetent E. coli cells.
[0162] Ampicillin-resistant transformants were cultured and plasmid DNA was analyzed by PCR. The pHAT-ALDO 1 vector was purified from DH5.alpha. UltraMAX cells using the Qiagen High Speed Plasmid Maxi Kit (Qiagen GMBH, Hilden, Germany) and transformed in E. coli host expression strain BL21(DE3)pLysS. PCR amplification of the ALDO 1 fragment from transformed positive colonies yielded the 297 by fragment indicated in the gel shown in FIG. 6 .
Example 6
Cloning, Expressing and Purification of Recombinant Phosphoenolpyruvate Protein Phosphotransferase (PPP) Proteins
[0163] Two genetically unrelated encapsulated S. pneumoniae strains, serotype 2 strain D39 (Avery 1995, Mol Med 1: 344-365) and serotype 3 strain WU2 (Briles 1981, J Exp Med 153: 694-705) were used together with their unencapsulated derivatives, strain R6 (ATCC, Rockville Md.) and strain 3.8DW (Watson at al., 1990, Infect Immun 58: 3135-3138). Pneumococci were grown in THY or on blood agar plates as previously described (Mizrachi Nebenzahl, et al., 2004, FEMS Microbiol Lett 233: 147-152). Two Escherichia coli strains were used, DH5α UltraMAX (DH5α; Invitrogen Corp, Carlsbad, Calif., USA) and BL21(DE3)pLysS (BL21; Promega Corp, Madison, Wis., USA) and were grown in lysogeny broth (LB).
[0164] The nucleotide sequence of the NP — 345645 PPP protein was amplified from pneumococcal serotype 3 strain WU2 genomic DNA according to the published sequence of serotype 4 strain TIGR4 by PCR with the following primers:
[0165] Forward: 5′-GGATCCATGACAGAAATGCTTAAAG-3′ (SEQ ID NO:36) and Reverse 5′-GAGCTCTTAATCAAAATTAACGTATTC-3′ (SEQ ID NO:37) (supplemented with restriction enzyme sequences of BamHI (Takara Biomedicals, Otsoshiga, Japan) on the 3′ end and Sac1 on the 5′ end (Takara Biomedicals, Otsoshiga, Japan). The amplified product was cloned into the pHAT expression vector (BD Biosciences Clontech, Palo Alto, Calif., USA), and protein expression and purification were performed as previously described (Mizrachi Nebenzahl, et al., 2007 ibid). Verification of sequence identity was performed by plasmid insert sequencing. The tagged-purified protein was resolved by SDS-polyacrylamide gel electrophoresis (PAGE). Pneumococcal cell-wall proteins were separated by SDS-PAGE under reducing conditions and transferred to nitrocellulose membranes (Bio-Rad, Carlsbad, Calif., USA) as previously described (Ausubel F, 1989). Separation showed that the 75 kDa HAT-PPP fusion protein was ˜95% pure. The rPPP. The identity of PPP was further confirmed by immunoblot analysis using either rabbit anti-PPP antiserum or human sera. Immunoblotting with anti-HAT antibodies confirmed the identity of the protein sequence was verified by MALDI-TOF analysis as previously described using a Bruker Reflex-IV mass spectrometer (Bruker-Daltonik, Bremen, Germany) (Portnoi, et al., 2006, Vaccine 24: 1868-1873). MALDI-TOF analysis of this protein band identified rPPP in 99% accordance with the expected PPP protein (PI=4.6, Mascot score=92, Z score=2.43, extent of sequence coverage=39).
[0000] Immunization of Rabbits with rPPP
[0166] Three-month-old white albino rabbits (Harlan Laboratories, Israel) were initially immunized intramuscularly (IM) with 200 μg HAT-rPPP emulsified with complete Freund's adjuvant (CFA) (1:1) in the first immunization or with incomplete Freund's adjuvant (IFA) in booster immunizations. Two weeks after their final immunization rabbits were exsanguinated and sera prepared.
Surface Expression and Conservation of PPP in Different Pneumococcal Strains
[0167] To analyze surface expression and conservation, immunoblot analysis of cell-wall and membrane protein fractions from several pneumococcal strains using anti-rPPP antisera was performed. PPP was found to reside both in the cell-wall and in the membranes of different strains ( FIG. 17A ). The differences found in the molecular weight of PPP may result from post-translation modifications. In contrast to PPP, no cell-wall residence could be found for the rFabD protein ( FIG. 17B ).
[0168] Alignment of the protein sequence from the R6 strain with the published pneumococcal strains sequences, performed using both the Mascot software package (Matrix Science Ltd., UK) and Profound program (Rockefeller Univ.), demonstrated homology with >99% identity and 100% positivity with no gaps.
[0169] Flow cytometry analysis performed as previously described (Mizrachi Nebenzahl, et al., 2007 ibid) with the R6 bacteria strain probed with anti-PPP mAbs demonstrated PPP surface expression. Strain R6 bacteria were incubated with anti-rPPP mAb or pre-immune mouse serum, washed, and stained with Alexa Fluor 647-conjugated goat-anti-mouse-IgG (Jackson ImmunoResearch, West Grove, Pa.). Flow cytometry was performed using a FACSCalibur flow cytometer (Becton Dickinson, Mountain View, Calif.), and data were acquired and analyzed using BD CellQuest™ 3.3 software.
Age-Dependent Immunogenicity of PPP
[0170] In previous studies, a group of cell-wall proteins demonstrated age-dependent antigenicity in children. To test whether PPP belongs to this group, rPPP was immunoblotted with pediatric sera. Sera were collected longitudinally at 18, 30 and 42 months of age from healthy children attending day-care centers. Nasopharyngeal swabs were taken from the children bimonthly starting at 12 months of age for the entire 3.5-year duration of the study, and episodes of carriage of different serotype strains were documented (Lifshitz, et al., 2002, Clin Exp Immunol 127: 344-353). Increased PPP antigenicity was observed at 24 months relative to 7 and 12 months with variable recognition at 38 months of age ( FIG. 18 ).
[0000] Active Immunization with PPP Reduces Nasopharyngeal and Lung Colonization Upon Intranasal Challenge
[0171] Seven-week-old BALB/cOlaHsd (BALB/c) female mice (Harlan Laboratories, Israel) or seven-week-old CBA/CaHN-Btk xid J(CBA/Nxid; Jackson Laboratories, Bar Harbor, Me., USA) mice were housed in sterile conditions under 12-h light/dark cycles and fed Purina Chow and tap water ad libitum.
[0172] BALB/c or CBA/Nxid mice were immunized subcutaneously (SC) with 5 or 25 μg rPPP or a 25-μg NL fraction as positive control (Portnoi, et al., 2006 ibid), emulsified with CFA and boosted (days 14 and 28) with IFA. One week after third immunization the mice were anesthetized with Terrel isoflurane (MINRAD, NY, USA) and inoculated intranasally (IN) on day 42 with a sublethal dose (5×10 7 ) of S. pneumoniae Serotype 3 strain WU2. Mice were sacrificed by cervical dislocation 3 and 48 h later, and the nasopharynx (NP) and right lobe lung were excised, homogenized and samples were plated onto blood agar plates for bacterial enumeration. After a similar immunization regimen, BALB/c mice were challenged IN with a lethal dose (10 8 CFU) of strain WU2, and mortality was monitored daily.
[0173] Mice immunized with rPPP demonstrated a significant reduction in colonization at 3 h ( FIG. 7A ) and 48 h ( FIG. 7B ) after inoculation with strain WU2 and at 48 h ( FIGS. 7C and D) after inoculation with strain D39. Immunization with rPPP reduced mortality in BALB/c following an IN lethal challenge with WU2 strain (p<0.05, FIG. 7E ).
Adhesion is Mediated by PPP
[0174] To analyze whether PPP is involved in pneumococcal interaction with the host, the ability of rPPP to inhibit pneumococcal adhesion to cells was tested. A549 cells (type II epithelial lung carcinoma cells; ATCC, Rockville, Md., USA) or Detroit562 cells (pharyngeal carcinoma derived cells; ATCC, Rockville, Md., USA) were cultured on fibronectin-coated 96-well plates (2.5×10 4 cells/well) in DMEM (without antibiotics). Experiments were conducted in triplicate with rPPP (0-600 nM) as previously described (Blau, et al., 2007, J Infect Dis 195: 1828-1837). Inhibition of adhesion to A549 cells by anti-rPPP antibodies was also performed.
[0175] In a dose-dependent manner, rPPP significantly inhibited the adhesion of strain WU2 and its unencapsulated derivative strain 3.8DW and of D39 and its unencapsulated derivative strain R6. Rabbit anti-rPPP antisera significantly inhibited the adhesion of strains WU2 and 3.8DW. Mouse anti-rPPP antisera significantly inhibited the adhesion of strains D39 and R6 in a dose-dependent manner.
Example 7
Active Immunization with Glutamyl tRNA Synthetase
[0176] Active immunization with Glutamyl tRNA synthetase (GtS, NP — 346492, SEQ ID NO: 17) using alum as adjuvant is described in Mizrachi et al., J Infect Dis. 196,945-53, 2007. The cloning of the gene was by amplification of the gene using primers constructed according to the TIGR4 sequence and the gene was amplified from S. pneumoniae serotype 3 strain WU2. The amplified gene was inserted into the pHAT vector as described in Example 3.
[0177] Thirty-nine percent of rGtS-immunized mice survived a lethal bacterial challenge, whereas no control mice survived. The results suggested that GtS, an age-dependent S. pneumoniae antigen, is capable of inducing a partially protective immune response against S. pneumoniae in mice. Active immunization with rGtS using CFA as adjuvant: BALB/c mice were immunized three times IM with 10 μg of rGtS in CFA/IFA/IFA in 3 weeks intervals. Mice were subsequently challenged with S. pneumoniae serotype 3 strain WU2. Survival was monitored up to 8 days after challenge. As depicted in FIG. 8 , sixty percent of immunized mice survived the intranasal lethal challenge as opposed to 20% of adjuvant immunized (control) mice.
Example 8
Active Immunization with NADH Oxidase (NOX)
[0178] The cloning of the gene was by amplification of the gene using primers constructed according to the R6 sequence and the gene was amplified from S. pneumoniae R6. The amplified gene was inserted into the pHAT vector as described in Example 3.
[0179] BALB/c mice were IP immunized with 25 μg of rNOX protein (NP — 345923, SEQ ID NO: 8), 10 μg of a mixture of non-lectin (NL) proteins as a positive control and adjuvant only as a negative control. The immunizations were performed in the presence of CFA in the first immunization and IFA in the following 2 booster immunizations given in two weeks intervals. Mice were subsequently challenged with a lethal dose of S. pneumoniae serotype 3 strain (WU2). Survival was monitored daily for 7 days. While only 50% of control mice survived the bacterial challenge 100% of NL immunized and 92% of rNOX immunized mice survived the challenge as shown in FIG. 9 .
Example 9
[0180] Passive immunization with Pneumococcal surface immunogenic protein B (PsipB; NP — 358083, SEQ ID NO:34). The cloning of the gene was by amplification of the gene using primers constructed according to the TIGR4 sequence and the gene was amplified from S. pneumoniae serotype 3 strain WU2. The amplified gene was inserted into the pHAT vector as described in Example 3.
[0181] BALB/c mice were IP passively immunized two times with 100 μl of anti-PsipB antiserum 24 and 3 hours prior to bacterial challenge. Mice were IP challenged with S. pneumoniae strain 3 (WU2). Survival was monitored up to 7 days. Administration of either anti PsipB antiserum or the anti NL antisera protected the mice (80 and 70% respectively, FIG. 10 ) from a lethal challenge, while the control (preimmune) serum did not protect the mice from such challenge.
Example 10
Active Immunization with Trigger Factor (TF, NP 344923, SEQ ID NO:6)
[0182] The cloning of the gene was by amplification of the gene using primers constructed according to the TIGR4 sequence and the gene was amplified from S. pneumoniae strain R6. The amplified gene was inserted into the pET32a+ vector lacking the thioredoxin sequence. The vector contain a 5.7kDs tag protein which contains 6 consecutive histidines.
[0183] BALB/c mice were IP immunized (three times; CFA/IFA/IFA) with 25 μg of TF. Mice were subsequently challenged IN with S. pneumoniae serotype 3 strain WU2. Survival was monitored for 21 days. 25 μg TF elicited a protective immune response against a lethal challenge (80%) while mice immunized with adjuvant only were not protected (19% and 23 survival, respectively, FIG. 11 )
Example 11
FtsZ Cell Division Protein (NP — 346105, SEQ ID NO:10)
[0184] The cloning of the gene was by amplification of the gene using primers constructed according to the TIGR4 sequence and the gene was amplified from S. pneumoniae strain R6. The amplified gene was inserted into the pET32a+ vector lacking the thioredoxin sequence. The vector contain a 5.7kDs tag protein which contains 6 consecutive histidines.
[0185] BALB/c mice were IP challenged with S. pneumoniae serotype 3 strain WU2 after 1 hour neutralization with rabbit anti-FtsZ antiserum, preimmune serum or anti NL serum. Survival was followed up to 7 days. Both the anti FtsZ and the anti NL antisera protected the mice from a lethal challenge (50% and 86%, respectively), while the preimmune serum protected 30% of the challenged mice ( FIG. 12 ).
Example 12
PTS System, Mannose-Specific IIAB Components NP — 344822, SEQ ID NO:25)
[0186] The cloning of the gene was by amplification of the gene using primers constructed according to the TIGR4 sequence and the gene was amplified from S. pneumoniae strain R6. The amplified gene was inserted into the pET32a+ vector lacking the thioredoxin sequence. The vector contain a 5.7kDs tag protein which contains 6 consecutive histidines.
[0187] BALB/c mice were IP challenged with S. pneumoniae strain 3(WU2) after 1 hour neutralization with rabbit anti-PTS antiserum. Survival was followed up to 7 days. Both the anti PTS and the anti NL antisera protected the mice from a lethal challenge (40 and 100%, respectively), while only 10% of mice survived following challenge with bacteria pretreated with preimmune serum ( FIG. 13 ).
Example 13
Vaccination with 6-Phosphogluconate Dehydrogenase (6PGD, NP357929, SEQ ID NO:22)
[0188] Use of 6PGD for inducing protective immune response in mice was described in Daniely et al., 144:254-63. 2006. Immunization of mice with r6PGD protected 60% of mice for 5 days and 40% of the mice for 21 days following intranasal lethal challenge, while none of the control mice survived the same challenge after four days.
Example 14
Active Immunization with Elongation Factor G (EFG, NP344811, SEQ ID NO:7)
[0189] The cloning of the gene was by amplification of the gene using primers constructed according to the R6 sequence and the gene was amplified from S. pneumoniae strain S. pneumoniae serotype 3 strain WU2. The amplified gene was inserted into the pHAT vector lacking the thioredoxin sequence. The vector contains a 5.7kDs tag protein which contains 6 consecutive histidines.
[0190] BALB/c mice were immunized IP with 25 μg of EFG in the presence of Alum. Mice were subsequently challenged IN with S. pneumoniae serotype 3 strain WU2. Survival was monitored for 21 days. As shown in FIG. 14 , EFG elicited a protective immune response against a lethal challenge in 30% of the mice, while all control mice, immunized with adjuvant only, succumbed 5 days following the bacterial challenge.
Example 15
Clinical Studies
[0191] The first Phase 1 study is performed in 20-25 adults, testing the candidate vaccine for safety and immunogenicity. The second Phase 1 study evaluates 2 or 3 dosage levels of the vaccine in groups of 20-25 infants each for safety and immunogenicity.
[0192] The first Phase 2 study is performed in 100-150 infants at a developed world site using the dosage level chosen in Phase 1, and evaluates safety and immunogenicity as well as obtain more information about a potential surrogate assay. The second Phase 2 study at a developed world site is performed in 300-500 in infants in multiple sites, and evaluates interactions with other concomitant vaccines for extended safety and immunogenicity. The third Phase 2 study is performed in parallel 200 infants at the developing world location at which the Phase 3 efficacy study performed, to confirm immunogenicity and safety before Phase 3.
[0193] The Phase 3 efficacy study would be performed in a developing world site in 50,000 infants as a placebo-controlled double-blind study with a clinical endpoint.
[0194] The Phase 3 immunogenicity study would be performed in parallel in a developed world site using 3 different lots of final manufacturing-scale vaccine in 4 groups of 200 infants each. The Phase 3 safety study would be performed in parallel in 10,000 infants in developed world sites.
Example 16
Verification of Immunogenicity and Age-Dependency of Nox and GtS
[0195] To verify that GtS induces an age-dependent immune response, sera from 3 healthy children attending day care centers (with documented episodes of carriage of different S. pneumoniae serotypes) were obtained longitudinally between 18-42 months of age. A representative series revealing quantitative and qualitative enhancement of antibody responses to rGtS protein over time is shown in FIG. 15 . The rGtS protein was undetected by the infants' sera at 18 and slightly detected at 30 months of age. Maximal detection of rGtS with the children's sera was observed at 42 months of age. Sera obtained from a healthy adult detected rGtS to the highest extent.
[0196] Immunoblot analysis of rNOX with sera obtained longitudinally from children attending day-care centers demonstrated age-dependent enhancement in protein recognition in all 3 children ( FIG. 16 ).
[0197] While specific embodiments of the invention have been described for the purpose of illustration, it will be understood that the invention may be carried out in practice by skilled persons with many modifications, variations and adaptations, without departing from its spirit or exceeding the bounds of the present invention. | Vaccine compositions and methods for protecting a mammalian subject against infection with S. pneumoniae are disclosed. These vaccine compositions include as the active ingredient a purified preparation of the cell wall protein ABC transporter substrate-binding protein having the Accession No. NP_344690 and the amino acid sequence set forth in SEQ ID NO: 32, optionally together with one or more pharmaceutically acceptable adjuvants. | 2 |
[0001] This patent issues from a continuing application which claims priority from International Patent Application Ser. No. PCT/EP03/00674 which was filed on Apr. 10, 2002, which is hereby incorporated by reference in its entirety.
FIELD OF THE DISCLOSURE
[0002] This disclosure relates generally to firearm housings, and, more particularly, to methods and apparatus to lock a dust cover in a firearm housing.
BACKGROUND
[0003] In the following disclosure, positional terms such as “above” and “below” are used with reference to a gun in its normal firing position, that is, positioned to shoot “forward” (away from the shooter) in a generally horizontal plane.
[0004] Dust covers for hand-held firearms have long been known in the art, especially from their use with handguns that have a housing. Example uses include covering the magazine opening, (e.g., the automatic pistol MAS Mod. 1938) or the ejection opening (e.g., the combat rifle 44) of the firearm. In the case of a magazine dust cover, the dust cover employs a mechanical locking device such as a simple catch piece that may be opened and closed by hand. In the case of an ejection opening dust cover, the action of a spring causes the dust cover to open automatically when the moving breechblock opens the mechanical locking device. When not firing or when handling the gun, the ejection door may be closed by hand.
[0005] In traditional guns, the housing is made of steel or sheet metal that is sufficiently rigid to ensure a faultless operation of the locking device, even if the housing is constantly stressed by the spring when the dust cover is in the closed position.
[0006] Modern guns, however, often employ a plastic housing in which an expanded metal insert is added proximate to the locking device so that the locking device will seat properly. With improvements in design and construction, plastic housings have become more and more lightweight and, accordingly, more and more flexible. As a result, a housing of this type becomes temporarily deformed in a noticeable manner if, for example, the gun falls on the ground or strikes a solid obstacle with sufficient force. This deformation can cause the locking device to disengage in an undesired manner, so that the aforementioned cover opens just when the danger of foreign object entry is especially great. For example, dirt may enter the uncovered opening if the gun were to impact with a hard surface, such as a floor.
[0007] In housings with two ejection openings (for right-handed or left-handed marksmen), the opening that is not in use should remain closed in order to prevent possible damage that could otherwise result from, for example, sand or dust entering the gun. Moreover, as a general rule during operation, the marksman checks the used ejection opening only, and does not check the unused one.
[0008] To improve operation, expanded reinforcements could be embedded around the ejection opening and into the dust covers. However, these measures would be counter-productive because they would cause an increase in the weight of the housing. Another option would be to redesign the locking device so that it supports larger tolerances. This would mean, however, an increase in the cost of the firearm. Also, the required space is often not available.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a schematic illustration of the truncated, rear part of an example semi-automatic rifle that is constructed in the so-called Bullpup configuration.
DETAILED DESCRIPTION
[0010] FIG. 1 is a schematic illustration of the truncated, rear part of an example semi-automatic rifle that is constructed in the so-called Bullpup configuration. In this example, the rifle has a housing 1 that surrounds the breechblock and its motion path (not shown in the figure). The housing 1 ends directly behind the aforementioned motion path. A floor plate 3 sits on the rear side of the housing 1 and, thus, directly borders the rear end of the motion path of the breechblock. Thus, to a certain extent, the rear stock that is traditional in sporting rifles has been left out of the figure. A magazine 5 is arranged on the underside of the housing 1 near the floor plate 3 . The handle piece (not shown in the figure) is located in front of the magazine 5 .
[0011] A first dust cover 7 is visible above the magazine 5 . This dust cover 7 is activated for left-handed marksmen. A second dust cover for right-handed marksmen is arranged on the opposite side (not shown) of the housing 1 and is a mirror image of the first dust cover 7 .
[0012] The dust cover 7 covers an ejection opening 17 . This opening is partially visible in the figure because the dust cover 7 is shown in a partially cutaway view. The dust cover 7 is generally rectangular. An axle 11 extends beneath and parallel to the underside edge of the opening 17 . The underside of the dust cover 7 is pivotably mounted to the axle 11 . The free upper edge 9 of the dust cover 7 extends approximately parallel to the underside edge of the cover 7 .
[0013] In the illustrated example, a continuous, multiply crimped, and highly ferromagnetic steel sheet metal strip 13 is inserted into the side of the dust cover 7 that faces the housing. The strip 13 is oriented parallel to the upper edge 9 of the dust cover 7 . Because of its crimping, the strip either emerges from the dust cover 7 or lies close to the surface of the dust cover 7 at a minimum of three points. One of these points is located approximately in the middle of the upper edge 9 . Another of these points is near the front edge of the dust cover 7 . The last point is near the rear edge of the dust cover 7 . In the illustrated example, the strip 13 is manufactured together with the dust cover 7 in a composite casting. The free parts of the strip 13 are treated on the surface (e.g., bonded, phosphatized, or the like) in order to prevent rusting.
[0014] Proximate to each point of the strip 13 that emerges or lies close to the surface of the dust cover, a magnetic pin 15 is inserted into the wall of the housing 1 above the ejection opening 17 . The magnetic pins 15 may be flush with a facing surface of the housing 1 , or may even project slightly above the embedded plastic of the housing 1 . Magnetic pins 15 and strip 13 are constructed and arranged so that they lie flat against each other when the dust cover 7 is closed.
[0015] An inner contour of the opening 17 is constructed to complement the outer contour of the dust cover 7 (taking into account tolerances). Opposite this inner contour, however, the actual opening is made as a shoulder in the housing wall at least in the area of the magnet pins 15 , so that the closed dust cover 7 sits on this shoulder, but, in addition, borders flush with the outer surface of the housing 1 (except for the area of the axle 11 ). Thus, interfering edges, which could lead to untimely detachment of the magnetic lock, are avoided. An application of force from the outside, which could cause an untimely opening of the dust cover 7 , is also prevented.
[0016] From the preceding description, one possessing ordinary skill in the art will appreciate the advantages of the illustrated device. For example, a magnetic lock employing a metal strip 13 and magnetic pins 15 as the locking mechanism is simple,cost-effective, and achieves reliable locking of the dust cover or covers 7 on a hand-held firearm or handgun, even if the housing 1 becomes deformed as a result of an applied force, e.g., as a result of dropping the weapon.
[0017] Magnetic locks have long been known for use in furniture and appliances, such as refrigerators. However, these magnetic locks are considered to be low-quality, whereas high-quality furniture typically employs mechanical locks. The magnetic locks in refrigerators function primarily for the purpose of ensuring that children who become trapped in the refrigerator can free themselves by simply pushing on the door, which would often not be possible if a mechanical lock had been engaged. As a result of this history, the stigma of a lesser locking function is still associated with the magnetic lock.
[0018] However, a magnetic lock is far superior to a mechanical lock under certain conditions in a handgun, such as, if the parts held together do not consist entirely of ferromagnetic material. Specifically, if the breechblock of the gun consists mostly of ferromagnetic material and is moved closely past the disclosed magnetic lock, the magnetic holding force of the lock will not significantly impede the breechblock movement because the lock is embedded on all sides in plastic. Furthermore, a magnetic lock can be constructed in such a way that it acts over a long distance, thus preventing a possibly existent magnetic field of the breechblock from simultaneously affecting the entire magnetic lock. If the illustrated magnetic lock is accidentally disengaged (e.g., if the housing 1 is temporarily deformed), it will also shut itself again. For example, if an edge 9 of the dust cover 7 moves outwardly due to a deformation of the housing 1 , the edge 9 is pulled shut again after the deformation is removed. Thus, the projecting edge 9 will not cause the lock to disengage.
[0019] The dust cover 7 can cover more than one opening. For example, the dust cover 7 may cover the magazine opening and/or another opening (such as one provided for the storage of a cleaning tool or the like) in the gun. Preferably, however, the dust cover 7 is located to cover an ejection opening 17 for cartridge shells, and the recoil movement of the breechblock opens the magnetic lock securing the dust cover 7 .
[0020] It would be possible to construct the dust cover 7 out of sheet metal and to embed one or more magnets into the opposing housing 1 . However, it is disadvantageous to manufacture a sheet metal cover of this type because it is more costly than a plastic cover, as the latter does not require any finishing work. Moreover, a sheet metal cover is considerably heavier than a plastic cover. Therefore, the illustrated example magnetic lock has at least one strip 13 made of ferromagnetic material inserted into the dust cover 7 near its free edge 9 . Opposite the strip 13 , at least one magnetic pin 15 is inserted into the housing 1 of the gun, whereby the longitudinal axis of the pin 15 extends perpendicularly or approximately perpendicularly to the strip 13 .
[0021] The strip 13 is made of ferromagnetic material—usually steel sheet metal—and, thus, reinforces the dust cover 7 (which is made of plastic) to a significant extent. Thus, a lightweight construction is achieved, which, moreover, is quite rigid in the areas that are subject to the magnetic effect. The stability of the dust cover 7 is, therefore, ensured, which results in good action of the magnetic lock.
[0022] If the ferromagnetic strip 13 is viewed as a plane, then the axis of the pin-shaped magnets and/or magnetic pins 15 extends in a generally perpendicular manner relative to the strip 13 . A magnetic pin 15 is quite lightweight and acts as a local reinforcement of the housing 1 . Also, it is possible to manufacture extremely powerful magnets in the form of relatively small pins using sintering technology. Thus, the magnetic pins 15 may be injected, adhered or welded into the housing 1 . The embedding of the magnetic pin 15 by at least its width into the plastic housing 1 protects its sintered compact from breaking into pieces due to forceful impacts or the like. Even if broken, the embedded pieces will remain at the desired site and position in the housing 1 and, thus, retain their magnetic effect.
[0023] In experiments it has proven advantageous to allocate at least three magnetic pins 15 to the dust cover or each dust cover 7 . A strip 13 made of ferromagnetic material is inserted into the dust cover 7 opposite each magnetic pin 15 .
[0024] To illustrate an example firearm, consider a rather large caliber cartridge, such as a long shotgun cartridge of the caliber 12 , which corresponds to an example dust cover 7 that can be approximately 90 mm long and approximately 25 mm high. This dust cover 7 may be made (aside from the strip or strips 13 inserted into the dust cover) entirely out of plastic. The three magnetic pins 15 act as a reinforcement of the upper edge of the ejection opening 17 . In the area of the ejection opening 17 , the plastic housing 1 may be designed so that it is at times double-walled. In such a case, the magnetic pins 15 are preferably embedded solidly in both wall layers.
[0025] It can be advantageous to have adjacent magnetic pins 15 oriented so that alternating, opposite poles point to the outside of the housing 1 , or that all magnetic pins 15 point to the outside with the same pole. The preferred arrangement depends on whether a single sheet metal strip 13 is inserted in the upper edge of the dust cover 9 which opens to the bottom, or whether a different steel sheet metal strip 13 is allocated to each magnet.
[0026] Although certain example methods and apparatus have been described herein, the scope of coverage of this patent is not limited thereto. On the contrary, this patent covers all methods and apparatus fairly falling within the scope of the appended claims either literally or under the doctrine of equivalents. | Methods and apparatus to lock a dust cover in a firearm housing are disclosed. An example firearm disclosed herein comprises a housing constructed substantially from non-magnetic material and defining an opening; a dust cover to cover the opening in the housing, the dust cover being pivotable between an open position and a closed position; and a magnetic lock to secure the dust cover in the closed position. | 5 |
This Application is a continuation of prior application Ser. No. 09/218,503 filed Dec. 22, 1998 (now abandoned).
FIELD OF THE INVENTION
The present invention relates generally to intravascular stents for implanting into a living body. In particular, the present invention relates to intravascular stents that are expanded by an inflatable balloon catheter and to a method and apparatus for mounting and securing a stent on a balloon catheter.
BACKGROUND OF THE INVENTION
Intravascular stents having a constricted diameter for delivery through a blood vessel and an expanded diameter for applying a radially outwardly extending force for supporting the blood vessel are known in the art. Selfexpandable articulated stents are described, for example, in U.S. Pat. No. 5,104,404, entitled “Articulated Stent” to Wolff. Balloon expandable articulated stents are commercially available under the trade name Palmaz-Schatz Balloon-Expandable stents from Johnson & Johnson International Systems Co.
In conventional stent mounting and securing procedures, the stent is usually first slid over the distal end of a balloon catheter so that the expandable balloon is disposed within the longitudinal bore of the stent. The stent is then crimped or pinched to mount or secure the stent and maintain its position with respect to the expandable balloon as the balloon catheter is advanced to the target area. This crimping is often done utilizing the fingers or a plier-like device to pinch the stent. One shortcoming of this conventional mounting and securing means is that it often produces irregular distortion of the stent which could cause trauma to the lumen being treated. Another shortcoming is that it may weaken a portion or portions of the stent which could result in stent failure. Yet another shortcoming of conventional mounting and securing methods is that they may distort the stent in such a way as to cause the stent to expand in the target area in a non-uniform manner which could result in a portion of the lumen not being properly supported.
Yet another shortcoming of conventional mounting and securing methods is irregular distortion of the stent could produce protrusions in the stent which could cause trauma to the patient.
Therefore, it would be highly desirable to have a method and an apparatus that permits a stent to be secured over the expandable balloon of a balloon catheter without causing irregular distortion or weakening the stent.
OBJECTS AND SUMMARY OF THE INVENTION
It is an object of this invention to provide an apparatus for securing a stent on a balloon catheter by substantially uniformly distorting the stent.
It is another object of this invention to provide an apparatus for securing a stent on a balloon catheter that reduces the likelihood that the stent will expand in a nonuniform manner.
It is yet another object of this invention to provide a method of securing a stent on a balloon catheter that reduces the likelihood that the stent will be weakened by the securing procedure.
It is a further object of this invention to provide an apparatus for securing a stent on a balloon catheter, comprising:
a) a first clamping portion provided with a first clamping portion recess, said first clamping portion recess sized and adapted to receive a stent crimping sleeve;
b) a second clamping portion provided with a second clamping portion recess, said second clamping portion recess sized and adapted to receive a stent crimping sleeve, said first clamping portion recess and said second clamping portion recess defining a longitudinal stent crimping sleeve channel having a variable cross-sectional diameter, said first and said second clamping portions adapted for movement in a first direction away from each other to a first position and in a second direction toward each other to a second position to selectively impart pressure to a stent crimping sleeve disposed in said longitudinal stent crimping sleeve channel, said clamping portion recesses sized and adapted so that said longitudinal stent crimping sleeve channel has a substantially circular cross-sectional diameter when said first and said second clamping portions are in said second position;
c) a stent crimping sleeve disposed in said crimping sleeve channel, said sleeve having a first end, a second end, an outer surface, and an inner surface defining a longitudinal stent crimping bore therethrough, said longitudinal stent crimping bore having a selectively variable-substantially circular cross-sectional diameter and sized and adapted to receive a balloon catheter with a stent mounted thereon, said stent crimping sleeve further adapted to selectively and substantially uniformly vary said substantially circular cross-sectional diameter of said longitudinal stent crimping bore in response to pressure applied to said external surface of said stent crimping sleeve by said first clamping portion and said second clamping portion when said first clamping portion and said second clamping portion are moved in said second direction.
It is still another object of this invention to provide a method of securing an expandable stent having a longitudinal bore on a balloon catheter, comprising the steps of:
a) constructing an apparatus comprising: a first clamping portion provided with a first clamping portion recess, said first clamping portion recess sized and adapted to receive a stent crimping sleeve; a second clamping portion provided with a second clamping portion recess, said second clamping portion recess sized and adapted to receive a stent crimping sleeve, said first clamping portion recess and said second clamping portion recess defining a longitudinal stent crimping sleeve channel having a variable cross-sectional diameter, said first and said second clamping portions adapted for movement in a first direction away from each other to a first position and in a second direction toward each other to a second position to selectively impart pressure to a stent crimping sleeve disposed in said longitudinal stent crimping sleeve channel, said clamping portion recesses sized and adapted so that said longitudinal stent crimping sleeve channel has a substantially circular cross-sectional diameter when said first and said second clamping portions are in said second position; a stent crimping sleeve having a first end, a second end, an outer surface, and an inner surface defining a longitudinal stent crimping bore therethrough having a selectively variable substantially circular cross-sectional diameter and sized and adapted to receive a balloon catheter with a stent mounted thereon, said stent crimping sleeve further adapted to selectively and substantially uniformly vary said substantially circular cross-sectional diameter of said longitudinal stent crimping bore in response to pressure applied to said external surface of said stent crimping sleeve by said first clamping portion and said second clamping portion;
b) disposing said stent crimping sleeve in said stent crimping sleeve channel;
c) disposing said stent in said longitudinal stent crimping bore of said stent crimping sleeve;
d) disposing said balloon catheter in said longitudinal bore of said stent; and
e) moving said first and said second stent clamping portions from said first position to said second position so as to apply pressure to said external surface of said stent crimping sleeve in an amount sufficient to decrease the substantially circular cross-sectional diameter of said longitudinal stent crimping bore in an amount sufficient for said inner surface of said stent crimping sleeve to impart sufficient pressure to said stent to secure said stent to said balloon catheter.
It is a further object of this invention to provide an apparatus for securing a stent on a balloon catheter, comprising:
a) a first clamping portion having a first clamping portion recess and a second clamping portion having a second clamping portion recess, said first and said second clamping portion recesses defining a longitudinal stent crimping element channel with a variable cross-sectional diameter, said first and said second clamping portions adapted for movement in a first direction away from each other to a first position and in a second direction toward each other to a second position;
b) a plurality of crimping elements disposed within said longitudinal stent crimping element channel defining a stent crimping sleeve channel having a variable cross-sectional diameter, said plurality of crimping elements adapted for movement in a first direction away from each other to a first position and in a second direction toward each other to a second position; and
c) a stent crimping sleeve disposed in said longitudinal stent crimping sleeve channel, having a first end, a second end, an outer wall, and an inner wall defining a longitudinal bore therethrough having a selectively variable substantially circular cross-sectional diameter, said clamping portions said crimping elements, and said sleeve adapted and disposed so that when said first clamping portion, said second clamping portion, and said plurality of crimping elements are disposed in the second position, said crimping elements define a longitudinal stent crimping sleeve channel having a substantially circular crosssectional diameter and said longitudinal stent crimping bore defines a longitudinal bore having a substantially circular cross-sectional diameter.
It is a yet another object of this invention to provide an apparatus for securing a stent on a balloon catheter, comprising:
a) a first clamping portion and a second clamping portion, said first clamping portion provided with a first surface, a second surface and a third surface defining a first clamping portion recess, said second clamping portion provided with a first surface, a second surface, a third surface, a fourth surface and a fifth surface defining a second clamping portion recess, said first and said second clamping portion recesses defining a longitudinal stent crimping element channel with a variable diameter, said first and said second clamping portions adapted for movement in a first direction away from each other to a first position and in a second direction toward each other to a second position;
b) a first crimping element disposed within said longitudinal stent crimping element channel said first crimping element provided with a first crimping element contact surface, a second crimping element contact surface, a first clamping portion contact surface, and a stent crimping sleeve contact surface;
c) a second crimping element disposed within said longitudinal stent crimping channel, said second crimping element provided with a first crimping element contact surface, a second crimping element contact surface, a first clamping portion contact surface, and a stent crimping sleeve contact surface;
d) a third crimping element disposed within said longitudinal stent crimping channel, said third crimping element provided with a first crimping element contact surface, a second crimping element contact surface, a second clamping portion contact surface, and a stent crimping sleeve contact surface;
e) a fourth crimping element disposed within said longitudinal stent crimping channel, said fourth crimping element provided with a first crimping element contact surface, a second crimping element contact surface, a second clamping portion contact surface, and a stent crimping sleeve contact surface, said crimping elements adapted for movement in a first direction away from each other to a first position and in a second direction towards each other to a second position, said stent crimping sleeve contact surfaces defining a stent crimping sleeve channel having a variable cross-sectional diameter that is substantially circular—when said plurality of crimping elements are disposed in said second position; and
f) a stent crimping sleeve disposed in said longitudinal stent crimping sleeve channel, said sleeve having a first end, a second end, an outer wall, and an inner wall defining a longitudinal bore therethrough having a selectively variable substantially circular crosssectional diameter, said clamping portions, said crimping elements, and said sleeve adapted and disposed so that when said first clamping portion and said second clamping portion are in the second position, said crimping sleeve contact surfaces define a stent crimping sleeve channel having a substantially circular cross-sectional diameter and said longitudinal bore defines a longitudinal bore having a substantially circular cross-sectional diameter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of a stent placed on a balloon catheter before the stent has been secured to the balloon;
FIG. 2 is a side view of the stent of FIG. 1 after the stent has been secured to the balloon utilizing conventional securing methods;
FIG. 3 is a cross-sectional end view of a stent securing apparatus constructed in accordance with this invention with the clamping portions disposed in a first or non-securing position;
FIG. 4 is a cross-sectional end view of a stent securing apparatus constructed in accordance with this invention with the clamping portions disposed in a second or securing position;
FIG. 5 is a cross-sectional side view of a stent crimping sleeve constructed in accordance with the invention;
FIG. 6 is an end view of the stent crimping sleeve shown in FIG. 5;
FIG. 7 is a cross-sectional side view of the stent crimping sleeve of FIGS. 5 and 6 with the balloon catheter and stent of FIG. 1 disposed within it prior to the stent being secured to the balloon;
FIG. 8 is an end view of FIG. 7;
FIG. 9 shows the stent crimping sleeve shown in FIGS. 5 and 6 disposed between the first and second clamping portions with the first and second clamping portions disposed in a first or non-securing position;
FIG. 10 shows the stent crimping sleeve shown on FIGS. 5 and 6 disposed between the first and second clamping portions with the first and second clamping portions moved to a second or securing position;
FIG. 11 shows the stent of FIG. 1 secured to the balloon catheter after being secured in accordance with the invention;
FIG. 12 shows an alternative embodiment of the invention having a first clamping portion and a second clamping portion disposed in a first position;
FIG. 13 shows the clamping portions shown in FIG. 12 with a plurality of crimping elements disposed between the clamping portions;
FIG. 14 shows the clamping portions and crimping elements of FIG. 13 disposed in a second position;
FIG. 15 shows FIG. 13 with a stent crimping sleeve disposed between the crimping elements with the clamping portions and the crimping elements disposed in a first or non-securing position;
FIG. 16 shows the embodiment shown in FIG. 15 with the clamping portions and the crimping elements disposed in a second or securing position;
FIG. 17 is a cross-sectional side view of an alternative embodiment of the invention which utilizes a catheter protector and a catheter protector and stent positioners;
FIG. 18A is an end view of the second catheter protector and stent positioner shown in FIG. 17;
FIG. 18B is an end view of the first catheter protector shown in FIG. 17; and
FIG. 19 is an enlarged detailed view of a portion of FIG. 17 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a conventional balloon catheter 1 and shows a catheter 2 , a balloon 3 , and a stent 4 mounted on the balloon 3 prior to the stent 4 being secured on the balloon 3 . FIG. 2 shows the stent of FIG. 1 after it has been secured to the balloon by conventional methods, e.g., by pinching between the fingers or by crimping with a conventional plier-like device. As shown in FIG. 2, the ends of the stent protrude and there is some irregular distortion of the stent between the two ends of the stent.
FIG. 3 shows a stent securing apparatus 5 constructed in accordance with the invention. FIG. 3 shows a first clamping portion 6 having a first clamping portion recess 7 and a second clamping portion 8 having a second clamping portion recess 9 . The first clamping portion recess 7 and the second clamping portion recess 9 define a longitudinal stent crimping sleeve channel 10 with a selectively variable cross-sectional diameter. FIG. 3 shows the first clamping portion 6 and the second clamping portion 8 disposed in a first or non-securing position which provides a first clearance D 1 between the first clamping portion 6 and the second clamping portion 8 that is adequate for inserting an uncompressed stent crimping sleeve into the stent crimping sleeve channel 10 . FIG. 4 shows the first clamping portion 6 and the second clamping portion 8 of FIG. 3 moved to a second or securing position with a second clearance D 2 between the first clamping portion 6 and the second clamping portion 8 that is less than that D 1 . Thus, when disposed in the second or securing position, the first clamping portion 6 and the second clamping portion 8 are closer to each other than they are when disposed in the first position and, as shown in FIGS. 3 and 4, the crimping sleeve channel 10 has a smaller diameter. As also shown in FIG. 4, when the first clamping portion 6 and the second clamping portion 8 are in the second position, the crimping sleeve channel 10 has a substantially circular crosssectional diameter. The first clamping portion 6 and the second clamping portion 8 may be arranged in a variety of ways well known to those skilled in the art which permits selective movement of the first clamping portion 6 and second clamping portion 8 from the first position to the second position, i.e., toward and away from each other. In the embodiment shown, a channel 11 aligns the first clamping portion 6 and second clamping portion 8 and external pressure, e.g., finger pressure may be utilized to move the first clamping portion 6 and 8 from the first position to the second position. In another embodiment, pneumatic pressure or an electrical motor is utilized to move the clamping portions 6 and 8 . In an especially preferred embodiment, a pressure gauge and pressure regulator are utilized to control the amount of pressure applied. In still another embodiment, the first and second clamping portions 6 and 8 are mounted on a plier like hinged device.
FIG. 5 is a cross-sectional side view of a stent crimping sleeve 12 having an outer surface 13 and an inner surface 14 defining a longitudinal stent crimping bore 15 . FIG. 6 is an end view of FIG. 5 . The stent crimping bore 15 has a selectively variable substantially circular crosssectional diameter that changes in response to external pressure applied to the external surface 13 of the stent crimping sleeve 12 . The material comprising the stent crimping sleeve 12 is selected from a material which will substantially uniformly vary and maintain the substantially circular cross-sectional diameter of the longitudinal stent crimping bore 15 in response to pressure applied to the outer surface 13 of the stent crimping sleeve 12 . In a preferred embodiment, polyurethane is utilized.
FIG. 7 shows the stent 4 , balloon 3 , and catheter 2 of FIG. 1 disposed within the longitudinal stent crimping bore 15 of the stent crimping sleeve 12 shown in FIG. 5 prior to the stent 4 being crimped and secured to the balloon 3 . FIG. 8 is an end view of FIG. 7 .
FIG. 9 shows the stent crimping sleeve 12 of FIGS. 5 and 6 disposed in the stent crimping sleeve channel 10 between the first stent clamping portion 6 and second stent clamping portion 8 of the stent securing apparatus 5 . As shown in FIG. 9, the first stent clamping portion 6 and second stent clamping portion 8 are disposed in a first position which provides adequate clearance in the stent crimping sleeve channel 10 for the stent crimping sleeve 12 to be easily inserted or removed from the stent crimping sleeve channel 10 . Longitudinal bore 15 has a substantially circular cross-sectional diameter D 1 .
FIG. 10 differs from FIG. 9 in that the first stent clamping portion 6 and the second stent clamping portion 8 have been moved to a second position. The first clamping portion recess 7 and the second clamping portion recess are sized and cooperatively adapted so that when disposed in the second position the first and second clamping portions 6 and 8 define a channel 10 having a substantially circular cross-sectional diameter. As shown in FIG. 10, in response to the pressure applied by the first and second clamping portions 6 and 8 on the external wall 13 of the stent crimping sleeve 12 , the stent crimping sleeve 12 is compressed. This causes the diameter of the longitudinal stent crimping bore 15 to be reduced substantially uniformly to a substantially circular crosssectional diameter D 2 which is less than the uncompressed diameter D 1 shown in FIG. 9 . In response to the external pressure-applied to the outer surface 13 , the inner surface 14 of the stent crimping bore 15 applies a substantially uniform pressure to the stent 4 in an amount sufficient so as to substantially uniformly crimp the stent 4 and secure it on the balloon 3 with minimal irregular distortion of the stent 4 because the longitudinal bore 15 maintains its substantially circular cross-sectional diameter when the stent crimping sleeve 12 is compressed and the diameter of the stent crimping bore 15 is reduced.
FIG. 11 is a side view of the stent shown in FIG. 1 after it has been secured in accordance with the invention and removed from the stent securing apparatus 5 and shows that the stent 4 has been substantially uniformly crimped and secured on the balloon 3 with minimal irregular distortion.
FIGS. 12 to 16 show an alternative embodiment of the invention that utilizes a plurality of crimping elements disposed between the clamping portions to apply pressure to a stent crimping sleeve. FIG. 12 shows a first clamping portion 16 and a second clamping portion 18 . First clamping portion 16 is provided with a first surface 19 , a second surface 20 , and a third surface 21 defining a first clamping portion recess 66 . Second clamping portion 18 is provided with a first surface 22 , a second surface 23 , a third surface 24 , a fourth surface 25 and a fifth surface 26 defining a second clamping portion recess 67 . The surfaces 19 , 20 , 21 , comprising the first clamping portion recess 66 and the surfaces 22 , 23 , 24 , 25 , and 26 comprising the second clamping portion recess 67 define a longitudinal stent crimping element channel 27 with a selectively variable cross-sectional diameter.
As shown in FIG. 13, disposed within the longitudinal stent crimping element channel 27 is a first crimping element 29 , a second crimping element 30 , a third crimping element 31 and a fourth crimping element 32 . First crimping element 29 is provided with a first crimping element contact surface 33 , a second crimping element contact surface 35 , a first clamping portion contact surface 34 and a stent crimping sleeve contact surface 36 . Second crimping element 30 comprises a first crimping element contact surface 37 , a second crimping element contact surface 39 , a first clamping portion contact surface 38 and a stent crimping sleeve contact surface 40 . Third crimping element 31 is provided with a first crimping element contact surface 41 , a second crimping element contact surface 43 , a second clamping portion contact surface 42 and a stent crimping sleeve contact surface 44 . Fourth crimping element 32 is provided with a first crimping element contact surface 45 , a second crimping element contact surface 47 , a second clamping portion contact surface 46 , and a stent crimping sleeve contact surface 48 . The stent crimping sleeve contact surfaces 36 , 40 , 44 , and 48 define a stent crimping sleeve channel 10 , having a selectively variable crosssectional diameter.
FIG. 13 shows the first clamping portion 16 , the second clamping portion 18 , and the crimping elements 29 , 30 , 31 , and 32 disposed in a first or non-securing position, which provides a cross-sectional diameter No. of the stent crimping sleeve channel 101 that is adequate for inserting an uncompressed stent crimping sleeve 12 into the stent crimping sleeve channel 101 . As the first clamping portion 16 and the second clamping portion 18 are moved to the second position, surface 19 impinge on surface 34 , surface 21 impinges upon surface 38 , surface 23 impinges upon surface 46 and surface 25 impinges upon surface 42 moving the crimping elements 29 , 30 , 31 , and 32 to a second or securing position. FIG. 14 shows the first clamping portion 16 , the second clamping portion 18 , and the crimping elements 29 , 30 , 31 , and 32 disposed in a second position the stent crimping sleeve surfaces 36 , 40 , 44 , and 48 define a crimping sleeve channel 10 ′ having a substantially circular cross-sectional diameter D 2 that is smaller than diameter No. shown in FIG. 13 . The first clamping portion 16 and second clamping portion 18 may be arranged in a variety of ways well skilled to those skilled in the art which permits selective movement of the first clamping portion 16 and second clamping portion 18 in a first direction away from each other to a first position and in a second direction toward each other to a second position.
FIGS. 15 and 16 show a stent crimping sleeve 12 (previously discussed) disposed in the longitudinal stent crimping sleeve channel 10 ′. (The stent and balloon catheter have been omitted for clarity.) As shown in FIG. 15, when the first clamping portion 16 and the second clamping portion 18 , and the crimping elements 29 , 30 , 31 , and 32 are disposed in the first position, some portions of crimping element contact surfaces 36 , 40 , 44 , and 48 may not be in contact with some portion of the outer surface 13 of the stent crimping sleeve 12 because when the first clamping portion 16 , the second clamping portion 18 , and the crimping elements 29 , 30 , 31 , and 32 are in the first position, surfaces 36 , 40 , 44 , and 48 do not define a stent crimping sleeve channel 10 , having a substantially circular crosssectional diameter. Thus, when the first and second clamping portions and the crimping elements are in the first or non-securing position, gaps 68 may exist between the outer surface 13 of the stent crimping sleeve 12 and crimping element contact surfaces 36 , 40 , 44 , and 48 . As shown in FIG. 16, however, when first clamping portion 16 , second clamping portion 18 , and crimping elements 29 , 30 , 31 , and 32 are disposed in the second or securing position, substantially all of crimping element contact surfaces 36 , 40 , 44 , and 48 are in contact with the external surface 13 of the crimping sleeve 12 because surfaces 36 , 40 , 44 , and 48 are sized and adapted to define a stent crimping sleeve channel 10 ′ having a substantially circular cross-sectional diameter when the first clamping portion 16 , the second clamping portion 18 , and crimping elements 29 , 30 , 31 , and 32 are disposed in the second position.
As shown in FIG. 15, when the first clamping portion 16 , the second clamping portion 18 , and crimping elements 29 , 30 , 31 , and 32 are disposed in the first or non-securing position, the stent crimping bore 15 has a substantially circular cross-sectional diameter of D 1 . As shown in FIG. 16, when the first clamping portion 16 , the second clamping portion 18 , and crimping elements 29 , 30 , 31 , and 32 are disposed in the second or securing position, the stent crimping bore 15 has a substantially circular cross-sectional diameter D 2 that is smaller than D 1 . Because the stent crimping bore 15 maintains its substantially circular cross-sectional diameter when first clamping portion 16 , second clamping portion 18 , and crimping elements 29 , 30 , 31 , and 32 are disposed in the second position, the inner surface 14 of the stent crimping sleeve 12 applies substantially uniform pressure to the stent 4 to be crimped mounted on the balloon catheter 1 disposed within the longitudinal stent crimping bore 15 and substantially uniformly crimp and secure the stent 4 to the balloon catheter on which it is mounted with minimal irregular distortion of the stent 4 .
FIGS. 17 to 19 show an alternative embodiment of the invention in which a first catheter protector 60 and a second catheter protector and stent positioner 61 is utilized to protect the catheter shaft and also to limit the movement of the stent along the longitudinal axis of the catheter resulting in more precise placement on the catheter. FIG. 17 is a cross-sectional side view and shows a balloon catheter 1 , a stent 4 , a guide-wire 65 , a first catheter protector 60 and a second catheter protector and stent positioner 61 . FIG. 18A is an end view of the second catheter-protector and positioner 61 shown in FIG. 17 and FIG. 18B is an end view of the first catheter protector 60 shown in FIG. 17 . As shown in FIG. 18A, the second catheter protector and stent positioner 61 is circular in cross-section and comprises an outer ring 62 of compressible material and an inner ring 63 of substantially non-compressible material. The inner ring 63 is provided with an inner ring aperture 64 having a substantially circular cross-sectional diameter. As shown in FIG. 18B, the first catheter protector 60 is circular in cross-section and comprises an outer ring 62 ′ of compressible material and an inner ring 63 ′ of substantially non-compressible material. The inner ring 63 ′ is provided with an inner ring aperture 64 ′ having a substantially circular cross-sectional diameter. In a preferred embodiment, the substantially compressible material is polyurethane and the substantially non-compressible material is metal.
FIG. 19 is an enlarged view of the second catheter protector and stent positioner 61 and the first catheter protector 60 of FIG. 17 . As shown, the inner ring aperture 64 of the substantially non-compressible inner ring 63 of the second catheter protector and positioner 61 is sized sufficiently large so as to permit the catheter 2 to enter into the inner ring aperture 64 and is sized sufficiently small so as to prevent the stent 4 from entering into the inner ring aperture 64 . Thus, the inner ring aperture 64 is sized sufficiently small to prevent entrance of the uncrimped stent 4 and is sized sufficiently large to permit entrance of the balloon portion 3 of the catheter 2 into the inner ring aperture 64 . Because the inner ring aperture 64 is substantially non-compressible it protects the portions of the catheter 2 and guide-wire 65 disposed within the inner ring aperture 64 of the inner ring 63 during the securing procedure. The substantially non-compressible inner ring 63 also acts as a stop to positively position the stent 4 on the catheter 2 . In an especially preferred embodiment, the balloon portion of the catheter has an external diameter of about 0.9 to about 1.2 mm, the inner ring aperture 64 of the second catheter protector and stent positioner 61 has a diameter of about 1.4 mm, the unexpanded and uncrimped stent has an external diameter of about 1.7 to about 1.75 mm and the crimped stent has a diameter of about 1.0 to about 1.1 mm.
As shown in FIGS. 17, 18 A, 18 B, and 19 , the first catheter protector 60 has an inner ring aperture 64 ′ that is larger than the inner ring aperture 64 of the second catheter protector and stent positioner 61 . The inner ring aperture 64 ′ is sized large enough to permit the passage of an uncrimped stent through the inner ring aperture 64 ′ and into the longitudinal stent crimping bore of the stent crimping sleeve. In an especially preferred embodiment a diameter of about 1.9 mm to about 2.0 mm is utilized.
In operation, the uncrimped stent is advanced through the inner ring aperture 64 ′ of the first catheter protector 60 and into the longitudinal stent crimping bore until the stent contacts the second catheter protector and stent positioner 61 . Because the second catheter protector and stent positioner 61 has an inner ring aperture 64 that is smaller than the diameter of an uncrimped stent and greater than the diameter of the catheter, the catheter positioner and stent positioner 61 serves both to position the stent and to protect the distal end of the catheter. The catheter is then introduced into the longitudinal bore of the stent and the stent is crimped onto the balloon portion of catheter.
After the stent has been crimped on the balloon portion of the catheter, the catheter with the stent crimped on it is withdrawn by pulling the catheter through the inner ring aperture 64 ′ of the first catheter protector 60 . | Apparatus and method for securing a stent to a balloon catheter. A first clamping portion and a second clamping portion are arranged for movement toward and away from each other and are provided with recesses defining a channel to receive a stent crimping sleeve having a longitudinal bore. The stent is slid into the longitudinal bore of the stent crimping sleeve and the balloon catheter is then slid into the longitudinal bore of the stent. The first and second clamping portions are moved towards each other and apply pressure to the external surface of the stent crimping sleeve causing the internal diameter of the longitudinal bore to get smaller and apply pressure to the external surface of the stent and crimp the stent to the balloon. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a wet battery which needs to be topped up periodically with water or other fluid. The invention also relates to a vehicle-based water management system for use in connection with at least one unit on the vehicle which requires water for its operation.
2. Description of the Prior Art
In a motor vehicle such as a car, there are a number of units which require water for their operation and in which the supply of water must be regularly checked and topped up if necessary. These units include the radiator, the screen wash and the battery. Water is lost from the radiator due to leakage and evaporation. Water is consumed in normal use of the screen wash. Water is lost from the battery through evaporation and boiling caused by heating of the battery during its charging and discharging cycle and due to the engine temperature. In an electric vehicle, the batteries constitute the source of motive power, so it is particularly important that they be maintained in good condition at all times.
Presently, the vehicle owner must routinely inspect and refill the water supply in all these units. This is an inconvenient and irritating burden, yet damage may result or safety be compromised if the task is not done. Additionally, the water level in the cells of the or each battery should be carefully adjusted in order to optimize the performance and lifespan. This is particularly important in the case of an electric car or other vehicle. However, getting the water level right requires some skill and knowledge. Moreover, the need to check and fill each cell individually is time-consuming.
The present invention arose partly from a consideration of these problems and how they may be overcome.
SUMMARY OF THE INVENTION
In one aspect, the invention provides a wet battery comprising a plurality of cells, each cell having a respective fluid inlet, the battery having a channel which is shared by the fluid inlets for supplying fluid such as water to the cells of the battery, wherein each cell includes a float valve associated with its fluid inlet and arranged to automatically open for communication with the channel when the fluid in the cell is below a predetermined level.
According to this aspect of the invention, the procedure of maintaining the fluid level of each cell of the battery is simplified and may be automatically regulated, thereby ensuring optimum performance and lifespan.
In a preferred embodiment, the battery has an integral reservoir for temporarily holding a quantity of water. The reservoir is periodically filled manually or automatically, and then empties its content through the channel, which supplies the cells as required. Any excess water exits the channel through an overflow or may even be returned to the reservoir. According to this arrangement, the fluid level is automatically set by the valves and it is impossible to overfill the battery.
In another aspect, the invention provides a water management system on a vehicle, the system comprising water collecting means for providing a supply of water and distribution means for distributing the water from the supply to a plurality of units on the vehicle which require water for their operation.
According to this other aspect of the invention, a supply of water is always conveniently available for use by the units requiring water for their operation. The plurality of units may consist of a bank of two or more batteries in the case of an electric vehicle.
The water collecting means may be a master or central storage vessel which is filled manually. However, the water collecting means may include a source which generates water as a by-product. In one embodiment of the invention, an air-conditioning system is employed to provide the water supply. The condensate formed on the condenser of the air-conditioning system offers a reliable and clean source of water. It is also simple to collect, for example by using the conventional drip pipe of the condenser to feed the condensed water into a storage tank.
The inventor has tested the system on his own car and found that one-half of a liter of water may be collected from the car's air-conditioner in one 30-minute city journey. This result indicates that more than a sufficient amount of water to meet the usual requirements of the radiator, screen wash and battery can be collected in this way. Thus, an adequate supply of water to those units may be guaranteed. A sample of the collected water was tested and found to have a pH value of 6.4, i.e. substantially neutral. This further demonstrates the fitness of the collected water.
The automatic supply of the collected water to the units means that the vehicle owner is spared the inconvenience of having to regularly check and top up the units. Thus, the maintenance effort is beneficially reduced and the risk of breakdown is lowered. The collected water may also be used to provide a supply of drinking or washing water within the car.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention, in its various aspects, is illustrated, but not limited, by the following description of an embodiment, which refers to the accompanying drawings.
FIG. 1 is a schematic illustration of a water management system in accordance with the invention;
FIG. 2 ( a ) shows an internal view of a wet battery in accordance with the invention;
FIG. 2 ( b ) shows a component of the float valve of the battery of FIG. 2 ( a );
FIG. 2 ( c ) is an enlarged view of the float valve of the battery of FIG. 2 ( a );
FIG. 2 ( d ) shows another component of the float valve of the battery of FIG. 2 ( a ); and
FIG. 3 shows an external view of the battery of FIG. 2 ( a ).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to the drawings, and first FIG. 1, there is shown a water management apparatus for a motor car. The condenser unit 1 of the car's air-conditioning system serves as a source of water supply. Water generated in the condenser unit 1 is supplied to a central storage tank 5 via a pipe 2 and filter 3 . The pipe 2 is connected to the drip outlet of the condenser unit 1 . In this embodiment, the filter 3 is a mechanical filter for removing any dust, dirt or other solid contaminant from the collected water. The filter 3 is conveniently incorporated into the cap 4 of the tank 5 . The cap includes an overflow outlet 16 for excess water to be discharged when the tank 5 is full.
The filtered water is fed from the tank 5 , through piping 6 , to a plurality of water storage tanks or bottles 7 , 11 , 13 and to a battery water reservoir 9 (see FIG. 3 ). For this purpose, a pump 33 is associated with the tank 5 . The pump may be operated automatically or by means of a control within the vehicle in order to periodically top up the supplies 7 , 9 , 11 and 13 .
A water reservoir 9 , best seen in FIG. 3, is arranged for supplying water to the car's battery 15 . The water in the reservoir 9 is allowed to drain, under the action of gravity, through a channel 23 which supplies water to the battery cells. Any excess or unrequired water 25 escapes at an outlet of the channel. The arrangement of the reservoir 9 and channel 23 for supplying water to the battery 15 will be described later with reference to FIGS. 2 and 3.
One water storage tank 11 is arranged for supplying water to a screen washer unit comprising one or more spray jets 27 . In FIG. 1, the jet 27 is associated with a windscreen wiper 29 . However, the jet may be equally provided for cleaning a rear window or a car light, especially a headlight. A pump 35 , which is operated by means of a switch or lever on the dashboard or steering column, serves to supply water to the jet 27 through a pipe 12 in conventional manner.
The tank 11 may contain a cleaning agent. Water is fed into the tank 11 from the master tank 5 via a ball-valve 18 or the like. The valve 18 is closed when the tank 11 is full, so that any further water is discharged directly through an overflow 20 . This arrangement ensures that there is no loss of cleaning agent when the tank 11 is full. Since the tank 11 is regularly filled with water from the master supply, its capacity can be made smaller than the conventional screen wash tank.
Another water storage tank 13 provides a supply of water for the radiator 37 of the engine's cooling system. Water is sucked up to the radiator 37 from the tank 13 through a pipe 14 . A valve 22 and overflow outlet 24 arrangement, similar to that provided for the tank 11 , ensure that any coolant agent contained in the cooling system is not lost when the tank 13 is full.
A further water storage tank 7 provides a supply of water for drinking, handwashing or the like by the driver and any passengers. A pump 31 serves to pump the water to an outlet through a pipe 8 , when required. The outlet is preferably located in the car interior, although it may be located elsewhere, for example in the boot. An overflow pipe 26 discharges any excess water when the tank 7 is full.
Each of the pipes 2 , 6 , 8 , 12 and 14 which interconnect the various components of the system, suitably consists of flexible tube or hose of rubber or other water-impermeable material.
The storage bottles 11 , 13 and the battery 15 are preferably disposed in their normal positions within the engine compartment, that is in positions where they are accessible for inspection and the occasional addition of screen wash detergent or engine coolant. Therefore, fitting the water management system of the invention to an existing vehicle does not require extensive modification of the layout of the components of the engine compartment.
FIGS. 2 ( a )-( d ) and 3 illustrate the construction of part of a wet battery in accordance with an independent aspect of the invention. In this specification, the term wet battery refers to a battery containing fluid which needs to be periodically topped up. Although the wet battery to be described is particularly suitable for use in the water management system of FIG. 1, it is not limited to such an application.
Referring first to FIG. 2 ( a ), the battery 15 of this embodiment has six cells arranged in a linear array in conventional manner. For the purposes of illustration, only two of the cells 61 , 63 are shown in full in FIG. 2 ( a ). The other cells are the same. Each cell 61 , 63 comprises a collection of plate-like electrodes 65 immersed in electrolyte fluid 67 . A structural wall 69 separates, and isolates the fluid in, the adjacent cells.
The upper wall of each cell is defined by the bottom of the water channel 23 , already mentioned with reference to FIG. 1 . The channel 23 extends over the line of cells to allow water, or other fluid, flowing along the channel to enter the cells as required. For this purpose, the bottom of the channel includes two apertures for each cell. Referring to the enlarged view of FIG. 2 ( c ), a first aperture serves as a gas vent, to permit gas or air to escape from the battery as required. The first aperture consists of a chimney-like structure 71 , which extends to a level above the normal water level in the channel 23 , thereby preventing unwanted entrance of water through the gas vent. Alternatively, the channel 23 may include an internal wall extending longitudinally therein to isolate the gas vents 71 from the water-receiving portion of the channel. A second aperture 81 serves as a water inlet for the cell, to permit water to enter the cell to top up the electrolyte level. This second aperture 81 consists of a hole surrounded internally by a cylindrical guide wall 73 .
A float valve member 75 is disposed within each cell. The float valve member 75 has three main portions: a float portion 75 a , a valve portion 75 b , and a cup portion 75 c . The float portion 75 a extends laterally, suitably in a circular or rectangular shape, and floats on the surface of the battery fluid 67 . The float portion 75 a is suitably made of Styrofoam (trademark). The valve portion 75 b , which is shown in detail in FIG. 2 ( b ), extends vertically from the centre of the float portion 75 a and is supported and guided by the guide wall 73 . The distal end of the cylindrical valve portion 75 b is terminated in a sealing disc 75 j which internally engages the peripheral portion of the water inlet aperture 81 in a sealing manner when the valve is closed. The sealing disc 75 j is made of a resilient and water-impermeable material. The use of silicone rubber for the sealing disc is presently preferred.
As best seen in FIG. 2 ( b ), the valve portion 75 b comprises a plurality of radial vanes 75 d extending longitudinally and spaced circumferentially. The vanes 75 d serve to locate the valve portion 75 b centrally within the surrounding guide cylinder 73 , and thereby form a plurality of passageways between the valve portion 75 b and the inner surface of the wall 73 . The passageways allow the free flow of water into the cell when the valve is open.
This preferred configuration also prevents the accumulation of dirt such as oxide particles on the valve portion 75 b , and so ensures the free movement of the valve portion even when the fluid environment within the battery becomes contaminated as the battery ages.
Referring again to FIG. 2 ( b ), the valve portion 75 b further includes a mounting disc 75 e which provides an annular flange. The portions of the vanes 75 d below the disc 75 e are adapted to be received in a lower cylinder 75 h of the cup portion 75 c.
FIG. 2 ( d ) shows the cup portion 75 c of the float valve member 75 . This comprises an upper hollow cylindrical element 75 k , which is open at the top end and has a diameter greater than that of the guide wall 73 . The cup portion further comprises a lower hollow cylindrical element 75 h of a diameter which is smaller than that of the upper element 75 k and slightly greater than that of the valve portion 75 b . The lower cylindrical element 75 h is closed at its bottom end.
As best seen in FIG. 2 ( c ), the lower element 75 h accommodates the lower portion of the valve body 75 b . The flange of the disc 75 e is seated on the step which joins the upper and lower cylindrical elements 75 k , 75 h . The disc flange is preferably sealingly fixed to the step, for example by using adhesive.
The lower portion of the upper cylindrical element 75 k includes a plurality of fluid holes 75 g . The fluid holes 75 g are formed in the cylinder wall, at a certain height above the step.
The vertical movement of the float valve member 75 is limited in the downward direction by interlocking of the cup portion 75 c with the guide wall 73 . For this purpose, in this embodiment, the lower end of the guide wall terminates in an annular lip 73 a (see FIG. 2 ( c )), while the top, open end of the cup portion 75 c includes a plurality of internal lugs 75 f (see FIG. 2 ( d )). When the float valve member 75 drops below a predetermined level, the lugs 75 f (there are two by way of example in the present embodiment) latch onto the guide wall lip 73 a to arrest further downward movement. The vertical movement in the upward direction is limited by the engagement of the sealing disc 75 j with the water inlet aperture 81 when the valve is in the closed state.
It will be noted that guide wall 73 and the wall of the upper element 75 k of the cup portion form a continuous vertical barrier extending from the cell ceiling to the valve float portion 75 a . This arrangement serves to prevent the escape of fluid from the cell (via the said second aperture), especially during vibration when the vehicle is in motion. Any fluid which does enter the cup portion will, however, flow out through the holes 75 g therein when the fluid exceeds the level of those holes. As a further safeguard against the escape of fluid, a cylindrical baffle wall 77 extends vertically down from the cell ceiling to surround the upper part of the valve member 75 . The arrows 79 indicate the function of the baffle wall 77 in deflecting any fluid that splashes upwards within the cell.
The inclusion of the cup portion 75 c is optional, since the valve will operate without it. However, it is preferred for the reasons and advantages set out herein.
FIG. 3 is a perspective view of the top of the battery showing the channel 23 and reservoir 9 mentioned already with reference to FIG. 1 . In this embodiment, the channel 23 and the reservoir 9 are formed as an integral box-like structure 39 , which is conveniently made as a plastic moulding. An internal wall 41 divides the structure into the fluid reservoir 9 and the supply channel 23 . The upper wall of the box may be removable or openable (not shown), especially over the channel 23 to permit inspection. The box is preferably also made of clear plastic for this purpose. The portion of the upper wall or lid over the channel encourages condensation of any battery fluid vapour escaping from the vents 71 . The condensate usefully collects in the bottom of the channel and thus may reduce the amount of water that needs to be supplied from the reservoir.
Water is pumped into the reservoir 9 by the pump 33 (see FIG. 1) through an inlet 43 and enters the channel 23 therefrom via a port 45 formed in the wall 41 . The water flows down the channel 23 and enters each cell of the battery whose fluid level is such that the float valve aperture 81 is open. Any excess water exits from the outlet 47 , from where it may be wasted or returned to the reservoir 9 or tank 5 . It is not essential to fill the reservoir 9 automatically. In an application where a water management system such as that shown in FIG. 1 is not employed, a manual filling port 49 and associated plug 51 can be provided. In that case, the inlet 43 is either plugged or not provided at all.
The reservoir 9 , channel 23 and float valve members 75 may be constituted as a cover assembly to be fitted to the body of a conventional battery, thereby enabling the battery manufacturer to fabricate a battery in accordance with the invention without the need to re-design or re-tool the body of the battery.
In operation, water is fed into the channel 23 through the port 45 and travels down the channel toward the end having the outlet 47 . For any cell of the battery in which the fluid level is below a predetermined value, the float valve member 75 will drop down to open a gap between the aperture 81 and sealing disc 75 j . Thus, the water will enter this cell through the gap.
The water flows down between the guide wall 73 and the valve body 75 b , enters the bottom of the cup 75 c and exits through the fluid holes 75 g , thereby topping up the cell fluid level. When the fluid level has risen again to the reference value, the float valve member 75 will also reside at a higher level to close the gap thereby preventing further water entry. The fluid level in each cell is self-regulated in this way. The cells may be topped up, as required, either in sequence or simultaneously, depending on the speed of the water flow through the channel. The water may be supplied to the channel 23 continuously or periodically. In the system of FIG. 1, the reservoir 9 is periodically charged, whether by manual instruction or automatically, and then allowed to empty over a short period, suitably a few minutes. This intermittent mode of operation is preferred to using a continuous flow of water. Especially, the intermittent flow of water can be generated when the vehicle is not in motion, which prevents accidental opening of the cell valves and unwanted entry of water due to vibration or shock.
The advantages of the described construction of the wet battery include the following. The provision of the common channel serving to supply the water to all the battery cells means that there is no need to interconnect the individual cell valves. Also, as compared with using a hose connection, the channel is easily accessible, less liable to blockage and simple to clean. Building the float valves into the structure of battery body enables each float member to occupy the full width of the cell. This improves the weight of the float valve member and the response to changes in the fluid level. The construction of the valves is simple and therefore of low cost, yet reliable. The water used to top up the cells does not need to be pressurised, nor supplied continuously.
The water management system of the invention is suitable for use on any vehicle including car, electric car, lorry, bus, train, boat, ship and various kinds of aircraft. Any one or more units requiring a water supply may be incorporated. It is not essential to supply water to the four units of the example, although in the case of the car, it is convenient to do so. Some modern vehicle batteries are completely sealed and do not require water top up. Here, the system remains suitable for any or all of the radiator, screen wash and drinking supplies. The wet battery of the invention has application in the above vehicles plus vehicles such as fork lift trucks and milk floats which use electrical power for their traction and/or other functions. The battery of the invention is equally useful in applications outside of the field of vehicles, such as emergency and stand-by power supplies. | A water management system for a motor vehicle in which water is collected from the condenser ( 1 ) of the air-conditioning unit, stored in a master water tank ( 5 ) and distributed therefrom to the battery ( 15 ), screen wash jet ( 27 ) and radiator ( 37 ). The vehicle owner is thus spared the inconvenience of regularly checking and topping up the water supply for these items. The risk of breakdown is also reduced. In another aspect of the invention, a wet battery ( 15 ) incorporates a plurality of float valves ( 75 ) for regulating the fluid level in respective cells ( 61, 63 ) of the battery. Water is passed through a common channel ( 23 ) into which the float valves ( 75 ) open when the fluid level is below a preset limit. The battery fluid is thereby automatically kept at the required level for optimum performance and lifetime of the battery. | 1 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to an electronic device for indicating the presence of electromagnetic interference (EMI). More specifically, the present invention relates to a stability indicator in a electronic device for detecting and indicating the presence of a high electromagnetic field in the immediate vicinity of the device. In particular, the present invention relates to a fail-safe detection circuit embodied in a tympanic thermometer that prevents the taking of a temperature reading in the presence of high EMI event and displays a warning.
2. Prior Art
The diagnosis and treatment of many body ailments depends upon an accurate reading of the internal or core temperature of a patient's body, and in some instances, upon comparison to a previous body temperature reading. For many years, the most common way of taking a patient's temperature involved utilization of Mercury thermometers. However, such thermometers are susceptible to breaking and must be inserted and maintained in the rectum, axilla or mouth for several minutes, often causing discomfort to the patient.
Because of the drawbacks of conventional Mercury thermometers, electronic thermometers were developed and are now in widespread use. Typically, such electronic thermometers have a probe connected by wires to a remote unit containing electronic circuitry. The probe is sheathed in a protective, disposable cover before being inserted into a patient's mouth, axilla or rectum. Using predictive techniques, the patient's temperature reading is taking a significantly shorter time period, for example thirty seconds, compared to several minutes required for conventional Mercury thermometers. Also, the electronic thermometer in some instances provide more accurate temperature readings than Mercury thermometers.
Although electronic thermometers provide relatively more accurate temperature readings than Mercury thermometers, they nevertheless share many of the same drawbacks. For example, even though electronic thermometers provide faster readings, a half minute must still pass before an accurate reading can be taken. Finally, electronic thermometers must still be inserted into the patient's mouth or rectum which can cause patient discomfort or adversely affect temperature reading accuracy if the probe is moved during the course of measurement.
Tympanic thermometers provide nearly instantaneous and accurate reading of core temperature without the undue delay attendant with other thermometers. The tympanic membrane is generally considered by the medical community to be superior to oral, rectal or axillary sites for taking a patient's temperature. This is because the tympanic membrane is more representative of the body's internal or core temperature and more responsive to changes in core temperature. Tympanic thermometers, those thermometers that sense the infrared emissions from the tympanic membrane, offer significant advantages over Mercury or conventional electronic thermometers.
Recent efforts to provide a method and apparatus for measuring body temperature inside the tympanic membrane have produced several excellent tympanic thermometers. For example, U.S. Pat. No. 5,293,877 to O'Hara et al. provides for a tympanic thermometer that measures internal body temperature utilizing the infrared emissions from the tympanic membrane and within the ear canal itself, and is herein incorporated by reference in its entirety.
The tympanic thermometer of O'Hara et al. is comprised of a probe unit that has a handle and a probe head body terminated in a probe tip which is inserted into the external ear canal. The handle houses a circuit board that controls the operation of the thermometer and a display that displays temperature readings and other information. The probe head body is attached to the distal end of the circuit board and houses a seal assembly, optical waveguide tube, infrared filter and thermopile detector. The probe head body further includes a first bore in communication with a second narrower second bore. The distal end of the first bore forms a tip with an opening thereto for passing infrared emissions from the tympanic membrane into the probe head body. The infrared filter is mounted in the opening and rejects unwanted emissions while the optical waveguide tube conducts the infrared emissions to the thermopile detector located at the proximal end of the tube. In order to prevent contamination from entering the probe head body, a seal assembly is also provided that furnishes a watertight barrier against liquid and debris from entering through the interface between the probe tip and the infrared filter.
The user operates the thermometer by inserting the probe tip into the patient's ear canal and depressing the SCAN button once the probe tip is properly seated inside the ear canal. At this point, infrared emissions from the tympanic membrane are filtered through the infrared filter and conducted by the optical waveguide tube until detected by the thermopile detector. Actuating the SCAN button also alerts the microcomputer that the tympanic comparative computation algorithm should commence. Once the microcomputer is alerted, it starts acquiring the thermopile output level at a rate of approximately seven times per second and stores the maximum temperature reading for display to the user. However, being electronic devices tympanic thermometers still suffer from the effects of nearby sources of electromagnetic interference.
It is well known in the electronic art that circuits and other electronic devices, like tympanic thermometers, may be adversely affected by the presence of electromagnetic interference. By definition, electromagnetic interference is an unwanted electromagnetic signal which may degrade the performance of an electronic device by creating undesirable voltages or currents in the device's circuitry. The cause of an electromagnetic interference problem is usually an unplanned coupling between an electromagnetic source and a receptor by means of a transmission path. Such a transmission path may be conducted or radiated. Conducted interference occurs by means of metallic path wherein an electrical device is connected to a power source while radiated interference occurs by means of near- and far-field electromagnetic field coupling. It is the latter type of interference that poses the most trouble to medical devices in hospitals.
Sources of radiated interference usually originate from transmitters and other similar types of communication equipment, especially cellular phones. In a hospital or clinical environment, almost all electronic medical devices are designed to sufficiently suppress or reduce most interference generated by an electromagnetic signal in that particular environment. However, mobile radio transmitters and cellular phones radiate particularly high levels of electromagnetic interference, especially where in close proximity to an electronic medical device. In addition, many common medical devices emit EMI and can themselves pose a threat to other medical equipment. These potential sources of EMI include diathermy units, magnetic resonance imaging (MRI) systems, lasers and cauterizers.
In particular, the front-end circuitry of tympanic thermometers which senses the core body temperature of a patient is especially susceptible to EMI radiated by these aforementioned sources. A doctor, for example, operating a cauterizer next to a nurse who is taking a temperature reading using a tympanic thermometer will generate sufficient EMI from the cauterizer to adversely influence the accuracy of the temperature reading taken by the thermometer's probe. The problem faced by medical practitioners in using tympanic thermometers is that the practitioner does not know when an inaccurate temperature reading has been taken in the presence of a high electromagnetic environment because there is usually no outward indication from the tympanic thermometer that the temperature reading is in error. Further, conventional methods of suppressing electromagnetic interference, like shielding and filtering, are insufficient in addressing the problem because the thermometer's circuitry cannot be properly shielded from a close EMI source since shielding merely attenuates, but does not eliminate the interference.
As of yet, nothing in the prior art has addressed the problem of developing an electromagnetic interference detector that gives an outward indication that a tympanic thermometer is being operated in a high electromagnetic environment and prevents the thermometer from taking a temperature reading.
Therefore, there exists a need in the medical device art for a stability indicator that detects and warns the practitioner of the presence of high EMI while disabling the apparatus from taking a temperature until the EMI event has passed.
SUMMARY OF THE INVENTION
In brief summary, the present invention relates to a stability indicator for a tympanic thermometer that warns the practitioner that the thermometer is being used in a high electromagnetic environment and prevents the taking of a temperature reading until the EMI event has passed.
Accordingly, it is the principal object of the present invention to provide a novel and accurate means for the detection of EMI in the vicinity of the thermometer body.
A further object of the present invention is to provide an outward indication to the user that the thermometer is being operated in a high electromagnetic environment.
Another paramount object of the present invention is to provide a fail-safe circuit for preventing the taking of a temperature reading in a high electromagnetic environment.
These and other objects of the present invention are realized in a presently preferred embodiment thereof, described by way of example and not necessarily by way of limitation, which provides for a stability indicator for detecting and indicating the presence of EMI in the vicinity of the thermometer body while preventing the taking of core body temperatures by the thermometer.
Additional objects, advantages and novel features of the invention will be set forth in the description which follows, and will become apparent to those skilled in the art upon examination of the following more detailed description and drawings in which like elements of the invention are similarly numbered throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top view of the tympanic thermometer showing the display according to the present invention;
FIG. 2 is a block diagram showing the front-end circuitry of the tympanic thermometer according to the present invention;
FIG. 3 is a circuit diagram of the front end circuitry according to the present invention;
FIGS. 4-6 are flow charts showing the software routine and sub-routines for the detection, display and disabling features according to the present invention.
DETAILED DESCRIPTION
As shown in the exemplary drawings for the purposes of illustration, an embodiment of an electromagnetic stability indicator made in accordance with the principles of the present invention, referred to generally by reference 10, is provided for sensing and indicating the presence of EMI by a tympanic thermometer and prevent the taking of a temperature reading by the thermometer until the EMI event has passed.
A prior art tympanic thermometer 11 is shown in FIG. 1. The basic hardware configuration of tympanic thermometer 11 comprises a thermometer body 12 and a probe head 13. Thermometer body 12 includes a display 14 for displaying information to the user, a SCAN button 15 for initiating the taking of a temperature reading by tympanic thermometer 11, and an EJECT RELEASE button 16 for ejecting a probe cover 17 from the probe head 13 after a temperature reading has been taken.
Probe head 13 includes a probe head seal 20 that comprises an assembly of seal components (not shown) which seal off the probe head 13 and prevents water and other contaminants from entering the interior portion of probe head 13. The distal end of probe head 13 also includes a probe head extension 18 which is adapted to be inserted into the ear canal of a patient when a temperature reading is to be taken. The probe head extension 18 comprises a probe tip 19 which forms an aperture therethrough where an infrared filter 21 is seated therein for filtering ambient light that enters through tip 19. Probe head 13 also houses front end circuitry 22 which permits tympanic thermometer 11 to sense a high EMI event through the electrical interconnection traces and the ground plane located therein. A more detailed description of the probe head seal 20 is found in applicant's co-pending U.S. Patent Provisional Application Ser. No. 60/003,240 to Vodzak et al. entitled "Titanium Probe Tip with Watertight Seal" and is hereby incorporated by reference in its entirety.
In brief, tympanic thermometer 11 is operated by engaging a sterile probe cover 17 onto the distal end of probe head extension 18 and placing extension 18 into the ear canal of a patient (not shown). Once the probe head extension 18 is properly inserted inside the ear canal, the user presses down on SCAN button 15 and thermometer 11 instantly takes a core temperature reading from the patient's tympanic membrane and displays the same on display 14. A more detailed description of the prior art tympanic thermometer and its related method of use is disclosed in U.S. Pat. No. 4,790,324 to O'Hara et al. entitled "Method and Apparatus for Measuring Internal Body Temperature Utilizing Infrared Emissions" and is hereby incorporated by reference in its entirety.
Referring to FIG. 2, front-end circuitry 22 of the probe head 13 showing the electronics of EMI stability indicator 10 is illustrated in functional block form. Thermopile detector 23 is connected to an operational amplifier 26 through a first multiplexer 25 at input I1 while a circuit ground 24 is also connected to amplifier 26 through an input I2 of multiplexer 25. Thermopile detector 23 is preferably a commercial detector, 2MCLWPXE, manufactured by DEXTER Research of Dexter, Mich., for sensing infrared radiation, however any suitable infrared detector is felt to fall within the scope of the present invention. Circuit ground 24 is a simple circuit ground connected to the non-inverting input of operational amplifier 26 and provides a means of measuring offset voltages inherent in operational amplifier 26 so that such offset voltages can be subtracted from the thermopile readings taken from thermopile detector 23. An offset voltage is defined as the voltage required to reduce the DC output voltage of amplifier 26 to zero if the amplifier is connected to a circuit ground. By subtracting the offset voltage from the thermopile reading, a more accurate temperature reading from the patient's tympanic membrane is achieved. Further, circuit ground 24 is used as a means of sensing the presence of high EMI event in the vicinity of thermometer body 12 by repeatedly measuring the circuit ground 24 input for offset voltages and comparing those input readings to a preset reference value or predetermined threshold found in a microcontroller 29. If the difference in the maximum and minimum offset voltages any one input reading meets or exceeds the preset reference value found in a EEPROM 32 (not shown) of microcontroller 29, microcontroller 29 directs an error condition be written to display 14 and prevents a temperature reading from being calculated. Preferably, microcontroller 29 is a HD4074808 manufactured by Hitachi of America Limited of Brisbane, Calif., however any microprocessor suitable for sampling sensor inputs is felt to fall within the scope of the present invention.
Operational amplifier 26 is a high gain amplifier that amplifies the voltage reading from thermopile detector 23 when the first multiplexer is set at input I1. At input I2, the operational amplifier 26 is connected to ground so that any output from amplifier 26 reflects offset voltages generated in amplifier 26. These offset voltages are then subtracted from the thermopile detector 23 reading in order to give an accurate temperature of the tympanic membrane. Second multiplexer 27 is connected to operational amplifier 26 through an input I3 for sending the thermopile detector 23 readings and offset voltages to microcontroller 29 through an analog to digital converter 28. Further, second multiplexer 27 has two other inputs, I4 and I5, for connecting the head thermistor 30 and the tip thermistor 31 respectively to the analog to digital converter 28. Thus, second multiplexer 27 channels one of three inputs, I3, I4 and I5, through to analog to digital converter 28 at any one time.
Analog-to-digital converter 28 converts the analog signals sent through multiplexer 27 into digital signals and transmits these signals to microcontroller 29. Preferably, analog-to-digital converter 28 is a model TSC500 dual slope integrating analog-to-digital converter manufactured by Telcom Semiconductor of Mountain View, Calif. and first and second multiplexers 25, 27 are a model 74HC4052 manufactured by Texas Instruments of Dallas, Tex., however any analog-to-digital converter or multiplexer suitable for converting and channeling sensor inputs is felt to fall within the scope of the present invention. Finally, operational amplifier 26 is preferably a model OP-177 manufactured by Analog Devices of Norwood, Mass., however any operational amplifier with a low internal noise characteristic suitable for adding a large gain to a sensor signal is felt to fall within the scope of the present invention.
Referring to FIG. 3, a more detailed description of the operation and structure of front-end circuitry 22 is shown. First multiplexer 25 may select one of two inputs, I1 and I2, for channeling through operational amplifier 26. When the input I1 is selected, thermopile detector 23 generates a voltage output signal which is proportional to the net infrared radiation incident upon detector 23 coming from an infrared source such as the tympanic membrane. The switch to input I1 by first multiplexer 25 causes a low impedance path from thermopile detector 23 to one side of first resistor 40 so that the thermopile detector 23 is electrically connected to the operational amplifier 26. Further, the combination of first resistor 40 and first capacitor 33 between first multiplexer 25 and operational amplifier 26 form a low pass filter which passes low frequency signals so that noise outside the bandwidth of the voltage output signal is attenuated and a clean signal is generated. Preferably, first resistor 33 is a conventional 100 ohm resistor and first capacitor 33 is a standard 0.1 microfarad capacitor.
The operational amplifier 26 is configured as an active low pass filter such that when the signals are passed through amplifier 26 the circuit noise in each signal is effectively reduced. To accomplish this low pass filtering, a second resistor 34 is placed in parallel with a second capacitor 35 and a third resistor 36 is placed in parallel with a third capacitor 37, thereby forming first and second combinations. First and second combinations are then placed in series with one another, thus forming an effective low pass filtering circuit for signals passing through operational amplifier 29. Preferably, second resistor 34 is a 40.2 K Ohm conventional resistor, second capacitor 35 is a standard 0.1 microfarad capacitor, third resistor 36 is a 100 ohm conventional resistor and third capacitor 37 is a standard 0.1 microfarad capacitor.
Second multiplexer 27 receives input from operational amplifier 26, head thermistor 30 and tip thermistor 31 and selectively outputs these three inputs, I3, I4 and I5 respectively, to an analog-to-digital converter 28 to digitize and forward these outputs to microcontroller 29. Information from head thermistor 30, tip thermistor 31 and thermopile detector 23 are used in combination with calibration coefficients retrieved in the EEPROM 32 for the purpose of determining the final temperature of a tympanic membrane.
Referring to FIGS. 4-6, a detailed description of the software routine and subroutines used to determine both the temperature of the tympanic membrane and whether there is interfering EMI in the vicinity of tympanic thermometer 11 that exceeds the predetermined threshold is shown in flow chart format. When the user engages the probe cover 17 to the probe head extension 18, microcontroller 29 initializes a data buffer inside microcontoller's 29 Random Access Memory (RAM) (not shown) and clears flags in the RAM, checks modes and equivalences, and sets up the Analog-to-Digital Converter 28 for data acquisition from the thermopile 23 and head and tip thermistors 30,31. Microprocessor 29 further initializes the minimum null A/D to 8000 (in hexadecimal) and the maximum null A/D to 0000 (also in hexadecimal) so that the lowest possible maximum null A/D value is initialized and the highest possible minimum null A/D value. By initializing the minimum and maximum null A/D values in this manner, at least one maximum and minimum null A/D reading is retained in the data buffer.
After the data buffer is fully initialized, microprocessor 29 takes a plurality of voltage output readings and stores these readings in the data buffer prior to the user actuating SCAN button 15. Further, after the voltage output readings have been stored, microcontroller 29 instructs first multiplexer 25 to select input I2 which causes a low impedance path between ground and first resistor 40. This selection grounds the input to operational amplifier 26 so that any voltage present in the output is due to offset voltages generated inside operational amplifier 26. Once input I2 has been selected, software within microcontroller 29 establishes a "pre-scan" loop subroutine that takes one or more null input readings of circuit ground 24 per loop subroutine and sends these readings through operational amplifier 26 where the reading is soon after digitized by an analog-to-digital converter 28. The loop subroutine provides microcontroller 29 with sufficient null input readings for establishing a minimum and maximum reference values for null input readings prior to the user pressing SCAN button 15.
Once the user presses SCAN button 15, microcontroller 29 will terminate the "pre-scan" subroutine and direct the microcontoller 29 to enter a subroutine A. In subroutine A, microcontroller 29 fills a "post-scan" buffer with a set of voltage output readings, a single tip thermistor reading from a tip thermistor 31 and single head thermistor reading from a head thermistor 30. Microprocessor 29 then calculates the final temperature of a tympanic membrane. Preferably, microcontroller 29 takes 14 voltage output readings when a set of readings are taken, however any suitable number of readings that permit microcontroller 29 to accurately determine the temperature of the tympanic membrane is felt to fall within the scope of the present invention. Once all these sensor readings have been taken for the purpose of temperature measurement, microprocessor 29 then determines whether sufficient EMI is present that would interfere with the accuracy of the temperature being taken by tympanic thermometer 11.
To determine whether sufficient EMI is present, microcontroller 29 first enters a subroutine B and initializes a feedback loop counter to a count of 9. After initialization of the counter, microcontroller 29 then enters into a "post-scan" loop where one offset voltage reading is taken and compared against maximum and minimum offset voltage values previously stored in the data buffer during the "prescan" loop. If the one offset voltage reading exceeds either the maximum or minimum offset voltage values stored, then that new offset voltage reading will replace the maximum or minimum value in the data buffer therein. After the minimum and maximum values are determined, the counter is increased by an increment of one and the "post-scan" loop returns and acquires another single offset voltage reading. The "post-scan" loop will continue to update the maximum and minimum offset voltage values until the counter reaches a count of 15. Once the counter reaches 15, microcontroller 29 enters a subroutine C.
In subroutine C a Maximum-Minimum Difference is determined by subtracting the minimum offset voltage value from the maximum null input value stored in the data buffer. Once the Maximum-Minimum Difference is determined, that difference is compared against a pre-determined Maximum Allowed Difference stored in EEPROM 32. Preferably, the pre-determined Maximum Allowed Difference or predetermined threshold stored in the EEPROM 32 is 6 A/D counts, although any suitable number of A/D counts for determining a pre-determined Maximum Allowed Difference is felt to fall within the spirit and scope of the present invention.
If the value derived from subtracting the Maximum-Minimum Difference from the Maximum Allowed Difference is a negative value, then microcontroller 29 writes a numeral "6" to an error handler (not shown) which calls the error message and displays it at display 14. However, if the above value turns out to be a positive value, then there isn't a sufficient EMI event present in the vicinity of tympanic thermometer 11 that would interfere with its operation and microcontroller 29 directs that the temperature of the tympanic membrane be calculated and displayed. To determine the tympanic membrane temperature, microcontroller 29 searches both the "pre-scan" and "post-scan" information previously stored in the data buffer and acquires the highest voltage output reading from thermopile 23, head thermistor reading, tip thermistor reading and an average null A/D reading. Once this information is gathered, microcontroller 29 calculates the tympanic membrane temperature using a polynomial equation stored in the microcontroller's 29 memory (not shown) and displays that temperature at display 14. Once the temperature is displayed the software routine returns to START.
Although particular embodiments of the invention have been shown, it is not intended that the invention be limited thereby, instead, the scope of the present invention is intended to be limited only by the appended claims. | The present invention is directed to an electronic device for sensing and indicating the presence of electromagnetic interference in the vicinity of a electronic thermometer and preventing the display of a core body temperature reading when the electromagnetic interference exceeds a predetermined threshold. Disclosed is a tympanic thermometer comprising circuitry and a microprocessor that takes a a plurality of voltage readings from the null input of an operational amplifier in the circuitry. After taking into account ambient temperature conditions into the temperature calculations, the microprocessor compares the average value of the voltage readings taken from the null input against a predetermined threshold in the memory of the microprocessor. If the value exceeds the predetermined threshold, then the microprocessor prevents the display of the core body temperature and directs a display to write an error message. However, if the value does not exceed the predetermined threshold, the microprocessor directs the displays the core body temperature taken by the tympanic thermometer. | 6 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of my application Ser. No. 115,866 filed Nov. 2, 1987 and assigned to Dowasue Industries Ltd. (now U.S. Pat. No. 4,854,384 of Aug. 8, 1989) the disclosure of which application is incorporated herein by reference thereto.
BACKGROUND OF THE INVENTION
This invention relates to a pipeline plug or packer for plugging a pipeline, such as a crude oil pipeline, at a selected location therealong.
Pipeline packers of the type to which the present invention relates are designed to act as positionable shut-off valves inside a pipeline. The packer is typically loaded into the pipeline through a standard pig trap and the packer is transported along the pipeline by the fluid flowing in the line. Tracking of the packer is typically done from above ground with a sensor receiving signals from a transmitter located on the packer. When the packer reaches the desired position, the pipeline pumping equipment is stopped to stop the flow and the packer is activated by remote control so as to seal the pipeline at that location. With two packers spaced some distance apart, it is possible to isolate a section of the pipeline, thereby allowing that section of the pipeline to be drained to provide a substantially liquid-free environment without draining the entire line. After the desired work in the pipeline has been accomplished, the packer is released by remote control, and the flow through the pipeline is started up to move the packer along the line with the packer being thereafter removed through a further pig trap.
The pipeline packer must be capable of forming a reliable seal under a wide variety of conditions. In mountainous country, extremely high pipeline hydrostatic heads are common, typically being in the order of several hundred pounds per square inch and, in extreme cases, pressure heads as high as 700 pounds per square inch may be encountered.
SUMMARY OF THE INVENTION
It is therefore a basic object of the present invention to provide an improved pipeline packer, which packer is capable of gripping and sealing against a pipeline interior wall in a reliable fashion under high pressures.
A further general object of the invention is to provide an improved pipeline packer which is compact, capable of navigating relatively tight bends, which is reliable and self-contained, and incorporates its own source of hydraulic energy.
It is a further object of the invention to provide simple and reliable pipeline wall gripping brake shoe activating arrangements; a further object is to provide means which protect against extrusion and creep of the annular seal under the differential pressures which may be encountered during use.
A further objective is to provide an improved packer incorporating a self-contained energy supply and two-stage pressurization and depressurization.
A pipeline packer in accordance with the invention for plugging pipeline at a selected location typically includes several of the following features in suitable combination:
(1) a body assembly having an upstream high pressure end and a downstream low pressure end and adapted for insertion into and propulsion through the pipeline in the axial direction under the influence of fluid pressures acting thereon;
(2) a plurality of brake shoes capable of gripping interior wall of the pipeline mounted to said body assembly and extending thereabout in circumferentially spaced relation;
(3) said brake shoes being mounted to said body assembly for generally radial motion of each brake shoe relative to said body assembly from a non-gripping to a pipeline wall gripping position;
(4) a pair of annular wedging means mounted to said body assembly for relative axial movement therebetween;
(5) fluid pressure activated means associated with said annular wedging means for effecting said relative axial movement and to said brake shoes for moving same to the pipeline wall gripping position;
(6) an annular sealing member of elastomeric material mounted to said body assembly between said pair of annular wedging means and co-operating therewith to expand radially outwardly as relative motion of the annular wedging means toward one another occurs thereby to bring the sealing member into engagement with the interior wall of the pipeline to substantially prevent leakage of fluid around said body assembly;
(7) fluid pressure supply and control means connected to said fluid pressure activated means and adapted, on command, to cause said brake shoes to be urged radially outwardly into gripping relation with the pipeline wall and to effect said relative axial movement between said annular wedging means to expand said sealing member into sealing engagement with the pipeline wall.
Preferably, the fluid pressure activated means associated with said annular wedging means comprises first piston and cylinder means.
In a typical embodiment the fluid pressure supply and control means includes a source of fluid pressure, and valve means for controlling admission to and release of the fluid from the fluid pressure activated means.
As a further feature of the invention said fluid pressure activated means includes respective piston and cylinder means associated with each brake shoe and being mounted to said body assembly, and wherein said body assembly includes a main body section to which said brake shoes and their associated piston and cylinder means are mounted, an elongated rod mounted to said main body section and extending outwardly therefrom, said first piston and cylinder means being defined by a piston formed on said rod and a cylinder surrounding said piston and slidable relative thereto along said rod with a variable volume chamber being defined between the piston and the cylinder, one of said pair of annular wedging means being secured to said cylinder and the other one being secured relative to the main body section.
Preferably said piston is defined by an outwardly stepped portion on said rod, and said cylinder defining radially stepped portions each respectively mating with the rod and the piston formed thereon, and said variable volume chamber being an annular chamber defined by the radially stepped portions on said rod and said cylinder, said piston and cylinder being at the high pressure end of said body assembly. The cylinder is preferably of an open-ended sleeve-like configuration and the upstream high pressure end of the piston is exposed to the pressure existing, in use, in the pipeline.
Another feature of the invention provides means movable from a retracted position to an advanced position in juxtaposition to a downstream low pressure side of said elastomeric sealing member to reinforce the same and assist in preventing extrusion and creep of the sealing member under the influence of the differential axial pressures acting thereon when in use. The above-noted movable means preferably comprises circumferentially spaced radially movable plunger means adapted to move to a radially outer sealing member reinforcing position under the influence of a differential pressure acting across said sealing member when the latter is in sealed engagement with a pipeline wall. Springs or other suitable means are associated with each of said plunger means to effect retraction thereof to an inoperative position in the absence of the differential pressure.
As a further feature of the invention said body assembly has a main body section to which said brake shoes and their associated piston and cylinder means are mounted, each brake shoe being mounted to the radially outer end of a piston rod having a piston formed on a radially inner end thereof, and the fluid pressure supply and control means including passages in said body assembly to supply and release pressurized fluid to and from the interiors of the cylinder means within which said pistons are located to force the same, on command, radially outwardly to the pipeline wall gripping positions and, on command, to release said fluid from said cylinder means to allow the pistons and the brake shoes to retract.
Preferably the piston and cylinder means for the brake shoes each together define an annular zone communicating with a supply of pressurized fluid which acts on the piston in a direction such as to cause retraction thereof together with the brake shoe when the fluid pressure has been released from the interiors of the cylinder means.
As an added feature each cylinder means and its associated piston are removable from said main body section to facilitate repair and replacement thereof.
In accordance with a further feature of the invention said fluid pressure supply and control means includes a pressure intensifier means between said source and the piston and cylinder means, means for by-passing said intensifier during a first stage of the admission of the pressurized fluid to the piston and cylinder means and means to render the intensifier operative during a second stage of the admission to bring the brake shoes and the annular sealing member into the pipeline wall gripping and sealing positions respectively. The supply and control means is preferably arranged such that during said first stage, the fluid being admitted has essentially the same pressure as the pressure at said source and during said second stage the pressure of the fluid being admitted is a multiple of the source pressure.
The source of fluid pressure preferably comprises a chamber divided into two compartments by a movable partition, one of said compartments containing pressurized gas and the other containing a hydraulic liquid so that when said control means is activated, the pressurized gas forces the liquid out of the compartment and into the fluid pressure activated means for effecting said motion of the brake shoes and the annular wedging means.
In the embodiment described hereafter, the source of pressure is disposed in a first module, said control means being disposed in a second module, and said body assembly with the gripping and sealing means comprising a third module, the three modules being linked together by flexible joint means to enable the packer to travel through relatively tight bends in a pipeline.
Further features and advantages of the invention will become apparent from the following description of a preferred embodiment of same, reference being had to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In drawings which illustrate a preferred embodiment the invention:
FIG. 1 is side elevation view of a packer in accordance with the present invention positioned within a pipeline;
FIG. 2 is a longitudinal section view of the gripping and sealing module portion of the packer;
FIG. 3 is a cross-section view taken along line 3--3 in FIG. 2;
FIG. 4 is a partial end elevation view of the main body section of the packer;
FIG. 5 is a longitudinal section view of the module which contains the fluid pressure supply and control means including the pressure intensifier;
FIG. 6 is a longitudinal section view of the module which incorporates the source of fluid pressure;
FIG. 7 is a schematic diagram of the hydraulic fluid supply and control system showing the manner in which it is connected to the various hydraulic piston cylinder assemblies.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring firstly to Figure the pipeline packer 10 is illustrated as being disposed within a pipeline. The packer 10 comprises three main modules 12, 14 and 16. Module 12 is the gripping and sealing module and it contains the necessary mechanisms to effect gripping and sealing of the packer within the pipeline. Module 14 contains the fluid pressure supply and control means and module 16 comprises the source or supply of pressurized hydraulic fluid.
The three modules 12, 14 and 16 are linked together by flexible universal joints 18 and 20 in a manner known per se in the prior art. Hydraulic lines 22 and 24 between the modules 12, 14 and 16 are formed as spirals thereby to allow flexing movement between the modules without overstressing the hydraulic lines.
The gripping and sealing module 12 will be described in detail hereafter but by way of a general introduction to it it is noted here that sealing of the pipeline is accomplished by way of a polyurethane elastomer sealing ring 28 which is radially expanded by virtue of annular wedge rings to be described hereafter. The pipeline gripping action is effected by means of a plurality of circumferentially arranged brake shoes which are expanded radially outwardly against the interior wall of the pipeline by respective piston and cylinder means to be described hereinafter.
It will also be noted that the gripping and sealing module 12 is supported within the pipeline by front and rear annular flanges or pig rubbers 32 and 34. In like manner, the frontal ends of modules 14 and 16 are supported by annular pig rubbers 36 and 38. All of these pig rubbers are of a generally cup-shaped cross-section and they are made of a tough long wearing polyurethane elastomer material to provide for long life before there is any need for replacement.
Turning now to FIGS. 2-4, the gripping and sealing module 12 will be described in greater detail. As noted previously, both front and rear ends of the module 12 are provided with annular cup-shaped flanges or pig rubbers 32 and 34 which serve to slidably support the module 13 for movement along the pipeline interior while at the same time sealingly engaging the pipeline wall so that the packer may be moved along the pipeline by a flow of fluid therein. The module 12 includes a main body section 40 to which the brake shoes 30 and their associated activating piston and cylinder means are mounted. The main body section 40 is of a generally annular configuration and it includes a relatively large bore 42 extending axially thereof. An elongated rod 44 is mounted in the main body section 40 and it includes a reduced diameter neck portion 46 which is seated within the bore 42 within the main body section. The rod 44 includes outwardly stepped portions, the first one of such stepped portions 48 seating in a corresponding annular step formed in the aft end of main body section 40. The neck portion 46 is firmly retained within bore 42 by means of screw threads 50 which engage corresponding threads formed in the aft end portion of the previously noted universal joint 18. The aft end of rod 44 includes a smooth cylindrical portion 52 and, at the rear end of rod 44 there is an outwardly stepped portion defining a piston 54. A cylinder 56 surrounds the piston 54 and is slidable relative thereto along the rod 44 with a variable volume chamber 58 being defined between the piston 54 and the cylinder 56. It will of course be seen that the cylinder includes internal cylindrical walls 60 and 62, cylindrical wall 62 being stepped radially inwardly of wall 60. The piston 54 slides along cylinder wall 60 while cylinder wall 62 slides along cylindrical portion 52 of the rod 44. Multiple annular seals 66 are provided on piston 54 so as to make good sealing engagement with the cylindrical wall 60 of cylinder 56 while further seals 68 are provided on the cylindrical wall 62 of cylinder 56 thereby to make for fluid tight engagement between these components. It will accordingly be seen that the variable volume chamber 58 is an annular chamber and it is defined by and between the radially stepped portions on the rod 44 and the cylinder 56. The piston 54 and the cylinder 56 are located at the high pressure end of the overall body assembly, (the body assembly being the overall general assembly which comprises the module 12). The upstream high pressure end of the piston 54 is exposed to the pressure existing during use within the pipeline.
It will be noted that the forward end of cylinder 56 is radially inwardly stepped at 70 and that an annular wedge ring 72 is mounted thereon and firmly secured thereto by the studs 74. The annular wedging ring 72 has a frustro-conical wedging surface 74 thereon which defines a cone angle of approximately 45° relative to the longitudinal axis of the module 12. It will also noted from FIG. 2 that a pressure balancing passage 76 extends through the rear flange or pig rubber 34 and through the wedging ring 72. This passage provides a pressure balancing effect which will be noted hereinafter.
The rearward face of main body section 40 is provided with a complementary annular wedging surface 80, also having a smooth frustro-conical shape and a cone angle of approximately 45° to the axis of the module 12.
The previous noted annular sealing ring 28 is located between and seated on the annular wedging surfaces 74 and 80 and, as again shown in FIG. 2, the sealing ring is itself provided with opposed wedging surfaces 82 sloped to correspond with the annular wedging surfaces 74 and 80. Hence, as cylinder 56 moves axially forwardly along piston 54, the wedging ring 72 thereon moves toward the annular wedging surface 80 formed on the main body section 40. The interaction of the wedging surfaces with the sealing ring 28 causes the latter to be expanded radially outwardly such that the outer surface 86 of the sealing ring comes into close sealing engagement with the interior surface of the pipeline wall. This surface 86 is preferably provided with a series of narrow V-shaped grooves thereby to enhance the sealing effect. The sealing ring 28 is preferably made of a tough polyurethane elastomer having a Durometer hardness of approximately 85.
It will be noted that the rod 44 has an elongated passage 90 extending longitudinally thereof from the extreme front end of the rod through a check valve 92 and thence communicating with a transverse passage 94 formed in the piston 54. This passage 94 communicates with the annular chamber 58 formed between the radially stepped portions of the piston 54 and cylinder 56. Hence, as hydraulic fluid under pressure is supplied through the passageways 90 and 94, the cylinder 56 is caused to move forwardly along the rod 44 thus causing the annular sealing ring 28 to be expanded radially outwardly in the manner described previously. The annular seals 66 and 68 prevent leakage of hydraulic fluids between the rod 44, piston 54 and cylinder 56.
During use of the packer, it will be appreciated that substantial differential pressures are applied to the elastomeric sealing ring 28. Ordinarily, this tends to cause distortion and creep of the seal ring 28 in the axial direction. In order to alleviate this problem, a plurality of anti-extrusion plungers 96 are provided, these plungers being mounted in the rear portion of the main body section 40 just forwardly of the annular wedging surface 80. These anti-extrusion plungers 96 are disposed in circumferentially spaced apart relationship and, although only one of them is shown in FIG. 2, six equally spaced such plungers are actually provided in the embodiment being described These anti-extrusion plungers 96 include an elongated plunger shaft having a plurality of annular seals 100 at the radially inner end thereof. Escape of the plunger shaft 98 from the bore within which it is contained is prevented by means of an annular bushing 102 threaded into the outer portion of the bore. A compression spring 104 surrounds the shaft of the plunger and bears against the above-noted bushing 102 thereby urging the plunger radially inwardly. The lower end of the bore within which the plunger is mounted communicates with a passage 106 which leads into the space which exists between the rod 44 and the radially inwardly facing surface of the elastomeric seal ring 28. It was previously noted that a pressure balancing passage 76 extends through the rear flange 34 and the wedging ring 72. Hence, this annular space beneath the seal ring 28 is at the same pressure as the pressure on the upstream high pressure side of the packer. This upstream high pressure acts on the inner end of the plunger shaft and causes all of the anti-extrusion plungers 96 to be projected radially outwardly such that their outer ends come into close juxtaposition to the interior wall of the pipeline. Thus, under extreme pressure conditions, when the seal ring 28 bulges outwardly as indicated by the dashed lines, the several anti-extrusion plungers, in their extended positions, help to stabilize the sealing ring and prevent undue extrusion and distortion thereof. When the pressure differential reduces down to a fairly nominal level, the springs 104 retract the anti-extrusion plungers so that they are incapable of interfering with the movement of the packer along the pipeline.
At this point it might be noted that the main body section is also provided with a plurality of skid buttons 110, such buttons being located in circumferentially spaced relationship around the main body section. The purpose of the skid buttons is to contact the interior wall of the pipeline during passage around a tight bend or the like thereby to prevent contact of the pipeline wall with the various other components of the packer module 12 thus reducing wear and tear on such components.
The structures for activating the brake shoes 30 will now be described. It will be seen from FIGS. 2 and 3 in particular that each brake shoe is mounted to the radially outer end of a short, stout piston rod 120, such piston rod 120 having a piston 122 formed on the radially inner end thereof. The piston and piston rod are in turn slidably mounted in a cylinder sleeve 124. Each cylinder sleeve is retained within the main body section 40 by means of a retainer ring 126. A radially outer end of the cylinder sleeve is stepped inwardly and provided with seals 128 which bear against the exterior surface of piston rod 120. Piston 122 is of course also provided with suitable annular seals so that it sealingly engages the smooth inner bore provided by the cylinder sleeve 124. The exterior of the cylinder sleeve 124 is also provided with several annular seals to form a good seal with the bore of the main body section.
It will be noted from FIGS. 2 and 3 that the brake shoes 30 and their respectively associated pistons, piston rods and cylinder sleeves etc. are disposed in circumferentially spaced radially arranged relationship around the axis of the packer module 12. Two such radial arrays are provided, each array lying in a plane which is normal to the above-noted longitudinal axis of the packer module.
In order to extend the various brake shoes 30 radially outwardly, it will be noted that the radially inner end of each piston communicates via a short radial bore 130 with an annular channel 132 extending around and defined between the main body section and the neck 46 of the rod. Shallow grooves are actually formed in both the neck 46 and the main body section 40 to achieve this purpose. Leakage of pressurized fluid out of these annular channels 132 is prevented by means of multiple annular seals 134 extending around the neck 46 of the rod on opposing sides of channels 132. Each of the annular channels 132 communicates with the previously noted longitudinally extending passage 90 via lateral passageways 136, each passageway 136 being provided with a respective one way check valve 138. Hence, as fluid under pressure is applied via passage 90, such fluid enters the annular channels 132 and thence passes through the short passageways 130 leading into the individual cylinder and piston assemblies to which the respective brake shoes 30 are secured. Pressurized fluid causes the brake shoes to move radially outwardly relative to the main body section from a retracted non-gripping to an extended pipeline wall gripping position.
It might be noted here that the brake shoes, or at least that portion of same making contact with the pipeline interior wall, are made from a relatively soft malleable metal such as aluminum having a hardness preferably from about 65 to about 90 Brinell hardness units. This particular feature is described in greater detail in the previously noted application Serial No. 115,866. By providing the brake shoe contacting surface with a relatively malleable metal, damage to the pipeline wall interior surfaces is substantially prevented. This is of considerable importance to pipeline operators.
The means for effecting radial extension of the brake shoes 30 have been described. It is also of some importance to have means for positively retracting the brake shoes 30 after the pressure thereon has been released. It will have been noted during the course of the description of the piston rods 120, pistons 122 and cylinder sleeves 124, that an annular space or region is defined between the radially stepped portions of the cylinder sleeves 124 and the piston 122. This annular space is designated at 140. With reference to FIGS. 2 and 3 it will be noted that each cylinder sleeve 124 is surrounded by a shallow annular groove 142. This shallow annular groove communicates with all the other shallow annular grooves 142 by means Of drilled passageways 144 thus enabling the passageways and the annular spaces 140 to be pressurized by way of a suitable inlet 146 with a suitable pressurizing gas, preferably an inert gas such as nitrogen. The supply pressure is typically arranged to be in the order of 400-1000 psi thereby to positively retract the pistons 122 and the attached brake shoes 30 at the end of a cycle thus avoiding catching and breakage of the brake shoes on any obstructions appearing on the inside of the pipeline.
The fluid pressure and supply means for activating and deactivating the gripping and sealing module 12 will now be described with particular reference to FIGS. 5, 6 and 7. Reference will be had firstly to FIG. 7 which is a schematic of the overall system. With reference firstly to module 16, the same comprises a pressure resistant chamber 150 having an axially movable piston 152 therein, such piston being mounted for movement along an axially extending shaft 154. The piston 152 essentially separates chamber 150 into two separate annuluar compartments 156 and 158. Compartment 156 typically contains nitrogen gas while compartment 158 contains hydraulic oil. The piston 152 is of course provided with suitable annular seals thereby to prevent leakage or blow-through of the nitrogen into the hydraulic oil. The nitrogen is provided at a pressure such that when the oil has been fully displaced outwardly of the chamber, the residual pressure of the nitrogen is still in the order of 2000 psi. Suitable inlet check valve means 160 are for recharging the nitrogen supply.
The pressurized oil from module 16 passes through the previously noted spiral hydraulic line 24 through a one-way check valve and into the module 14. Module 14 is the control center for the packer. This module contains a number of drilled passageways for the hydraulic oil with suitable solenoid valves and check valves being provided together with a pressure intensifier thereby to achieve the desired final result.
Referring firstly to FIG. 5, the control module includes a cylindrical casing 160, such casing being provided with machined metal end pieces 162 and 164, such end pieces having outwardly projecting neck portions 166 for connection to the previously noted universal joints 18 and 20 which serve to connect the three modules together and which at the same time provide for transmission of the pressurized hydraulic fluid. Suitable annular seals on neck portions 166 prevent any leakage of the high pressure fluids. Module 14 includes a region within which is packaged the electronic control module broadly designated by reference 170. The electronic control module includes main and backup batteries and a circuit board including means for receiving remote signals (techniques which in themselves are well known in the art) with the circuit board incorporating suitable circuitry so as to activate or deactivate the four solenoid valves which are to be referred to hereinafter.
Referring again to FIG. 7 it will be seen that the incoming hydraulic oil from module 16 passes through a one-way check valve 172. The drilled passageways in module 14 include a first passageway 174 which passes through a first solenoid valve (Sol.1). Line 174 continues on through a further one-way check valve 176 and then connects with an output line 178 which communicates via spiral hydraulic line 22 with the gripping and sealing module 12.
Returning back to check valve 172, another branch of the hydraulic line designated by reference 180 passes through a second solenoid valve (Sol.2) and thence such line 180 leads into the inlet or low pressure end of a pressure intensifier 182. Pressure intensifiers are, per se, well known in the art. As illustrated in FIG. 5, the pressure intensifier includes an axially movable piston 184 defining a relatively large piston area 186 at the one end thereof and a relatively small piston area 188 at the opposing end. As is well known, the ratios of these two areas determine the degree of pressure multiplication. Since in this case it is desired to increase the applied pressure from about 2000 psi to about 10,000 psi, it is quite apparent that piston area 186 must be about five times greater than piston area 188.
It is also noted here that hydraulic passage 180 is also connected via a branch line 190 to and through a third solenoid valve (Sol.3). The outlet of this valve in turn leads to a return tank 192, the function of which is to accept the hydraulic fluid at the end of a cycle, which fluid was originally present in module 12.
The various passages for supplying pressurized hydraulic fluid to piston 54 and cylinder 56 for expanding the sealing ring 28 and for supplying pressurized fluid to the several piston and cylinder assemblies for effecting radial expansion of the brake shoes 30 were previously described. The passageways for releasing the hydraulic fluid from these components are not shown in FIG. 2 although they are schematically illustrated in FIG. 7. Specifically, hydraulic line 194, together with its associated branch lines and check valves, serves to exhaust the several pressure activated piston and cylinder assemblies thereby to permit radial contraction of the sealing ring 28 and inward radial retraction of the brake shoes 30 upon completion of a cycle. The hydraulic fluid which is displaced as a result of this action passes along passageway 194 and thence through a fourth cylinder valve (Sol.4), with the spent hydraulic fluid returning to the previously noted return tank 192.
In the operation of the packer, it will be assumed that the complete packer has been moved along within a pipeline by virtue Of the flow therein until it has reached a preselected location. A signal is then transmitted in any suitable manner to the electronic control module 170. As a result of this signal, Sol. 1 opens to allow pressurized hydraulic fluid to flow from module 16 outwardly through line 24, check valve 172, passageway 174 and check valve 176 and then outwardly through passage 178 and hydraulic line 22 into the sealing and gripping module 12. The pressurized hydraulic fluid enters the passage 90 and thence forces its way into the annular chamber 58 defined between the radially stepped portions of cylinder 56 and piston 54 with the result being that the annular wedging surface 74 moves toward wedging surface 80 thus causing the seal ring to be expanded radially outwardly into sealing engagement with the inner wall of the pipeline. At about the same time the two radial disposed arrays of brake shoes 30 (and their associated pistons and piston rods) move radially outwardly into contact with the interior wall of the pipeline. This action serves to initially "set" the sealing and gripping module 12 at a hydraulic oil pressure in the order of 2000-2500 psi.
The control modules to close Sol.1. Then Sol.2 is opened to allow the pressurized oil entry into the large end of the pressure intensifier 182 which, in a typical case, acts to multiply the pressure some five times up to a pressure of approximately 10,000 psi. A pressure sensing switch (not shown) can be utilized to sense when this pressure is reached following which Sol. 2 closes. As a result of this final pressurizing action, the brake shoes 30 firmly grip the inside wall of the pipeline and the resilient sealing ring firmly seals against liquid bypass. The anti-extrusion plungers 96, by virtue of the pressure differential arising, project radially outwardly for the purposes previously described.
In order to release the packer after the packer has served its purpose, the control module opens Sol. 3 to allow the hydraulic fluid to flow from the large end of the pressure intensifier 182 back into the return tank 192. This reduces the pressure in the system from 10,000 to 2000 psi. Sol. 3 then closes following which Sol. 4 opens to allow the hydraulic fluid to flow from module 12 thus reducing the hydraulic pressure from 2000 pounds down to substantially atmospheric pressure. The pressurized nitrogen in the several piston assemblies causes retraction of the brake shoes 30 and the strong contraction of the annular sealing ring 28 forces the annular wedging surface 74 away from annular wedging surface 80 thus returning module 12 essentially to its initial condition. Sol.4 then closes. As the packer has then completed a full cycle of operation it will be subsequently removed from the pipeline, inspected, and the hydraulic oil drained from the return tank and module 16 replenished with fresh hydraulic oil and a supply of pressurized nitrogen.
While a preferred embodiment of the invention has been described by way of example, those skilled in the art will realize that various changes and modifications may be made while still remaining within the spirit and scope of the invention. For example, many of the features of the invention are applicable to the pipeline packer as described in the above-noted application Serial No. 115,866 which incorporates dual wedge-action activated brake shoes as opposed to the fluid pressure piston and cylinder activated brake shoe system disclosed herein. For definitions of the invention reference is to be had to the appended claims. | The pipeline packer described herein typically includes a main body adapted for propulsion through the pipeline is an axial direction. A brake shoe support assembly is located on the main body and a plurality of circumferentially spaced brake shoes capable of gripping the interior wall of the pipeline are mounted to the support assembly. Fluid pressure activated devices are associated with the brake shoe support assembly for urging the brake shoes radially outwardly into gripping engagement with the pipeline to secure the main body in a desired location in the pipeline against the pipeline pressure forces acting thereon. A pair of annular wedges are also mounted to the main body for axial movement toward each other as the fluid pressure activated device acts on the brake shoe support assembly to urge the brake shoes into gripping engagement. An annular sealing member of elastomeric material is located between the annular wedges and is adapted to co-operate with same so as to expand radially outwardly as the annular wedges move toward each other. The packer also includes fluid pressure supply and control systems connected to the fluid pressure activated devices so that on demand the brake shoes are urged into gripping relationship with the pipeline while at the same time the annular sealing member is expanded into sealing engagement with the pipeline wall. | 5 |
BACKGROUND OF THE INVENTION
This invention relates to a thermoplastic resin composition which is a blend of a thermoplastic urethane elastomer and a specifically selected thermoplastic fluororesin having flexibility. The resin composition is particularly suitable for extrusion to form, for example, tubes or coverings of electric wires or cables.
Urethane elastomers are widely used as thermoplastic resins having excellent mechanical properties. In particular urethane elastomers having a glass transition temperature lower than room temperature are largely used as extrusion molding materials to form various tubes and coverings of electric wires and cables.
However, from some aspects thermoplastic urethane elastomers have disadvantages too. First, compared with more popular thermoplastic resins such as polyvinyl chloride resins conventional urethane elastomers are generally inferior in extrudability and hence offer greater load to extruders. Therefore, when an urethane elastomer is extruded with an extruder primarily designed for extrusion of other thermoplastic resins it is likely that the extrusion output per unit time and some other items of extrusion conditions are unstable by reason of insufficient power of the extruder.
Thermoplastic urethane elastomers relatively low in hardness have another disadvantage that the extrusion molded products have considerably tacky surfaces. When the products such as tubes or covered wires are left stacked at room temperature the products stick to each other, and in some cases the struck products cannot easily be separated from one another. In industrial practice it is often to apply an antisticking agent in the form of powder or paste to the extruded products of urethane elastomer, but the application of such a powder or paste is troublesome and in many cases raises the need of removing the antisticking agent at the stage of using the extruded products. In some cases the tacky products tend to stick to articles made of different materials and consequently raise certain problems. For example, when a cable having an urethane elastomer covering is used in an industrial robot there is a possibility that the cable sticks to a rack or another cable covered with a different material and consequently breaks as the robot repeats preprogrammed operations.
Besides, as covering materials for electric wires and cables conventional thermoplastic urethane elastomers are not fully satisfactory in resistance to heat aging and in this respect are inferior to conventional fluororesins.
SUMMARY OF THE INVENTION
It is an object of the present invention to obviate the above explained disadvantages of thermoplastic urethane elastomers, without sacrificing the flexibility inherent to the elastomers, by blending a conventional thermoplastic urethane elastomer with a specifically selected thermoplastic fluororesin which possesses flexibility.
According to the invention the above object is accomplished by blending 100 parts by weight of a thermoplastic urethane elastomer with 1-100 parts by weight of a thermoplastic and fluorine-containing graft copolymer which is obtained by graft polymerization of vinylidene fluoride with an elastomeric copolymer of at least two principal monomers including at least one fluorine-containing monomer and a subsidiary monomer which has at least one double bond and peroxy group, the elastomeric copolymer having a glass transition temperature below room temperature.
In this invention it is preferred to use an urethane elastomer having a glass transition temperature below room temperature.
The thermoplastic and fluorine-containing graft copolymer used in this invention belongs to a group of fluorine-containing graft copolymers disclosed in U.S. Pat. No. 4,472,557. In the graft copolymer the "trunk" polymer is a fluorine-containing elastomeric copolymer, and the "branch" segments are of crystalline polyvinylidene fluoride. The graft polymerization of vinylidene fluoride is accomplished by using thermal decomposition of the peroxy groups in the trunk polymer. In this invention it is preferred that the weight ratio of the graft polymerized vinylidene fluoride to the trunk polymer is in the range from 20:100 to 80:100. This graft copolymer itself serves as a soft and flexible fluororesin which can easily be molded by extrusion and other conventional resin molding methods. The graft copolymer can be well melted at temperatures suitable for molding conventional thermoplastic urethane elastomers. For example, the graft copolymer has a melting temperature of about 170° C.
In the graft copolymer a preferred example of the trunk polymer, viz. elastomeric copolymer having peroxy groups, is a copolymer of vinylidene fluoride, chlorotrifluoroethylene and a relatively small amount of an unsaturated peroxy compound such as t-butyl peroxyallylcarbonate.
The thermoplastic resin compositions according to the invention are soft and flexible fluororesins and serve as improved substitutes for conventional thermoplastic urethane elastomers. Each of the blended resin compositions of the invention is better in extrudability than the urethane elastomer used in that composition. That is, when the blended resin composition is melted and kneaded in the cylinder of an extruder the torque generated by the motion of the screw is smaller than the torque generated in the case of kneading the urethane elastomer itself. Furthermore, compared with the urethane elastomer the blended resin composition is lower in the coefficient of kinetic friction of a molded product with either the same material or a different material and weaker in surface tackiness of molded products. Besides, by virtue of incorporating a fluororesin the blended resin composition is considerably improved in resistance to heat aging and in some cases possesses improved flame retardency.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Thermoplastic urethane elastomers are classified into several types according to the types of the employed polyol, such as caprolactones, adipates, ethers and carbonates. In this invention it is possible to use a conventional thermoplastic urethane elastomer of any type, and preferably one having a glass transition temperature below room temperature.
As to the fluorine-containing graft copolymer the principal monomers for the elastomeric copolymer, which is the trunk polymer, can be selected from various combinations. It is preferable to employ a combination of two or three fluorine-containing compounds, but it is also possible to use a combination of at least one fluorine-containing compound and at least one unsubstituted hydrocarbon such as, for example, propylene and/or ethylene. More particularly it is preferred to employ a combination of vinylidene fluoride (VDF) and chlorotrifluoroethylene (CTFE), combination of VDF and hexafluoropropene (HFP), combination of VDF, HFP and tetrafluoroethylene (TFE). As to the subsidiary monomer having at least one double bond and peroxy group, examples of useful compounds are unsaturated peroxyesters such as t-butyl peroxymethacrylate and t-butyl peroxycrotonate and unsaturated peroxycarbonates such as t-butyl peroxyallylcarbonate and p-menthane peroxyallylcarbonate. It suffices to mix a relatively small amount of such an unsaturated peroxide with the above described principal monomers. That is, in general it suffices that the unsaturated peroxide monomer amounts to about 0.05 to 5 wt % of the monomer mixture to be copolymerized.
The branch polymer of the fluorine-containing graft copolymer is always polyvinylidene fluoride. It is preferable to graft polymerize 20-80 parts by weight of VDF with 100 parts by weight of the above described fluorine-containing elastomeric copolymer. When the amount of the graft polymerized VDF is less than 20 parts by weight the graft copolymer in melted state has a relatively high viscosity, and hence it is not easy to accomplish good blending of the graft copolymer with a thermoplastic urethane elastomer by melt blending. When the amount of the graft polymerized VDF is more than 80 parts by weight it is likely that both the graft copolymer and a blend of the graft copolymer with a thermoplastic urethane elastomer are insufficient in softness or flexibility.
A resin composition according to the invention is obtained by blending 100 parts by weight of a thermoplastic urethane elastomer with 1 to 100 parts by weight of the above described graft copolymer. If the amount of the graft copolymer is less than 1 part by weight the effects of the blending are insufficient. If the amount of the graft copolymer is more than 100 parts by weight the blended resin composition becomes too different from the urethane elastomer because in the blended resin composition the urethane elastomer is dispersed in a continuous phase of the graft copolymer. It is preferred to blend 5 to 80 parts by weight of the graft copolymer with 100 parts by weight of an urethane elastomer.
Usually the blending is accomplished by a melt blending method using, for example, a twin-roll kneader or an extruder. However, if desired it is possible to accomplish blending by dissolving both the urethane elastomer and the graft copolymer in a polar solvent such as dimethylformamide.
The following nonlimitative examples are illustrative of the invention.
EXAMPLE 1
1. Preparation of Fluorine-containing Graft Copolymer
Initially a 100-liter stainless steel autoclave was charged with 50 kg of purified water, 100 g of potassium persulfate, 150 g of ammonium perfluorooctanoate and 100 g of t-butyl peroxyallylcarbonate (abbreviated to BPAC). The gas atmosphere in the autoclave was repeatedly replaced by nitrogen gas, and then the gas was purged. After that 12.5 kg of VDF monomer and 7.55 kg of CTFE monomer were introduced into the autoclave, and the resultant mixture was subjected to copolymerization reaction at a temperature of 50° C. for 20 h while continuing stirring. The reaction product was in the state of white latex. From this latex a rubber-like powder was obtained by salting-out treatment. The powder was washed with water, dried in vacuum, then washed with n-hexane to completely remove unreacted residue of BPAC and again dried in vacuum. The dried powder weighed 16 kg. This powder was of an elastomeric copolymer of VDF, CTFE and BPAC. Thermal analysis of this copolymer with a differential scanning calorimeter (DSC) revealed the existence of an exothermic peak at 160°-180° C., which was attributed to decomposition of peroxy group. By DSC analysis the glass transition temperature of the copolymer was about -21° C. By iodometric titration the content of active oxygen in the copolymer was measured to be 0.042%.
To carry out a graft polymerization reaction, 12 kg of the above copolymer powder was charged in a 100-liter stainless steel autoclave together with 75 kg of 1,1,2-trifluoro-1,2,2-trichloroethane (solvent). The gas atmosphere in the autoclave was repeatedly replaced by nitrogen gas, and then the gas was purged. After that 6 kg of VDF monomer was charged into the autoclave, and the resultant mixture was subjected to polymerization reaction at 95° C. for 24 h with continuous stirring. The reaction product was separated from the solvent and dried to obtain 16.6 kg of a graft copolymer in the form of a white powder. By calculation from the weight of the obtained graft copolymer, the weight ratio of the graft polymerized VDF to the elastomeric trunk copolymer was 38.3:100.
The obtained graft copolymer was pelletized with an extruder having a diameter of 30 mm (length-to-diameter ratio of the cylinder was 22) at a temperature of 180°-200° C.
2. Blending of Graft Copolymer and Urethane Elastomer
As a conventional thermoplastic urethane elastomer, MIRACTRAN P22M of Nippon MIRACTRAN Co. was employed. The urethane elastomer in the form of pellets was dried at 80° C. for 4 hr.
In a drum type tumbler 100 parts by weight of the urethane elastomer was mixed with 5 parts by weight of the fluroine-containing graft copolymer prepared and pelletized by the above described process. The resultant mixture was melted and kneaded by using the aforementioned extruder to thereby accomplish blending of the urethane elastomer with the fluorine-containing graft copolymer and obtain the blended resin composition in the form of pellets.
EXAMPLES 2-4
In these examples the thermoplastic uerthane elastomer used in Example 1 was blended with the fluorine-containing graft copolymer prepared in Example 1 at different ratios. That is, in Examples 2, 3 and 4 the blending ratio of the graft copolymer to the urethane elastomer was 20:100, 50:100 and 80:100 by weight, respectively.
COMPARATIVE EXAMPLE
In this case, 120 parts by weight of the graft copolymer prepared in Example 1 was blended with 100 parts by weight of the thermoplastic urethane elastomer used in the foregoing examples.
EVALUATION TESTS
The blended resin compositions of Examples 1-4 and Comparative Example were each subjected to the following tests.
The results of the tests are shown in the Table at the end of the description.
(1) Torque generated in kneading melted resin
The testing apparatus was a laboratory mixer for plastics in which the capacity of the mixing chamber was 60 ml. The mixer was kept heated at 200° C., and a given quantity of the blended resin composition in the form of pellets was filled into the mixing chamber provided with a rotor. The quantity of the blended resin composition was determined by the following equation, wherein "resin" refers to the blended resin composition and S.G. stands for specific gravity. ##EQU1##
The mixer was left at rest for 1 min to allow the resin composition to melt. Then the rotor was revolved at a rate of 40 rpm, and the maximum value of torque generated by the revolution was measured.
(2) Kinetic coefficient of friction
The blended resin composition in the form of pellets was molded into 150 mm square sheets having a thickness of 2 mm by compression molding at a temperature of 200° C. Care was taken to obtain resin sheets having smooth surfaces. The resin sheets were used as specimens in the following tests (a) and (b).
(a) Friction with the same resin
Kinetic coefficient of friction between two sheets of the resin composition was measured by the test method according to ASTM D 1894 at a temperature of 23° C. The sled load was 200 g, and the sliding speed was 150 mm/min.
(b) Friction with carbon steel
Kinetic coefficient of friction between a sheet of the resin composition and a plate of a carbon steel (S45C) was measured with a friction abrasion tester (EFM-III-EN of Orientech Co.). The load was 5 kgf/cm 2 , and the sliding speed was 0.2 m/sec.
(3) Tensile strength
The blended resin composition in the form of pellets was melted and kneaded in a twin-roll mixer which was operated at a temperature of 170° C. for 30 min. Then the melted resin composition was formed into a sheet having a thickness of 1 mm by compression molding, wherein a pressure of 60 kgf/cm 2 was applied for 2 min at a temperature of 200° C. This resin sheet was punched to form dumb-bell specimens No. 3 according to JIS K 6301. Using these specimens, tensile strength and elongation at break were measured at 23° C. with an Instron type tensile tester. The pulling speed was 200 mm/min.
(4) Hardness
Using the resin sheet molded to form the aforementioned dumb-bell specimens, the durometer hardness A of the resin composition was measured by the test method according to JIS K 7215.
(5) Heat aging
The dumb-bell specimens formed for the tensile test were kept heated at 150° C. in a gear oven for 168 h. After that the specimens were subjected to the above described tensile test at 23° C. to measure the tensile strength and elongation at break, and the measurements were compared with the measurements in the tensile test (3) to indicate the resistance to heat aging by the percentages of the retained tensile strength and elongation.
REFERENCES 1 AND 2
The above described tests were made also on the thermoplastic urethane elastomer used in the foregoing examples (Reference 1) and the fluorine-containing graft copolymer prepared in Example 1 (Reference 2). The results are included in the following Table.
__________________________________________________________________________ Comp. Ex. 1 Ex. 2 Ex. 3 Ex. 4 Ex. Ref. 1 Ref. 2__________________________________________________________________________Composition (parts by weight)Urethane elastomer 100 100 100 100 100 100 --Graft copolymer 5 20 50 80 120 -- 100Properties of ResinSpecific gravity 1.22 1.28 1.35 1.41 1.46 1.20 1.78Melt torque, max. (kg · m) 7.95 7.72 7.34 6.65 6.42 8.10 5.60Coefficient of friction 5.08 4.73 2.32 1.26 1.08 5.26 0.63with same resinCoefficient of friction 3.4 3.4 3.3 2.9 2.5 3.5 1.3with carbon steelTensile strength (kgf/cm.sup.2) 551 505 495 476 435 555 316Elongation (%) 560 550 542 522 515 569 480Hardness 80 81 83 85 88 79 93Heat AgingRetained tensile strength (%) 64 72 77 78 83 51 104Retained elongation (%) 89 92 90 90 95 91 102__________________________________________________________________________ | A thermoplastic resin composition, which is flexible and can easily be extruded, is obtained by blending (A) 100 parts by weight of a thermoplastic urethane elastomer with (B) 1-100 parts by weight of a thermoplastic graft copolymer obtained by graft polymerization of vinylidene fluoride with an elastomeric copolymer of at least two principal monomers including at least one fluorine-containing compound, e.g. vinylidene fluoride and chlorotrifluoroethylene, and an unsaturated peroxy compound. Compared with the urethane elastomer (A) itself, this resin composition is better in extrudability, lower in kinetic friction coefficient, weaker in surface tackiness of molded products and higher in resistance to heat aging. | 2 |
REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/040,200, filed Mar. 3, 2011, entitled READING MEMORY CELL HISTORY DURING PROGRAM OPERATION FOR ADAPTIVE PROGRAMMING, which is hereby incorporated by reference in its entirety and made part of this specification.
BACKGROUND
[0002] 1. Field
[0003] Subject matter disclosed herein relates to a memory device, and more particularly to write performance of a memory device.
[0004] 2. Information
[0005] Memory devices are employed in many types of electronic devices, such as computers, cell phones, PDA's, data loggers, and navigational equipment, just to name a few examples. Among such electronic devices, various types of nonvolatile memory devices may be employed, such as NAND or NOR flash memories, and phase-change memory, just to name a few examples.
[0006] A NAND flash memory cell may transition from one state to another state by applying a bias signal to a control gate of the memory cell. Applying such a bias signal may result in charging a floating gate disposed between the control gate and a channel of the memory cell. Consequently, the amount of such charge on the floating gate may determine whether the memory cell is conductive above a particular threshold voltage applied to the control gate during a process to read the memory cell. However, a memory cell's response to a particular bias signal may change over time due to physical changes within the memory cell that may result from aging and usage, for example. Thus, it may be difficult to select proper bias signals to program such memory cells as the memory cells physically change over time.
BRIEF DESCRIPTION OF THE FIGURES
[0007] Non-limiting and non-exhaustive embodiments will be described with reference to the following figures, wherein like reference numerals refer to like parts throughout the various figures unless otherwise specified.
[0008] FIG. 1 is a plot of characteristics of program step pulses, according to an embodiment.
[0009] FIG. 2 is a plot showing threshold voltage distributions for a population of memory cells in a memory array, according to an embodiment.
[0010] FIG. 3 is a schematic diagram of a NAND block memory array, according to an embodiment.
[0011] FIG. 4 is a schematic diagram of a NAND block memory array during a read operation, according to an embodiment.
[0012] FIG. 5 is a schematic diagram of a NAND block memory array during a program-verify operation, according to an embodiment.
[0013] FIG. 6 is a plot showing a threshold voltage distribution for a population of programmed data cells in a memory array, according to an embodiment.
[0014] FIG. 7 is a plot showing a threshold voltage distribution for a population of programmed flag cells in a memory array, according to an embodiment.
[0015] FIG. 8 is a flow diagram of a program-verify process, according to an embodiment.
[0016] FIG. 9 is a schematic diagram illustrating an exemplary embodiment of a computing system.
DETAILED DESCRIPTION
[0017] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of claimed subject matter. Thus, the appearances of the phrase “in one embodiment” or “an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in one or more embodiments.
[0018] Embodiments described herein include processes and/or electronic architecture involving modifying memory cell program conditions of a memory device in response to reading flag cells that store wear information of the memory device. As a memory device ages, “optimal” program conditions for writing to the memory device may change or evolve. An ability to modify such program conditions, such as voltage amplitude, pulse width, step size of program pulses, for example, may lead to improved program speed and/or reliability of the aging memory device. Accordingly, wear information, comprising information regarding aging and/or usage of the memory device or portions thereof, may provide a metric by which effects of the aging memory device may be determined or assessed. Herein, wear information will be called use-history information.
[0019] Use-history information may comprise counts of program-erase and/or read cycles that a memory device has been subjected to, or other information that may indicate effects of age and wear on a memory device. Other examples of use-history information may include a count of erase pulses involved in successfully erasing a memory block, or memory cells' voltage threshold distribution at a given probability after a first erase pulse, since both the count of erase pulses and the cells' threshold voltage distribution may change after cycling. In an implementation, a memory device may comprise a memory array partitioned to include data cells and flag cells. Flag cells may comprise memory cells used to store use-history information of the memory device while data cells may comprise memory cells used to store user data. Such user data, for example, may comprise data programmed by a processor executing an application. In comparison, use-history information stored in flag cells may be generated by a memory controller of the memory device, as described below. An array of memory cells in a memory device may be arranged so that a plurality of data cells shares a common wordline with a plurality of flag cells. Thus, a process of reading data cells on a wordline may involve concurrently reading flag cells on the same wordline. Such concurrent reading of data cells and flag cells may provide an opportunity to read use-history information of the data cells without a need for an additional process to read the flag cells. In a counter-example, if use-history information of data cells were stored in a portion of a memory array that did not share a common wordline, then reading the use-history information may involve a read process separate from (and in addition to) the process to read the data cells. Reducing a number of read processes, as may be accomplished in the embodiments described herein, may lead to faster-performing memory devices.
[0020] In a particular embodiment, as mentioned above, flag cells that share a common wordline with data cells may be read concurrently with reading the data cells during a program-verify (PV) process. Parameters of such a PV process may be modified based, at least in part, on use-history information of the data cells stored in flag cells. Accordingly, parameters of the PV process may be dynamically modified during the PV process, as described in detail below. For example, such dynamic modification may allow program pulse parameters to be modified during a program process. Such parameters may include program pulse amplitude, width, step size, and so on. A benefit of an ability to dynamically modify a PV process, as described herein, is that an extra process to read stored use-history information may be avoided, for example, thus improving memory device reliability without increasing operating speed of the memory device. Another benefit of an ability to dynamically modify parameters of a PV process is that values of PV parameters established at the beginning of life for a memory device need not be selected as a compromise between “optimal” values of a new memory device and “optimal” values of the aged memory device. For example, a memory designer need not be concerned with selecting program pulse parameters that are merely acceptable during a whole life of a memory device. Instead, program pulse parameters may be initially selected to be most desirable for the new memory device because such program pulse parameters may be modified as the memory device ages. Thus, in an embodiment, a method of programming a memory device may comprise storing use-history information regarding a memory array of the memory device in flag cells of the memory array. Such a first portion of memory cells may be read during a program-verify process to program data cells of the memory array, wherein the flag cells and the data cells may be responsive to or share the same wordline. In response to reading such use-history information, program pulse parameters of the program-verify process may be modified based, at least in part, on the read use-history information. In an implementation, such a program-verify process may comprise an incremental step pulse programming (ISPP) process, wherein a plurality of program pulses alternate with a plurality of verify processes, as discussed below. In another implementation, use-history information stored in flag cells may be updated in response to erasing data cells. In yet another implementation, flag cells may be programmed above a threshold voltage higher than that of programmed data cells. Though claimed subject matter is not so limited, a memory array that includes such flag and data cells may comprise a NAND block array.
[0021] FIG. 1 is a plot of characteristics of a program-verify (PV) bias signal 100 comprising program step pulses, according to an embodiment. A process of writing to a NAND memory cell, which may use PV bias signal 100 , may also comprise a process to verify that a particular bit was successfully written to the memory cell of a NAND block array. For example, program step pulses and verify processes may be alternately performed during a PV process. In a particular example, a first program pulse may be applied to a memory cell to program the memory cell to a “0” state. A verify process may follow the first program pulse to determine whether or not the memory cell was successfully programmed to a “0” state. If not, then a second program pulse having a higher magnitude than that of the first program pulse may be applied to the memory cell. A verify process may then be repeated, and so on. Such a memory cell may comprise a single level cell or a multi-level cell, for example. In one implementation, an ISPP process may be used, wherein a magnitude of a program pulse applied to a control gate of a particular memory cell may be sequentially increased until the particular memory cell is determined to be successfully programmed. As discussed in detail below, parameters of a PV bias signal, such as program pulse width, peak amplitude, step size between consecutive program pulses, and so on may be modified based, at least in part, on use-history information of the particular memory cell.
[0022] In detail, PV bias signal 100 may comprise one or more individual program pulses applied to a memory cell until the memory cell transitions to a programmed state. PV bias signal 100 may comprise a voltage signal applied to a control gate (e.g., a wordline) of memory cells of a NAND block array, for example. In particular, subsequent program pulses may have a greater peak amplitude than a previous program pulse. In one implementation, a series of such program pulses may comprise a waveform having individual peak amplitudes that sequentially increase from one pulse to the next. Such an implementation may address an issue of variability of physical and/or electrical characteristics of a plurality of memory cells in a NAND device, for example. As shown in FIG. 1 , a first program pulse 110 may be followed by a second program pulse 120 having a peak amplitude higher than that of the first program pulse. According to an ISPP process, and as mentioned above, a verify process may be performed between consecutive program pulses of PV bias signal 100 . Such a verify process may be used to determine whether programming a memory cell using a preceding program pulse was successful or not. For example, first program pulse 110 applied to a memory cell may be followed by a verify process to determine whether the memory cell was successfully programmed by program pulse 110 . If so, then PV bias signal 100 may no longer be applied to the memory cell (e.g., subsequent program pulses 120 , 130 , 140 , and so on need not be applied to the memory cell). However, if the memory cell was not successfully programmed, then second program pulse 120 , having a peak amplitude higher than that of first program pulse 110 may be applied to the memory cell. As before, second program pulse 120 applied to the memory cell may be followed by a verify process to determine whether the memory cell was successfully programmed by program pulse 120 . If so, then PV bias signal 100 may no longer be applied to the memory cell (e.g., subsequent program pulses 130 , 140 , and so on need not be applied to the memory cell). However, if the memory cell was not successfully programmed, then third program pulse 130 , having a peak amplitude higher than that of second program pulse 120 may be applied to the memory cell. Such a process may continue until the program pulse is successfully programmed. Such a PV bias signal 100 , of course, may comprise a variety of characteristic shapes and/or configurations, and claimed subject matter is not limited in this respect.
[0023] FIG. 2 is a plot showing threshold voltage distributions 200 for a population of memory cells programmed by the application of PV bias signal 100 , shown in FIG. 1 , for example, according to an embodiment. Such distributions may arise from physical variations of memory cells in an array due to usage (e.g., program-erase cycles), fabrication, and/or location on a semiconductor wafer, for example. To elaborate, variations in fabrication conditions from lot to lot and/or from region to region on a semiconductor wafer, for example, may lead to variations in characteristics and/or physical parameters of memory cells. Of course, such variations may result from any of a number of situations or conditions. For another example, physical position of a memory cell in a circuit may affect and/or modify physical parameters of the memory cell. In particular, capacitance, magnetic and electric fields, and/or heat may contribute to such variations, though claimed subject matter is not limited in this respect. Because one portion of memory cells in a memory array may behave differently from another portion of memory cells, a particular bias signal may affect some memory cells differently from other memory cells. Accordingly, one portion of memory cells in an array may behave differently from another portion of memory cells in response to an applied bias signal having a particular magnitude. For example, a particular magnitude of a program pulse applied to one memory cell may result in the memory cell being programmed to a “0” state, while the same program pulse applied to another memory cell may result in the memory cell failing to be programmed to a “0” state (so that another, higher magnitude program pulse may be applied if the memory cell is to finally be programmed to such a “0” state, for example).
[0024] Variations of properties of a population of memory cells in an array, as discussed above, may lead to a distribution 210 of threshold voltages of the memory cells after receiving a first program pulse 110 . Such a relatively broad distribution may be narrowed by applying subsequent program pulses 120 , 130 , and so on of PV bias signal 100 . For example, applying second and third program pulses 120 and 130 to the memory cells may lead to a distribution 220 of threshold voltages. Continuing, applying subsequent program pulses 140 and so on to the memory cells may lead to a distribution 230 of threshold voltages. In detail, such program pulses may be applied only to memory cells that are determined (e.g., by a verify process performed between program pulses, as described above) to have a threshold voltage below a particular value 240 , herein called a program-verify (PV) level. In this fashion, program pulses having increasingly large magnitudes may be sequentially applied to memory cells until the memory cells finally have threshold voltages at or above PV level 240 . In an implementation, PV level 240 may be below a V read level 250 , which is described in detail below.
[0025] FIG. 3 is a schematic diagram of an array portion 300 of a NAND block memory array, according to an embodiment. Array portion 300 may be partitioned to comprise a data cell area 310 and a flag cell area 320 . Data cell area 310 may include a plurality of data cells 315 to store data that may be generated by a processor (e.g., processing unit 920 shown in FIG. 9 ) executing an application, for example. Accordingly, such data cells may be user-accessible via read, write, and/or erase operations. In contrast, flag cell area 320 may include a plurality of flag cells 325 to store use-history information, and such flag cells need not be user-accessible, though claimed subject matter is not so limited. Instead, as explained in detail below, flag cells 325 may be accessed by a memory controller, such as memory controller 915 shown in FIG. 9 , for example. Both data cells and flag cells may comprise physically similar NAND memory cells. However, data cells and flag cells may be distinguished from one another in that NAND memory cells located in data cell area 310 may operate as data cells whereas NAND memory cells located in flag cell area 320 may operate as flag cells. In an implementation, a plurality of data cells located on a particular wordline among a plurality of wordlines 330 may be associated with corresponding flag cells that are co-located on the same particular wordline. For example, sixty data cells and four flag cells may be co-located on wordline WL 29 in FIG. 3 , though such particular numbers of memory cells are merely examples, and claimed subject matter is not so limited. Accordingly, in an implementation, a process of reading data cells 315 on a particular wordline may also include a concurrent reading of flag cells 325 on the same wordline. In such a fashion, as explained above, use-history information stored in flag cells 325 need not be read in a separate, additional, time-consuming process.
[0026] Array portion 300 may also include bitlines 360 that span across multiple data cells and/or flag cells in columns of the cell array. A drain select line (DSL) 340 or a source select line (SSL) 350 may be used to select among such bitline columns. A plurality of wordlines 330 may individually comprise data cells 315 and flag cells 325 , as described above. For example, wordlines 330 may comprise wordlines WL 0 through WL 31 , as shown in FIG. 3 .
[0027] As described above, array portion 300 may be partitioned to comprise a data cell area 310 and a flag cell area 320 . Prior to such partitioning, array portion 300 may comprise an array of substantially identical NAND cells. In an implementation, partitioning such an array need not involve any physical changes, such as changes to a circuit layout or architecture for example. Instead, partitioning may be implemented by performing read/write techniques for one portion (e.g., data cell area 310 ) of the array that may be different from read/write techniques for another portion (e.g., flag cell area 320 ) of the array. For example, 32K NAND cells may be located on a particular wordline. A memory controller, using appropriate addressing, may be adapted to store user data in 31K NAND cells (e.g., data cells 315 ) and to store use-history information in the remaining 1K NAND cells (e.g., flag cells). In another example, the first 31K NAND cells (e.g., data cells 315 ) may be programmed using wordline and/or bitline voltages that are different from that used for the remaining 1K NAND cells (e.g., flag cells), as explained in further detail below. In one implementation, a flag cell area 320 may comprise a spare area of a NAND block array, though claimed subject matter is not so limited.
[0028] FIG. 4 is a schematic diagram of a NAND block memory array 400 during a read operation, according to an embodiment. A memory controller, for example, may perform such a read operation by applying particular voltage levels to wordlines WL and/or bitlines 460 , for example. In the example shown in FIG. 4 , a memory controller (e.g., memory controller 915 , shown in FIG. 9 ) may apply a voltage V read to wordlines WL 0 through WL 31 except for WL 30 , which includes NAND cells that have been selected to be read. Applying voltage to a wordline being read (e.g., 0V, as in the example) may provide an opportunity to discriminate between “1” and “0” states of memory cells belonging to a particular wordline. V read applied to unselected wordlines may provide an opportunity to switch on unselected memory cells, regardless of their state. As discussed above, such NAND cells comprise a plurality of data cells in data cell area 410 and a plurality of flag cells in flag cell area 420 . Such a process may be repeated to sequentially read remaining wordlines, for example.
[0029] FIG. 5 is a schematic diagram of NAND block memory array 400 during a verify operation, according to an embodiment. A memory controller, for example, may perform such a verify operation by applying particular voltage levels to wordlines WL and/or bitlines 460 , for example. In the example shown in FIG. 5 , a memory controller may apply a voltage V read to wordlines WL 0 through WL 31 except for WL 30 , which includes NAND cells that have been selected to be verified. As discussed above, such NAND cells comprise a plurality of data cells in data cell area 410 and a plurality of flag cells in flag cell area 420 . Thus, wordline WL 30 may be held at a relatively low voltage (e.g., a voltage PV) compared to voltage V read applied to the remaining wordlines. A purpose of this verify operation may be to read use-history information from flag cells while concurrently verifying data cells that are being programmed. Such a process may be repeated to sequentially verify remaining wordlines, for example. In one implementation, flag cells may have been programmed to a higher threshold voltage than that of data cells. Such a higher threshold voltage may lead to a retention margin for flag cells, which is explained below and shown in FIG. 7 , for example.
[0030] FIG. 6 is a plot showing a threshold voltage distribution 600 for a population of programmed data cells 610 in a memory array, and FIG. 7 is a plot showing a threshold voltage distribution 700 for a population of programmed flag cells 710 in the memory array, according to an embodiment. Such a distribution of programmed data cells 610 may result from applying PV bias signal 100 , shown in FIG. 1 , for example, to data cells to be programmed. In other words, programmed data cells 610 may have been programmed by a PV bias signal 100 comprising a series on increasing-magnitude program pulses (e.g., step pulses), as discussed above. In particular, such programming may lead to programmed data cells 610 having a threshold voltage equal to or greater than a program-verify voltage PV. In an implementation, voltage PV may be substantially lower than V read , introduced above in FIGS. 4 and 5 . In contrast, a distribution of programmed flag cells 710 may result from applying a bias signal having a relatively larger magnitude compared to PV bias signal 100 , for example, to data cells 610 . In particular, programmed flag cells 710 may have a threshold voltage equal to or greater than a program-verify voltage PVf, which may be greater than voltage PV by an amount V delta . In an implementation, V delta may comprise a retention margin to account for a possibility that floating gates of flag cells may lose charge over time, resulting in lowered threshold voltages. V delta may also comprise a margin for read noise. For example, returning to FIGS. 4 and 5 , bias for a read operation and a verify operation are similar, with the verify operation differing from the read operation for the bias applied to the selected wordline (e.g., PV level instead of a lower voltage). Since a reliability margin for retention may be needed between the program level and the read level for memory cells, such cells may be programmed well above this level. While for data cells, being a read level lower (e.g., zero volts), the PV programming level may already comprise a retention margin, for example.
[0031] In an embodiment, a memory controller may comprise one or more counters to count events pertaining to data cells of an array. Such events may comprise erase cycles, program-verify cycles, and/or number of pulses used in an erase or program operation, just to name a few examples. A memory controller may use event counts to generate use-history information regarding the data cells. In one implementation, particular use-history information may pertain to all data cells on a particular wordline. In another implementation, particular use-history information may pertain to all data cells in a page or block of a memory device. For example, one page of a memory array may have a different use-history than that of another page. As another example, one wordline of data cells may have a different use-history than that of another wordline of data cells.
[0032] From time to time, such use-history information may be written to flag cells on the same wordline used by data cells to which the use-history information pertains. For example, in one implementation, such flag cells may be updated with new use-history information subsequent to a process to erase the data cells. In another implementation, flag cells may be updated with new use-history information subsequent to every ten, hundred, thousand or so such erase processes, just to list a few examples. In yet another implementation, flag cells may be updated with new use-history information subsequent to a generic write operation on the memory array. In still another implementation, flag cells may be updated with new use-history information as a result of the memory controller determining that such use-history information has substantially changed. In one implementation, use-history information stored in flag cells may comprise a four-bit nibble or an eight bit word, or any other number of bits, for example. A memory controller may comprise a lookup table and/or algorithm to decode read flag cell bits into use-history information that may be used to determine modifications of parameters of program pulses to program data cells. As explained above, such modifications may be performed during program-verify processes. Of course, such details regarding use-history information are merely examples, and claimed subject matter is not so limited.
[0033] FIG. 8 is a flow diagram of a program-verify process 800 , according to an embodiment. For example, a memory controller may perform process 800 to program a memory cell in response to receiving program instructions from a processor executing a program. Such a memory cell may comprise a NAND cell, such as data cell 315 shown in FIG. 3 , for example. At block 810 , a memory controller may select parameters for an initial program pulse, such as program pulse 110 shown in FIG. 1 . Such parameters may include, but are not limited to, voltage amplitude, pulse width, and voltage amplitude step size for a subsequent program pulse (e.g., program pulse 120 ). At block 820 , the memory controller may apply a program pulse via a wordline to a control gate of the memory cell. Subsequent to applying the first program pulse, the memory controller may verify that the memory cell was correctly programmed in a verify process, as in block 830 . As explained above, such a verify process may comprise a process of reading the state of the flag memory cells while verifying whether data cells are programmed. At diamond 840 , by reading the state of the memory cell, the memory controller may determine if the memory cell was successfully programmed by the program pulse. If so, then process 800 may be complete. If, however, the memory cell was not successfully programmed by the last-applied program pulse, then process 800 may proceed to diamond 850 , where the memory controller may determine whether the most recent program pulse was a first program pulse. If not, then process 800 may return to block 820 where a subsequent program pulse may be applied to the control gate of the memory cell. Such a subsequent program pulse may have a voltage amplitude larger by a step size than the voltage amplitude of the previous program pulse, as explained above. Process 800 may then repeat such program and verify processes as in blocks 820 and 830 until the memory cell is verified to be successfully programmed. On the other hand, if the most recent program pulse was a first program pulse, then process 800 may proceed from diamond 850 to block 860 , where use-history information stored in one or more flag cells may be used to modify subsequent program pulses. In particular, such flag cells may share the same wordline as the memory cell being programmed. Further such use-history information may pertain to the memory cell being programmed. Accordingly, based at least in part on the use-history information of the memory cell, it may be desirable to modify one or more parameters of the program pulses used to program the memory cell. For example, use-history information stored in flag cells may indicate that the memory cell to be programmed has experienced more than one-thousand program-verify cycles. In response to such a relatively large number of program-verify cycles, a memory controller may be configured to decrease program pulse step size for subsequent program pulses to be applied to the memory cell. A reason for such a decreased program pulse may be due to the fact that NAND cells tend to accumulate excess trapped charges in the oxide layer of the floating gate after a relatively large number of program-verify cycles, for example. In such a case, a program pulse need not be as large as before (e.g., near the beginning of the memory cell life) to generate a given threshold voltage. Thus, magnitudes of program pulses used to program a relatively old memory cell (e.g., having experienced a relatively large number of program and erase cycles) may be correspondingly reduced. After the memory controller determines modified parameters (if any modification is to occur) of subsequent program pulses, process 800 may return to blocks 820 and 830 , where program and verify processes may be repeated until the memory cell is verified to be successfully programmed.
[0034] FIG. 9 is a schematic diagram illustrating an exemplary embodiment of a computing system 900 including a memory device 910 . Such a computing device may comprise one or more processors, for example, to execute an application and/or other code. Memory device 910 may comprise a memory that includes NAND block array 300 , shown in FIG. 3 . A computing device 904 may be representative of any device, appliance, or machine that may be configurable to manage memory device 910 . Memory device 910 may include a memory controller 915 and a memory 922 . By way of example but not limitation, computing device 904 may include: one or more computing devices and/or platforms, such as, e.g., a desktop computer, a laptop computer, a workstation, a server device, or the like; one or more personal computing or communication devices or appliances, such as, e.g., a personal digital assistant, mobile communication device, or the like; a computing system and/or associated service provider capability, such as, e.g., a database or data storage service provider/system; and/or any combination thereof.
[0035] It is recognized that all or part of the various devices shown in system 900 , and the processes and methods as further described herein, may be implemented using or otherwise including hardware, firmware, software, or any combination thereof. Thus, by way of example but not limitation, computing device 904 may include at least one processing unit 920 that is operatively coupled to memory 922 through a bus 940 and a host or memory controller 915 . Processing unit 920 is representative of one or more circuits configurable to perform at least a portion of a data computing procedure or process. By way of example but not limitation, processing unit 920 may include one or more processors, controllers, microprocessors, microcontrollers, application specific integrated circuits, digital signal processors, programmable logic devices, field programmable gate arrays, and the like, or any combination thereof. Processing unit 920 may include an operating system configured to communicate with memory controller 915 . Such an operating system may, for example, generate commands to be sent to memory controller 915 over bus 940 . In one implementation, memory controller 915 may comprise an internal memory controller or an internal write state machine, wherein an external memory controller (not shown) may be external to memory device 910 and may act as an interface between the system processor and the memory itself, for example. Such commands may comprise read and/or write commands. In response to a write command, for example, memory controller 915 may provide a bias signal, such as bias signal 100 comprising a series of program pulses having individual peak amplitudes that sequentially increase from one pulse to the next, shown in FIG. 1 , for example. In particular, memory controller 915 may maintain use-history information regarding memory array 922 in flag cells 926 . Memory controller 915 may read the flag cells during a program-verify process to program data cells 924 . Flag cells and data cells may share the same particular wordline, as shown in FIG. 3 , for example. Memory controller 915 may modify parameters of a program-verify process based, at least in part, on read use-history information.
[0036] Memory array 922 is representative of any data storage mechanism. Memory array 922 may include, for example, a primary memory and/or a secondary memory. A primary memory may include, for example, a random access memory, read only memory, etc. While illustrated in this example as being separate from processing unit 920 , it should be understood that all or part of memory array 922 may be provided within or otherwise co-located/coupled with processing unit 920 . A secondary memory may include, for example, the same or similar type of memory as primary memory and/or one or more data storage devices or systems, such as, for example, a disk drive, an optical disc drive, a tape drive, a solid state memory drive, etc. In certain implementations, a secondary memory may be operatively receptive of, or otherwise configurable to couple to, a computer-readable medium 928 . Computer-readable medium 928 may include, for example, any medium that can carry and/or make accessible data, code, and/or instructions for one or more of the devices in system 900 . Computing device 904 may include, for example, an input/output 932 .
[0037] Input/output 932 is representative of one or more devices or features that may be configurable to accept or otherwise introduce human and/or machine inputs, and/or one or more devices or features that may be configurable to deliver or otherwise provide for human and/or machine outputs. By way of example but not limitation, input/output device 932 may include an operatively configured display, speaker, keyboard, mouse, trackball, touch screen, data port, etc.
[0038] While there has been illustrated and described what are presently considered to be example embodiments, it will be understood by those skilled in the art that various other modifications may be made, and equivalents may be substituted, without departing from claimed subject matter. Additionally, many modifications may be made to adapt a particular situation to the teachings of claimed subject matter without departing from the central concept described herein. Therefore, it is intended that claimed subject matter not be limited to the particular embodiments disclosed, but that such claimed subject matter may also include all embodiments falling within the scope of the appended claims, and equivalents thereof. | Subject matter disclosed herein relates to a memory device, and more particularly to write performance of a memory device. | 6 |
TECHNICAL FIELD
[0001] The present invention relates to the field of user authentication, and more particularly to a system and method to strengthen the confidentiality of user authentication when logging on to various system infrastructures.
BACKGROUND OF THE INVENTION
[0002] Different methods to safeguard a user's personal identity when logging in on a machine such as a computer system are well-known.
[0003] Some of these methods use biometrics or voice recognition technology or other recognition methods. A common characteristic of those methods is to apply intrusive procedures to the user such as submitting to fingerprinting or having his/her face or iris scanned. Whereas such technologies offer a robust identification mechanism, the incorporation of recognition sensors within existing machines can be a fastidious operation.
[0004] Moreover, these technologies still require a physical keyboard as a primary means to access a system network via personal authentication information such as a password.
[0005] The password generally consists of a code, typically an alphanumeric combination, which is uniquely associated with a user. The password is the confidential authentication information to be exploited by a verification system that checks the identity claimed.
[0006] Each time a user logs on to a computer, he/she enters his/her password via the physical keyboard. Keyboard layouts are different from one region to another, as some keyboards contain may 101 keys (e.g., for US zones) while others may have 102 keys (e.g., for French zones) or 112 keys (e.g., for Japan zones). Most keyboard layouts are AZERTY or QWERTY, while others are QWERTZ or can be completely different, like a Dvorak keyboard.
[0007] The keyboard layout is generally defined by an “Input Locale” which is a combination of an input language with an input method. Specifically the Input Locale describes the language being entered and how it is being entered. Moreover the keyboard layout is set by using regional and language options, like “glyph characters”, even if the basic keypad still reflects the “Latin character” layout.
[0008] In today's world, the use of the “Latin character” keyboard layout is the common way to gain access to a system for legitimate users. Whereas everyone is familiar with such a standard keyboard layout, it becomes easy to eavesdrop on a user when the user enters a password when logging on.
[0009] Moreover, the new trend of working conditions creates workplaces completely barrier-free with no partitions separating workstations. In such open-space structures, any attacker can easily exploit the open-space security weaknesses by illegitimately observing (e.g., over the shoulder) the password a legitimate user is entering.
[0010] This technique of password eavesdropping can be extremely effective to gain unauthorized access to a system, particularly, when people or individuals are located in a workplace, such as an open-space.
[0011] Whereas some of the existing password protection portals can be safe against fraudulent use, they are still exposed to security risks.
SUMMARY OF THE INVENTION
[0012] The present invention provides a safe and secure user identification method and system.
[0013] The present invention provides a language-independent user interface for: achieving a user recognition method; safely typing confidential authentication information of a legitimate user; registering the same; and authenticating the legitimate user when logging on.
[0014] The present invention further provides a user with a symbolic representation that is extremely effective against shoulder surfing or any other illegitimate observing.
[0015] The present invention further provides a safer and more secure user identification system, which can be easily incorporated in existing infrastructures, which is fully system platform independent, and which satisfies security directives when the user is logging on in barrier-free workplaces.
[0016] According to an aspect of the present invention, there is provided a method for preventing illegitimate access to a user computing machine, comprising: setting an authentication routine in the user computing machine; generating a virtual keyboard on the user computing machine; entering a user identification through the virtual keyboard, the user identification being entered according to a virtual keyboard form factor; comparing the entered user identification with a secure user identification previously stored in the user computing machine; and validating the user access to the user computing machine if a match occurs, otherwise denying access.
[0017] Further aspects of the invention will now be described, by way of illustrative implementation and examples, with reference to the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above and other items, features and advantages of the invention will be better understood by reading the following more particular description of the invention in conjunction with the accompanying drawings.
[0019] FIG. 1 shows a block diagram of an illustrative implementation of the present invention.
[0020] FIG. 2 is a functional diagram of the system of FIG. 1 .
[0021] FIG. 3 shows the configuration operations when configuring a portal, a workstation, a terminal server, or any computer equivalent system.
[0022] FIG. 4 shows the authentication operations when a user logs on to access a workstation, a terminal server, or any equivalent computer system.
[0023] FIGS. 5A and 5B exemplify, on two keyboard layouts, an authentication pattern.
DETAILED DESCRIPTION OF THE INVENTION
[0024] Embodiments of the invention are described below by way of examples with reference to the accompanying figures and drawings.
[0025] More specifically, according to a first aspect, the present invention provides a user recognition method and a system allowing for robust authentication of a legitimate user. A computer server provides to a user, a language-independent interface, hereafter referred to as a “virtual keyboard”, which allows a user to enter through a symbolic representation his/her authentication information. The virtual keyboard appears on the screen of the user machine, which may comprise a workstation or any individual equivalent computer system.
[0026] Embodiments of the present invention utilize a symbolic representation of the confidential authentication information that is based on the representation of the relative key position instead of the exact meaning of the character of the key. As such, the elements of the authentication information are defined by their relative location on the virtual keyboard. Each element is referenced by two parameters in the virtual keyboard: a row position it should reside on and a column position that intersects the given row.
[0027] In the present invention, the aforementioned symbolic representation of the authentication information combines a mathematical formula with a predefined sequence of the location of the keys on the virtual keyboard. The mathematical formula provides the user with the row to be selected while the predefined sequence locates the adequate column on the selected row. The predefined sequence is provided by establishing a key selection sequence. It may be defined by the legitimate user for later use, or may be defined by a system administrator or other authorized person.
[0028] The key selection sequence may be created by assigning a position to a key in an easy-to-remember mnemonic sequence. The use of a mnemonic sequence allows the user to easily remember the data attached to his/her ego and thus to easily recall his/her mnemonic sequence. However, the sequence may be any other complex combination that the user may safeguard.
[0029] The virtual keyboard comprises a variable key array matrix (rows and columns) arrangement. The form factor and the size of the variable key array matrix are initially defined when the user or a system administrator configures the system environment.
[0030] It is to be noted that the present invention may be used to generate a matrix for which the form factor outline is not restricted to a rectangular shape, as it will be further detailed with reference to FIG. 5 . The system can generate a polygonal shape for which rows and columns are shifted as shown in FIGS. 5A and 5B . Thus, the virtual keyboard arrangement differs from the physical keyboard layout.
[0031] It should be also noted that the virtual keyboard is language-independent and the predefined selection of the keys does not care what is engraved on the top of the keys. The top-keys can be either blank or randomly engraved because the mnemonics selection uses the relative position of the keys located on the virtual keyboard instead of the “Latin character” or “glyph character” representation of these keys if they exist.
[0032] Referring now to FIG. 1 , there is depicted a block diagram of an illustrative implementation of a system ( 100 ) of the invention. The system ( 100 ) comprises a recognition engine ( 102 ), a user machine ( 104 ), and a terminal server ( 112 ). The terminal server ( 112 ) is coupled to the user machine ( 104 ), and can also interface with a system infrastructure ( 114 ), such as LAN, WAN and/or the Internet.
[0033] An application configuration block ( 110 ) provides a user (shown as an arrow ‘user’) through a user interface ( 108 ) with the flexibility to enable or disable the recognition engine ( 102 ). When setting out, the application allows a legitimate user to enter his/her confidential authentication information through a virtual interface ( 106 ). The virtual interface ( 106 ) comprises a virtual keyboard (not shown here) that is displayed on the screen of the user machine ( 104 ), allowing the legitimate user to enter his/her confidential authentication information. The configuration of the application is an initial step to initialize, enable, and/or disable the functionalities of the invention.
[0034] FIG. 2 details in operation the system of FIG. 1 . The terminal server ( 212 ) enables the user machine ( 204 ) to authenticate a user (‘user’). The user interface ( 208 ) allows the user to interface with the user machine ( 204 ). As already explained with reference to FIG. 1 , the user secure information ( 210 ) is predefined by the user during the configuration of the application such that it is available on the terminal server ( 212 ). As such, when operating the authentication routine, the user secure information ( 210 ) is used by the recognition engine ( 202 ). When a user logs on, the recognition engine ( 202 ) initiates the virtual interface ( 206 ) and presents to the user a virtual keyboard on a screen ( 218 ). The user then enters the adequate authentication information ( 216 ) to be identified by the terminal server ( 212 ) to validate the access connection.
[0035] As detailed above, the form factor of the virtual keyboard differs from one user to another. Further, the form factor of the virtual keyboard differs from one system to another. These differences provide the system with better protection against an eavesdropping attack or illegitimate observing. In operation, the recognition engine ( 202 ) unloads the user secure information ( 210 ) that is stored in the terminal server ( 212 ). Then, the user secure information ( 210 ) is transmitted to the virtual interface ( 206 ) to generate a virtual keyboard ( 214 ) accordingly. The user secure information is an association of a mathematical formula ( 220 ) and a predefined sequence ( 222 ). This symbolic representation allows the user to select the appropriate keys on the virtual keyboard ( 214 ). By using the virtual keyboard the user applies his/her authentication information ( 216 ) to be identified as a legitimate user. The authentication information ( 216 ) is presented to the recognition engine ( 202 ) via the virtual interface ( 206 ). Then, the recognition engine ( 202 ) compares the user secure information coming from the terminal server ( 212 ) with the authentication information of the user. A hit comparison means that a legitimate user has been identified to gain access to the user machine. Thus, the recognition process comprises an initialization phase to configure the application and then a recognition phase each time a user logs on the machine.
[0036] A flow chart representing an illustrative recognition process ( 300 ) when configuring the application is now described with reference to FIG. 3 . The configuration of the application allows the user to customize the symbolic representation of the authentication information to be used later when logging on.
[0037] The configuration of the application includes creating a symbolic representation of the user password. A series of actions determines the configuration of the application the user wants to customize, as described below.
[0038] At 302 , the user initiates the configuration mode of the application in order to selectively enable the recognition engine.
[0039] At 304 , the terminal server checks the configuration of the application. If the user enables the application (Branch Yes) the terminal server unloads a generic virtual keyboard ( 306 ) to be customized ( 308 ) by the user. If the user disables the application (Branch No) the application is inactive.
[0040] At 306 , the generic virtual keyboard is displayed to the user via the screen of the machine. The generic virtual keyboard is customized at 308 . The virtual keyboard comprises a variable array (rows and columns) matrix. The size and the form factor are defined by the user or by the system administrator and can be different from the current machine physical keyboard layout.
[0041] At 308 , the user customizes his/her virtual keyboard configuration. First, a mathematical formula corresponding to the virtual keyboard array matrix in terms of rows is generated ( 310 ). Second the user defines a key sequence (step 312 ) corresponding to his/her user secure information in terms of the virtual key position in columns. Each key position in a column is to be aligned with the rows preliminary generated by the mathematical formula in 310 .
[0042] At 314 , the symbolic representation of the user secure information is generated combining the mathematical formula (step 310 ) with the predefined sequence (step 312 ).
[0043] At 316 , the symbolic representation is stored in the terminal server for later retrieval when the user logs on to another workplace.
[0044] It is to be noted that the storage of the symbolic representation can be done in various data recording medium, such as CDs or USB keys or equivalent. Those skilled in the art will perceive numerous possibilities to extend the storage of the symbolic representation. Such possibilities within the skill of the art are intended to be covered by the appended claims.
[0045] Referring now to FIG. 4 , a flow chart of an illustrative recognition process ( 400 ) when a user logs on a machine is now described.
[0046] At 402 , the user turns on a machine. The terminal server enables or disables the recognition engine according to the user initialization. The state of the recognition engine is used at 404 .
[0047] At 404 , a comparison is made to check the state of the recognition engine. If the recognition engine is enabled then the process proceeds to 406 otherwise the application is disabled and the user machine does not care about the recognition engine.
[0048] At 406 , the user machine receives a virtual keyboard from the terminal server. In an embodiment, the generation of the virtual keyboard may be a random generation. When displayed on a display of the user machine, the random virtual keyboard layout can have a different representation from the one that was preliminary created during the configuration of the application.
[0049] At 408 , the user requests to the terminal server for a user identification.
[0050] At 410 , the user enters his/her authentication information by applying both the mathematical formula and the predefined sequence. The mathematical formula indicates which rows belonging to virtual keyboard are to be selected by the user. The predefined sequence is applied to the keys that are located on the adequate columns corresponding to the adequate rows. The selection of the adequate keys may be made using the mouse or the scroll keys or any key typed on the physical keyboard (or using any other suitable selection methodology).
[0051] At 412 , the user machine obtains the user secure information from the terminal server corresponding to the user who is logging on. As previously detailed, the user secure information is created during the configuration of the application. The user secure information is compared at 414 to the authentication information the user applies to the virtual keyboard.
[0052] At 414 , a comparison is made to check the user secure information coming from the terminal server with the authentication information entered by the user. If a match comparison occurs (branch Yes of 414 ) then the recognition process accepts the user as a legitimate user and validates the access to the terminal server at 416 . In the other case (branch NO of 414 ) there is no matching between the user secure information and the authentication information and the user is asked to enter his/her identification again at 408 .
[0053] At 416 , the recognition method validates the user requested terminal server access.
[0054] In FIG. 5 , the symbolic representation of a user secure information is illustrated by two examples 5A and 5B on two virtual keyboard layouts.
[0055] As explained above, the mathematical formula considers the row position of the relative key position, while the predefined selection allows selecting the adequate key, in a preferred column. The row position (RP) is defined as the character (Ch) that is initially provided modulo (%) the number of rows (NbR) available in the virtual keyboard plus “1”.
[0000] RP=(Ch % NbR)+1; with % meaning modulo.
[0056] The predefined selection defines the adequate key to be selected on the column that intersects the row. The selection of the adequate keys can be expressed like the following sequence:
the second from the right; or the middle one; or any formula that allows for various line length (i.e., a relative description instead of a fixed one).
[0060] Assuming, for example, the authentication information of the user is three characters in length (e.g., “532”). The user defines his/her own predefined sequence that respectively allocates the position of the adequate key corresponding to each of the three characters as:
the second location from the left, corresponding to the first character (5); the second location from the right, corresponding to the second character (3); the first location from the left, corresponding to the third character (2).
[0064] Example 5A depicts the aforementioned example where a matrix of four rows (NbR=4) and a random number of columns represents the virtual keyboard that is displayed to the user.
[0065] Based on the mathematical formula RP=(Ch % NbR)+1 and the predefined sequence, as defined above, the correct sequence is:
Key position corresponding to the first character ‘5’ is: RP=(5% 4 )+1=2 in the second location from the left; Key position corresponding to the second character ‘3’ is: RP=(3% 4 )+1=4 in the second location from the right; and Key position corresponding to the third character ‘2’ is: RP=(2% 4 )+1=3 in the first location from the left.
[0069] FIG. 5B illustrates for the aforementioned example a matrix of six rows (NbR=6) and a random number of columns representing the virtual keyboard displayed to the user.
[0070] Based on the mathematical formula RP=(Ch % NbR)+1 and the mnemonics sequence, as defined above, the correct sequence is:
Key position corresponding to the first character ‘5’ is: RP=(5% 6 )+1=6 in the second location from the left. Key position corresponding to the second character ‘3’ is: RP=(3% 6 )+1=4 in the second location from the right. Key position corresponding to the third character ‘2’ is: RP=(2% 6 )+1=3 in the first location from the left.
[0074] It should be appreciated that while the invention has been particularly shown and described with reference to a various embodiment(s), changes in form and detail may be made therein without departing from the spirit, and scope of the invention. | The present invention prevents illegitimate access to a user computing machine. A method in accordance with an embodiment includes: setting an authentication routine in the user computing machine; generating a virtual keyboard on the user computing machine; entering a user identification through the virtual keyboard, the user identification being entered according to a virtual keyboard form factor; comparing the entered user identification with a secure user identification previously stored in the user computing machine; and validating the user access to the user computing machine if a match occurs, otherwise denying access. | 6 |
FIELD OF THE INVENTION
The present invention relates to an image sensor; and, more particularly, to a CMOS image sensor employing photodiodes which linearly increase the ability of keeping up photogenerated charges.
DESCRIPTION OF THE PRIOR ART
Generally, CCD (charge coupled device) has been widely used to process electronic image data. Although CCD technology provides an excellent data processing efficiency for electronic images, recent trends towards lower power consumption and greater system integration have spurred efforts to utilize existing submicron CMOS technology for electronic imaging applications. Such a CCD image sensor, which is different from CMOS image sensors to detect image signals through a switching operation of a transistor, detects the image signals using a charge coupling. Photodiodes in the CCD image sensor don't immediately extract photoelectric current, but extract it after the charges are accumulated into a signal packet for a predetermined time. Accordingly, since the conventional CCD image sensor has a sufficient integration time, high sensitivity and low noise image can be achieved.
However, since the conventional CCD image sensor should transfer the photogenerated charges continuously, the driving method is very complicated and high voltage of approximately 8V to 10V and high power of 1 W or more are needed. Also, compared with the submicron CMOS process to need about 20 mask processes, the conventional CCD image sensor to need about 30-40 mask processes may be relatively more complicated and also more expensive. Furthermore, since the signal processing circuit implemented by the CMOS process can not be manufactured in an area in which the conventional CCD image sensor is formed, the sensing and signal processing elements can not be made on one-chip, thereby depreciating the variety of its function.
APS (Active Pixel Sensor) detecting the image signals through a transistor switching, which is fabricated by combining the CMOS and CCD processes, has been disclosed in U.S. Pat. No. 5,625,210 entitled "Active pixel sensor integrated with a pinned photodiode" by Lee. et al.
Referring to FIG. 1, the APS is integrated with a pinned photodiode for sensing light from an object. To transfer the photogenerated charges generated in the pinned photodiode to an output node, i.e., a floating N+ region 17, a transfer 15a is formed between the pinned photodiode and the floating N+ region 17. A channel of the transfer transistor 15a is formed in a lightly doped N- region 16. Also, there is provided a reset transistor 15b having a highly doped N+ region 18 connected to a power supply VDD and the floating N+ region 17 as source/drain regions. The reset transistor 15b resets the floating N+ region 17 in response to a reset signal from a controller. The pinned photodiode is formed in a P-epi (epitaxial) layer 12 formed on a P substrate 11, consisting of a highly doped P+ region 14 and a highly doped N+ region 13. Additionally, in FIG. 1, the reference numerals 19 and 15c denote a field oxide layer and a select transistor, respectively.
In the unit pixel of the image sensor of FIG. 1, when the transfer transistor 15a and the reset transistor 15b are turned on, a reverse bias is applied between the highly doped N+ region 13 and the P-type layer (the P-epi layer 12 and the highly doped P+ region 14) and then the highly doped N+ region 13 is fully depleted. When the highly doped N+ region 13 is fully depleted, the voltage across the highly doped N+ region 13 is fixed to a specific voltage and it is called "pinning voltage." Since the pinned photodiode has a wide depletion region, it has a merit in that much photogenerated charges can be produced and accumulated.
As shown in FIG. 2a, when the depletion region of the highly doped N+ region 13 is extended, such a depletion mainly occurs downward because the concentration of the P-epi layer 12 is lower than that of the highly doped P+ region 14. Accordingly, this wide depletion region is contributed to the creation of many electron-hole pairs so that photoelectric capture of almost 100% may be obtained. These captured charges are transferred to the floating N+ region 17 through the transfer transistor 15a with a good sensitivity.
However, as shown in FIGS. 2b and 2c, the more the highly doped N+ region of the PN junction captures the photogenerated charges, the more the depletion region is decreased due to the reduction of the reverse bias across the PN junction. That is, the ability of capturing the photogenerated charges becomes worse. Also, since the area of the P-epi layer which gets out of depletion region becomes wider and then thermally generated charges increase at the deep P-epi layer, dark current becomes larger.
Furthermore, since the reverse bias across the PN junction decreases with the capture of photogenerated charges in the highly doped N+ region of the PN junction, the attraction of the highly doped N+ region to the photogenerated charges becomes weak, so that data from the captured charges is non-linear and is saturated, specifically in bright light. As a result, the sensitivity and resolution of the image sensor deteriorates in bright light.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a photodiode capable of capturing photogenerated charges linearly at the initial state.
It is another object of the present invention to provide a CMOS image sensor with good sensitivity and resolution.
It is further another object of the present invention to provide an improved method for obtaining image output data in the CDS (Correlated Double Sampling).
In accordance with an aspect of the present invention, there is provided a unit pixel in an image sensor, the unit pixel comprising: a photodiode including: a) an N-type semiconductor region and a P-type semiconductor region for a PN junction to which a reverse bias is applied; and b) a highly doped region formed on one of the N-type semiconductor region and the P-type semiconductor region for collecting carriers of electron-hole pairs generated in a depletion region of the PN junction so that a voltage drop of the reverse bias is linear; and an image data processing means for producing an image data in response to the carriers transferred from the highly doped region.
In accordance with another aspect of the present invention, there is provided a photodiode comprising: a semiconductor layer of a first conductive type, where a first voltage level is allied to the semiconductor layer; a first diffusion region of a second conductive type, wherein the first diffusion region is formed beneath a surface of the semiconductor layer and wherein a second voltage level is applied to the first diffusion region through a switching means; and a second diffusion region formed beneath the first diffusion region and within the semiconductor layer, wherein the second diffusion region is fully depleted between the first and second voltage levels, whereby the second diffusion region transfers carriers of electron-hole pairs to the first diffusion region.
In accordance with further another aspect of the present invention, there is provided a unit pixel in an image sensor, the unit pixel comprising: a semiconductor layer of a first conductive type, wherein a first voltage level is allied to the semiconductor layer; a first diffusion region of a second conductive type, wherein the first diffusion region is formed within the semiconductor layer and wherein the first diffusion region is fully depleted when a second voltage level is applied thereto; a second diffusion region of the second conductive type, wherein the second diffusion region is formed beneath a surface of the semiconductor layer and on a portion of the first diffusion region; a third diffusion region formed on the first diffusion region, surrounding the second diffusion region; and a transistor operating a switching means for evaluating a data sensing period and a reset level sensing period, wherein the second voltage level is applied to the second diffusion region between the data sensing period and the reset level sensing period, the transistor including: a) a gate electrode formed on the semiconductor layer, being apart from the second diffusion region; and b) a drain region electrically coupled to a power supply to provide the second voltage level, wherein the first diffusion region acts as a source region, whereby the second diffusion region receives carriers of electron-hole pairs from the first diffusion region so that the second diffusion region directly transfers the received carriers to an image data processing means.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects and features of the present invention will become apparent from the following description of the preferred embodiments given in connection with the accompanying drawings, in which:
FIG. 1 is a cross-sectional view illustrating a conventional APS;
FIGS. 2a to 2C are cross-sectional views illustrating a conventional pinned photodiode;
FIG. 3 is a cross-sectional view illustrating a photodiode in accordance with an embodiment of the present invention;
FIG. 4 is a graph illustrating potential generated in each layer of the photodiode of FIG. 3;
FIG. 5 is a cross-sectional view illustrating a photodiode in accordance with another embodiment of the present invention;
FIG. 6 is a circuit diagram illustrating a unit pixel of CMOS image sensor in accordance with the present invention;
FIG. 7 is a cross-sectional view illustrating the unit pixel having the photodiode of FIG. 5; and
FIG. 8 is a timing chart illustrating control signals in the CDS method in accordance with the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Hereinafter, the present invention will be described in detail referring to the accompanying drawings.
Referring to FIG. 3, a photodiode in accordance with the present invention includes a P-epi layer 302 formed on a P substrate 301 to which a ground voltage level is applied, a highly doped N+ region 304 which is formed beneath the surface of the p-epi layer 302 and receives supply power VDD through a switch 305, and a lightly doped N- region 303 which is formed beneath the highly doped N+ region 304. The lightly doped N- region 303 is fully depleted between a ground voltage and a power supply voltage VDD.
When a switch 305 is turned on, the lightly doped N- region 303 is fully depleted. At this time, the concentration of the lightly doped N- region 303 should be controlled in order that a voltage across the lightly doped N- region 303, i.e., pinning voltage (V pinning ), is about VDD/2. When the switch, which was turned on, is turned off, the potential of the highly doped N+ region 304, the lightly doped N- region 303 and the p-epi layer 302 may be VDD, V pinning and V ground , respectively (where, VDD>V pinning >V ground ).
Electrons of the electron-hole pairs which are generated in the depletion region by incident light are captured in the highly doped N+ region 304 via the lightly doped N- region 303 (while holes are transferred to the P-epi layer). In the photodiode of the conventional APS, since the highly doped N+ region 13 in FIG. 1, which is fully depleted region, captures the electrons, the more the highly doped N+ region 13 captures the electrons, the more depth (or size) of the depletion is shallow with the reduction of the reverse bias. However, in the present invention, the lightly doped N- region 303, which is fully depleted, doesn't capture and hold the charges continuously. That is, since the lightly doped N- region 303 transfers the captured charges to the highly doped N+ region 304, the potential VDD goes down so that the depletion region is diminished in a lateral direction. However, there may be no variation of the depth of the lightly doped N- region 303.
FIG. 4 is a graph illustrating a variation of the photodiode of FIG. 3. Referring to FIG. 4, if the switch 305 is turned on and, thereafter, it is turned off (section (a)), the voltages applied to the highly doped N+ region 304, the lightly doped N- region 303 and the P-epi layer 302 are VDD-V noise , V pinning and V ground , respectively, at the initial state. The reason why the highly doped N+ region 304 has a voltage of VDD-V noise , instead of VDD, is that the coupling noise from the switch and the charge injection noise may be generated. At section (b) in which light sensing is in process, the voltage drop of Vp1 is made in the highly doped N+ region 304 while the electrons are captured therein. At section (c) in which the light sensing operation is completed somewhat, the voltage in the highly doped N+ region 304 drops by Vp2 so that the voltage across the highly doped N+ region 304 is the same as the pinning voltage V pinning across the lightly doped N- region 303. If the voltage of the highly doped N+ region 304 continuously drops as shown in section (d), the pinning is dissolved and the voltage across the lightly doped N- region 303 drops according to an amount of the voltage drop in the highly doped N+ region 304.
As state above, the photodiode in accordance with the present invention can accumulate a lot of photogenerated charges because the potential of the highly doped N+ region 304 linearly drops up to the pinning voltage V pinning . Furthermore, since the depth of the depletion region is not decreased, most electrons are transferred to the highly doped N+ region 304. This photodiode set fourth above is called "on-transfer pinned photodiode." It should be noted that the on-transfer pinned photodiode acts as a photodiode together with a transfer.
On the other hand, in the conventional pinned photodiode, since the initial voltage drop starts from the pinning voltage, a non-linear voltage drop occurs.
It may be possible to apply the above "on-transfer pinned photodiode to a CMOS image sensor requiring a photodiode and a transfer transistor. To apply the "on-transfer pinned photodiode to the CMOS image sensor, as shown in FIG. 5, the photodiode in accordance with the present invention includes an additional highly doped N+ region 504. That is, the on-transfer pinned photodiode in a CMOS image sensor of the present invention includes a P-epi layer 502, a highly doped N+ region 504, a lightly doped N- region 503, and a highly doped P+ region 506.
The P-epi layer 502, which is formed on a P substrate 501 to which a ground voltage level is applied, contains the highly doped N+ region 504, the lightly doped N- region 503 and the highly doped P+ region 506. The highly doped P+ region 506 and the highly doped N+ region 504 are formed beneath the surface of the p-epi layer 502. As compared with the highly doped P+ region 506, the highly doped N+ region 504 occupies small area. In addition, the highly doped N+ region 504 is surrounded by the highly doped P+ region 506 and the highly doped P+ region 506 is in contact with the p-epi layer 502. Accordingly, the p-epi layer 502 has the same potential as the highly doped P+ region 506. Such a contact between the p-epi layer 502 and the highly doped P+ region 506 is achieved by two ion implantation masks which differ from each other in pattern size. The lightly doped N- region 503 for providing a full depletion region is formed beneath the highly doped P+ region 506 and the highly doped N+ region 504. The power supply VDD is applied to the highly doped N+ region 504 through a switch 505.
The on-transfer pinned photodiode in FIG. 5 has the highly doped P+ region 506 on the lightly doped N- region 503, being different from that in FIG. 4. Accordingly, the on-transfer pinned photodiode in FIG. 5 has all features of the pinned photodiode and the linear voltage drop feature illustrated in FIG. 4. As a result, the on-transfer pinned photodiode in FIG. 5 can collect the photogenerated charges much more for a short time with the linear operation of the power voltage drop.
While the voltage sensing range of the conventional pinned photodiode is from the pinning voltage to the ground voltage, the highly doped N+ region 504 of the on-transfer pinned photodiode (hereafter, referred to as an OT-PPD) in accordance with the present invention has a voltage range of the power supply voltage VDD (much more than the pinning voltage) to the ground voltage. High resolution and sensitivity of the image sensor may be improved by employing the above-mentioned OT-PPD. In particular, in the case where the OT-PPD is applied to the CMOS image sensor, such a CMOS image sensor may have merits of the typical CMOS image sensor with improved resolution and sensitivity. Furthermore, the CMOS image sensor having the OT-PPD in accordance with the preset invention may make the dynamic range (voltage variation range in the output of the unit pixel) maximum.
FIG. 6 is a circuit diagram view illustrating the CMOS image sensor having the OT-PPD in accordance with the present invention. As shown in FIG. 6, a unit pixel of the CMOS image sensor includes one OT-PPD 510 and three NMOS transistors (it should be note that a transfer transistor is not shown in FIG. 6). A first transistor is a reset transistor 520 for resting the photogenerated charges generated in the OT-PPD, a second transistor is a drive transistor 530 acting as a source follower, and a third transistor is a select transistor 540 for receiving address signals. The reference numeral 550 denotes a load transistor.
The reset transistor 520 is made up of a native gate so that the charge transfer efficiency is improved. Such a negative threshold voltage can prevent electron losses from being generated by a voltage drop of a positive threshold voltage and then contribute the charge transfer efficiency to be improved.
As stated above, since the unit pixel of the image sensor in accordance with the present invention doesn't use a transfer transistor, it is possible to make a highly integrated circuit by minimizing the size of the unit pixel. Further, the usage of the OT-PPD in the CMOS image sensor has an additional merit in that it is possible to exclude the change of unit pixel's operation, which is caused by the transfer transistor fabricating processes.
FIG. 7 is a cross-sectional view illustrating the CMOS image sensor having the OT-PPD in accordance with the present invention. The parts shown in the OT-PPD of FIG. 7 which are the same as those in FIG. 5 have the same reference numerals.
Referring to FIG. 7, a P-epi layer 502 is formed on a P+ substrate 501 to which the ground voltage is applied and the impurity concentration of the P+ substrate 501 is higher than that of the P-epi layer 502. By using such a P-epi layer 502, the "Cross Talk" between the unit pixels, which is caused by the random drift of the photogenerated charges generated in deep place of the substrate, is prevented. A gate of a reset transistor 610 receiving a rest signal is formed on the P-epi layer 502 and an edge 610a of the reset transistor 610 is aligned with an edge 503a of a lightly doped N- region 503 in a vertical straight line. Further, the edge 610a is apart from the edge of a highly doped N+ region 504 by a distance of X. An N+ drain diffusion region 620 of the reset transistor 610, which is formed in the P-epi layer 502, is electrically connected to a power supply voltage VDD. When the reset transistor 610 is turned on, the lightly doped N- region 503 is fully depleted between the power supply voltage VDD and the ground voltage. The electrons captured in the fully depleted region are immediately transferred to the highly doped N+ region 504.
On the other hand, a P-well region 630 is formed in the P-epi layer 502 in which a drive transistor 640 and a select transistor 650 are formed and also the drive and select transistors 640 and 650 have a LDD (Lightly Doped Drain) structure. Impurity ions are implanted into the channel regions of the drive and select transistors 640 and 650 in order to adjust their threshold voltage. Accordingly, while the drive transistor 640 and the select transistor 650, which are made up of the typical NMOS transistor, have a positive threshold voltage, the reset transistor 610 has a negative threshold voltage which doesn't require any ion-implantation to adjust the threshold voltage of the channel region. The gate of the drive transistor 640 is electrically connected to the highly doped N+ region 504 and an N+ drain diffusion region 620 is common to the drive transistor 640 and the reset transistor 610. The select transistor 650 having a diffusion region, which is common to the driver transistor 640, has another diffusion region as an output node.
If the reset transistor 610 is turned on, the voltage applied to the lightly doped N- region 503 becomes larger and the lightly doped N- region 503 is depleted. Then, when the lightly doped N- region 503 is fully depleted, the voltage applied to the lightly doped N- region 503 is fixed to the pinning voltage V pinning . At this time, the voltage across the highly doped N+ region 504 is increased up to VDD because the reset transistor 610 has been turned on yet. The charges positioned within the lightly doped N- region 503 flow into the N+ drain diffusion region 620.
Next, the OT-PPD starts the light sensing operation while the reset transistor 610 is turned off. Meanwhile, when the reset transistor 610 is turned off, the highly doped N+ region 504 doesn't maintain the voltage of VDD due to the clock feed-through and capacitive coupling, but has the voltage of VDD-V noise . In the present invention, to reduce such a noise, there is provided a predetermined distance X between the gate of the reset transistor 610 and the highly doped N+ region 504. As illustrated in FIG. 4, the linear charge collection ability of the OT-PPD may considerably increase, by increasing the time necessary to drop the voltage applied to the highly doped N+ region 504 from VDD-V noise to V pinning . Furthermore, since the preset invention may make the dynamic range maximum, higher resolution may be obtained.
The conventional unit pixel using the transfer transistor read out a reset level after turning off the transfer transistor and turning on the reset transistor and, thereafter, the voltage level of the sensing node is read out after turning on the transfer transistor and turning off the reset transistor. By obtaining the voltage difference between these two levels, actual data caused by the photogenerated charges are obtained. However, in the present invention, the voltage level of the sensing node is first read out and, thereafter, the reset level is read out.
FIG. 8 is a timing chart illustrating control signals in the CDS method in accordance with the present invention. As shown in FIG. 8, the OT-PPD senses light form an object (reset signal RESET to control the reset transistor is in a low level). When a select signal Sx is activated in a high level, a corresponding pixel is selected and then the sensing result in the OT-PPD by that time is output to the output terminal (in FIG. 6) of the unit pixel. Therefore, the data in the sensing node is obtained before the reset transistor is turned on ("1" in FIG. 8).
Next, to read out various noises generated in unit pixel array itself, the reset transistor is turned on ("2" in FIG. 8) and then noise level is obtained. Thereafter, if the select signal Sx is disabled when the reset signal is activated, the light sensing operation starts again.
As apparent from the above, since the full depletion layer in the OT-PPD transfers the captured charges to the highly doped N+ region immediately, the image sensor according to the present invention carries out fast and exact sensing operations. Furthermore, since the image sensor according to the present invention directly reads out the captured charges from the photodiode, the SNR (signal to noise ratio) is improved. Furthermore, since the present invention doesn't use a transistor in transferring the charges generated in the pinned photodiode, errors caused by the charge injection between the drain and the source may be prevented.
Although the preferred embodiments of the invention have been disclosed for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims. | The present invention relates to an image sensor; and, more particularly, to a CMOS image sensor employing photodiodes which linearly increase the ability of keeping up photogenerated charges. In accordance with the present invention, a unit pixel of a CMOS image sensor comprises: a photodiode including: a) an N-type semiconductor region and a P-type semiconductor region for a PN junction to which a reverse bias is applied; and b) a highly doped region formed on one of the N-type semiconductor region and the P-type semiconductor region for collecting carriers of electron-hole pairs generated in a depletion region of the PN junction so that a voltage drop of the reverse bias is linear; and an image data processing unit for producing an image data in response to the carriers transferred from the highly doped region. | 7 |
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
The present invention relates to a process for preparing known fungicidally active alkylanilides from 2-alkylhaloaromatics and heterocyclylamides.
EP-A-0 824 099 and WO-A-03010149 disclose that alkylanilides are obtained by reacting the appropriate acid chloride with the appropriate alkylaniline derivative.
Both preparation and handling of the acid chlorides and the preparation of the alkylanilides are associated with a considerable level of technical complexity. For example, the acid chlorides have to be purified before the reaction by a time-consuming and costly distillation step.
The anilines are prepared typically, as described in WO-A-3074491, by a complicated synthesis from the corresponding bromoaromatics and benzophenone imine or at temperatures of 150° C. and pressures of from 75 to 85 bar with ammonia gas, as described in WO-A-06061226.
Alkylanilines, however, frequently exhibit toxic properties and are potentially mutagenic.
The prior art discloses that aryl halides can be reacted with amides under palladium or copper catalysis to give alkylanilides (J. Am. Chem. Soc. 2002, 124, 7420).
It is frequently found, however, that metal-catalyzed reactions with heterocycles which can function as chelating ligands are inhibited. Furthermore, ortho-substituted haloaromatics are sterically hindered for a halogen exchange.
BRIEF SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a process for simple and selective preparation of alkylanilides, which does not have the disadvantages described in the prior art.
Surprisingly, conditions have been found under which heterocyclylamides can be reacted efficiently with ortho-substituted haloaromatics.
The present invention thus provides a process for preparing alkylanilides of the formula (I)
in which
R 1 is hydrogen, halogen, —CR′ (R′=hydrogen, fluorine or O—C 1-4 -alkyl), more preferably hydrogen; R 2 is —CH(Me)—CH 2 —CHMe 2 , —CH 2 —CH 2 -t-But, or
particular preference being given to —CH(Me)—CH 2 —CHMe 2 and
A is the radical of the formula (A1)
in which
R 3 is hydrogen, cyano, halogen, nitro, C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy, C 1 -C 4 -alkylthio, C 3 -C 6 -cycloalkyl, C 1 -C 4 -haloalkyl, C 1 -C 4 -haloalkoxy or C 1 -C 4 -haloalkylthio having in each case from 1 to 5 halogen atoms, aminocarbonyl or aminocarbonyl-C 1 -C 4 -alkyl; R 4 is hydrogen, halogen, cyano, C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy or C 1 -C 4 -alkylthio; R 5 is hydrogen, C 1 -C 4 -alkyl, hydroxy-C 1 -C 4 -alkyl, C 2 -C 6 -alkenyl, C 3 -C 6 -cycloalkyl, C 1 -C 4 -alkylthio-C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy-C 1 -C 4 -alkyl, C 1 -C 4 -haloalkyl, C 1 -C 4 -haloalkylthio-C 1 -C 4 -alkyl, C 1 -C 4 -haloalkoxy-C 1 -C 4 -alkyl having in each case from 1 to 5 halogen atoms, or phenyl;
or
A is the radical of the formula (A2)
in which
R 6 and R 7 are each independently hydrogen, halogen, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms, R 8 is halogen, cyano or C 1 -C 4 -alkyl, or C 1 -C 4 -haloalkyl or C 1 -C 4 -haloalkoxy having in each case from 1 to 5 halogen atoms,
or
A is the radical of the formula (A3)
in which
R 9 and R 10 are each independently hydrogen, halogen, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms, R 11 is hydrogen, halogen, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms,
or
A is the radical of the formula (A4)
in which
R 12 is hydrogen, halogen, hydroxyl, cyano, C 1 -C 6 -alkyl, C 1 -C 4 -haloalkyl, C 1 -C 4 -haloalkoxy or C 1 -C 4 -haloalkylthio having in each case from 1 to 5 halogen atoms,
or
A is the radical of the formula (A5)
in which
R 13 is halogen, hydroxyl, cyano, C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy, C 1 -C 4 -alkylthio, C 1 -C 4 -haloalkyl, C 1 -C 4 -haloalkylthio or C 1 -C 4 -haloalkoxy having in each case from 1 to 5 halogen atoms, R 14 is hydrogen, halogen, cyano, C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy, C 1 -C 4 -alkylthio, C 1 -C 4 -haloalkyl, C 1 -C 4 -haloalkoxy having in each case from 1 to 5 halogen atoms, C 1 -C 4 -alkylsulfinyl or C 1 -C 4 -alkylsulfonyl,
or
A is the radical of the formula (A6)
in which
R 15 is C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms, R 16 is C 1 -C 4 -alkyl, Q 1 is S (sulfur), O (oxygen), SO, SO 2 or CH 2 , p is 0, 1 or 2, where R 16 represents identical or different radicals when p is 2,
or
A is the radical of the formula (A7)
in which
R 17 is C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms,
or
A is the radical of the formula (A8)
in which
R 18 is C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms,
or
A is the radical of the formula (A9)
in which
R 19 and R 20 are each independently hydrogen, halogen, amino, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms, R 21 is hydrogen, halogen, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms,
or
A is the radical of the formula (A10)
in which
R 22 and R 23 are each independently hydrogen, halogen, amino, nitro, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having 1 to 5 halogen atoms, R 24 is hydrogen, halogen, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms,
or
A is the radical of the formula (A11)
in which
R 25 is hydrogen, halogen, amino, C 1 -C 4 -alkylamino, di(C 1 -C 4 -alkyl)amino, cyano, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms, R 26 is halogen, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms,
or
A is the radical of the formula (A12)
in which
R 27 is hydrogen, halogen, amino, C 1 -C 4 -alkylamino, di(C 1 -C 4 -alkyl)amino, cyano, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms, R 28 is halogen, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms,
or
A is the radical of the formula (A13)
in which
R 29 is halogen, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms,
or
A is the radical of the formula (A14)
in which
R 30 is hydrogen or C 1 -C 4 -alkyl, R 31 is halogen or C 1 -C 4 -alkyl,
or
A is the radical of the formula (A15)
in which
R 32 is C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms,
or
A is the radical of the formula (A16)
in which
R 33 is hydrogen, halogen, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms,
or
A is the radical of the formula (A17)
in which
R 34 is halogen, hydroxyl, C 1 -C 4 -alkyl, C 1 -C 4 -alkoxy, C 1 -C 4 -alkylthio, C 1 -C 4 -haloalkyl, C 1 -C 4 -haloalkylthio or C 1 -C 4 -haloalkoxy having in each case from 1 to 5 halogen atoms,
or
A is the radical of the formula (A18)
in which
R 35 is hydrogen, cyano, C 1 -C 4 -alkyl, C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms, C 1 -C 4 -alkoxy-C 1 -C 4 -alkyl, hydroxy-C 1 -C 4 -alkyl, C 1 -C 4 -alkylsulfonyl, di(C 1 -C 4 -alkyl)aminosulfonyl, C 1 -C 6 -alkylcarbonyl or in each case optionally substituted phenylsulfonyl or benzoyl, R 36 is hydrogen, halogen, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms, R 37 is hydrogen, halogen, cyano, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms, R 38 is hydrogen, halogen, C 1 -C 4 -alkyl or C 1 -C 4 -haloalkyl having from 1 to 5 halogen atoms,
or
A is the radical of the formula (A19)
in which
R 39 is C 1 -C 4 -alkyl,
characterized in that,
in a first step, carboxamides of the formula (II)
in which the A radical is as defined above
are reacted with haloalkylbenzenes of the formula (III)
in which
the R 1 and R 2 radicals are each as defined above and the substituent R 1 is preferably in the meta or para position, more preferably in the 4 position (para to X) of the aromatic; and the X radical is a halogen, preferably Cl or Br, more preferably Br, in a metal-catalyzed reaction.
The present invention further relates to compounds of the formula (III)
where
R 1 is hydrogen, halogen, −CR′(CF 3 ) 2 (R′=hydrogen, fluorine or O—C 1-4 -alkyl), more preferably hydrogen, and the substituent R 1 is preferably in the meta or para position, more preferably in the 4 position (para to X) of the aromatic; and R 2 is —CH(Me)—CH 2 —CHMe 2 and —CH 2 —CH 2 -t-But,
or
R 1 is halogen, —CR′(CF 3 ) 2 (R′=hydrogen, fluorine or O-C 1-4 -alkyl), more preferably hydrogen, and the substituent R 1 is preferably in the meta or para position, more preferably in the 4 position (para to X) of the aromatic; and R 2 is
and
X is a halogen, preferably Cl or Br, more preferably Br.
The present invention additionally relates to the compounds of the formulae (IV) to (VI)
A further aspect of the present invention relates to the use of the compounds of one of the formulae (II), (III), (IV), (V) and (VI) as reactants/intermediates in the process according to the invention described above.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
Not applicable.
DETAILED DESCRIPTION OF THE INVENTION
The inventive reaction will be described in detail with reference to scheme (I) below:
In connection with the present invention, the term “halogen” (X) encompasses elements which are selected from the group consisting of fluorine, chlorine, bromine and iodine, preference being given to using chlorine and bromine, and particular preference to using bromine.
Optionally substituted radicals may be mono- or polysubstituted, where the substituents may be the same or different in the case of polysubstitutions.
The definition “C 1 -C 6 -alkyl” encompasses the largest range for an alkyl radical defined herein. Specifically, this definition encompasses the meanings of methyl, ethyl, n-, isopropyl, n-, iso-, sec-, tert-butyl, and in each case all isomeric pentyls and hexyls.
The definition “C 2 -C 6 -alkenyl” encompasses the largest range for an alkenyl radical defined herein. Specifically, this definition encompasses the meanings of ethenyl, n-, isopropenyl, n-, iso-, sec-, tert-butenyl, and in each case all isomeric pentenyls and hexenyls.
The inventive compounds can optionally be used as mixtures of different possible isomeric forms, especially of stereoisomers, for example E and Z, threo and erythro, and also optical isomers, and if appropriate also of tautomers. It is possible to use both the E and the Z isomers, and also the threo and erythro isomers, and also the optical isomers, any mixtures of these isomers, and also the possible tautomeric forms.
The haloalkylbenzenes required are known in the prior art, for example from WO-A-03074491, or can be prepared by known methods by Friedel-Crafts alkylation or electrophilic aromatic halogenation.
A further possibility is that of reacting 2-halobenzaldehydes with Wittig reagents, in which case the propenone derivatives thus obtained, as described in WO-A-03074491, can be converted to cyclopropyl compounds.
Other possibilities are the hydroxyalkylation of aromatics or metalated aromatics with ketones or acid chlorides and, respectively, the subsequent elimination and reduction thereof. Proceeding from 1,2-dibromobenzene, this is illustrated by way of example in scheme (II):
Alternatively, it is also possible to obtain the halogen compounds in question from aniline derivatives by diazotization and Sandmeyer reaction.
According to the present invention, the haloalkylbenzene of the formula (IX)
in which X is a halogen atom, especially Br, is a preferred reactant.
Only some of the acid amides required are known, and they can be obtained from known acid halides, acids, esters or nitrites by known reactions.
This will be illustrated by the following example according to scheme (III):
The nitrogen source used may be aqueous or gaseous ammonia or one of its salts, for example ammonium acetate or sodium amide.
Useful solvents for the preparation of the acid amides include all solvents which are stable under the reaction conditions, for example ethers such as THF, 2-methyl-THF, dioxane, methyl t-butyl ether (MTBE), diethylene glycol, diethoxymethane, dimethoxymethane; aromatic hydrocarbons such as toluene, xylene, chlorobenzene, dichlorobenzene, benzene; aliphatic hydrocarbons such as petroleum ether, heptane, hexane, methylcyclohexane, cyclohexane; dimethylformamide (DMF); dimethylacetamide; N-methylpyrrolidone (NMP); dimethyl sulfoxide (DMSO), acetonitrile; butyronitrile; water; ketones such as acetone, methyl isobutyl ketone (MIBK); alcohols such as methanol, ethanol, isopropanol.
For the inventive reaction of the acid amide with the halobenzene derivative, metal catalysts are used. For this purpose, palladium and copper in all oxidation states are useful, for example in metallic form or in the form of salts.
According to the present invention, for example, Pd(OAc) 2 , Pd(OH) 2 , PdCl 2 , Pd(acac) 2 (acac=acetylacetonate), Pd(NO 3 ) 2 , Pd(dba) 2 , Pd 2 dba 3 , (dba=dibenzylideneacetone), dichlorobis(triphenylphosphine)palladium(II), Pd(CH 3 CN) 2 Cl 2 , tetrakis(triphenylphosphine)palladium(0), Pd/C or palladium nanoparticles, CuI, CuCl, CuSCN, Cu 2 O, CuO, CuCl 2 , CuSO 4 , CuBr, CuBr 2 , Cu 2 S, Cu(OAc) 2 , Cu(acac) 2 are suitable, preference being given to using the copper compounds or mixtures thereof.
According to the present invention, the catalysts are used in catalytic amounts. This means that the metal catalysts are used in concentrations of from 0.01 to 50.0 mol %, preferably of 1.0 to 20.0 mol %, based on the carboxamides of the formula (II).
The inventive reaction is preferably performed in the presence of ligands.
In the case of palladium catalysis, suitable ligands are, for example, selected from the group of carbene and phosphine ligands, particular preference being given to using xantphos and tris(t-butyl)phosphine.
In the case of copper catalysis, suitable ligands are, for example, selected from the group consisting of diamines, for example N,N′-dimethyl-1,2-cyclohexanediamine (cis or trans, racemic or as an enantiomer), N,N′-dimethylethylenediamine, ethylenediamine, N-methylethylenediamine, N-butylethylenediamine, N,N,N′-trimethylethylenediamine or else 1,10-phenanthroline, ethylenediaminetetraacetic acid, tetra-n-butylammonium fluoride, tris(3,6-trioxaheptyl)amine (TDA-1), particular preference being given to using N,N′-dimethyl-1,2-cyclohexanediamine.
The ligands are added to the metal catalyst in such a ratio that the desired catalytic action occurs.
According to the present invention, the ratio of ligand to metal catalyst is between 0.5 to 10 equivalents, preferably between 1 to 5 equivalents.
The reaction is preferably carried out in the presence of bases. Useful examples include alkali metal and alkaline earth metal hydroxides such as KOH, NaOH, Ca(OH) 2 , fluorides such as KF, phosphates such as K 3 PO 4 , and carbonates such as potash, soda, cesium carbonate or phosphazene bases, alkoxides such as sodium tert-butoxide, or phenoxides such as sodium phenoxide.
According to the present invention, the bases are used in concentrations of from 0.5 to 5 equivalents, preferably from 1.0 to 3 equivalents, based on the carboxamides of the formula (II).
The inventive reaction of the acid amide with the halobenzene derivative is preferably carried out in a solvent.
The solvents used are preferably dioxane, THF, diglyme, toluene, xylene, DMF.
According to the present invention, the acid amides and the halobenzene derivatives are reacted with one another in an equimolar ratio. In an alternative embodiment, the halobenzene derivative can also be used in excess, for example as a solvent.
According to the invention, the acid amides are reacted with the halobenzene derivatives at temperatures in the range from 20 to 200° C., preferably from 70 to 150° C.
In a particularly preferred embodiment of the invention, carboxamides of the formula (V) are reacted with compounds of the formula (X)
in which the X radical is a halogen
to give carboxamides of the formula (XI)
The examples which follow are intended to illustrate the subject matter of the invention in detail, but without restricting it thereto.
EXAMPLE 1
1-Bromo-2-(1,3-dimethylbutyl)benzene
28.4 g of 2-(1,3-dimethylbutyl)aniline in 134.9 g (667 mmol) of 40 percent hydrobromic acid in glacial acetic acid at 10° C. are admixed with 12.5 g (181 mmol) of sodium nitrite in portions with stirring within 1.5 h. Thereafter, 0.5 g of copper powder is added and the mixture is boiled under reflux for 1 h hour. Subsequently, 120 ml of water and sodium hydroxide solution are added until pH 12 is attained, and the organic phase is removed, washed with dilute hydrochloric acid and concentrated by evaporation under reduced pressure. After distillation in a Kugelrohr apparatus at 0.3 mbar/70° C. and purification of the main fraction by means of preparative HPLC, 8.3 g of a yellowish oil with a purity of 99.4% (determined by HPLC) are obtained.
1 H NMR (400 MHz, CDCl 3 ): 0.89 (dd, 6H), 1.17 (d, 3H), 1.32-1.38 and 1.46-1.53 (2m, AB, 2×1H), 1.54-1.6 (m, 1H), 3.34 (m, 1H), 7 (m, 1H), 7.21-7.28 (m, 2H), 7.52 (d, 1H).
5-Fluoro-1,3-dimethyl-1 H-pyrazole-4-carboxamide
19.9 g of 5-fluoro-1,3-dimethyl-1H-pyrazole-4-carbonyl chloride are added dropwise at 20-35° C. to a mixture of 35 g of 25 percent aqueous ammonia and 170 ml of THF. After stirring for 4 h, the organic solvent fraction is concentrated by evaporation under reduced pressure and 0.2 mol of potash and sodium chloride are added to saturation. After extracting four times with ethyl acetate and concentrating the combined organic phases by evaporation under reduced pressure, 16.6 g of a yellow solid are obtained.
1 H NMR (400 MHz, d 6 -DMSO): 2.64 (s, 3H), 3.63 (s, 3H), 6.9 (broad s, 1H), 7.18 (broad s, 1H).
N-[2-(1,3-Dimethylbutyl)phenyl]-5-fluoro-1,3-dimethyl-1H-pyrazole-4-carboxamide
A mixture of 0.221 g (1.16 mmol) of copper iodide, 3.21 g (23.22 mmol) of potash and 2.189 g of 5-fluoro-1,3-dimethyl-1H-pyrazole-4-carboxamide is admixed under argon with 330 mg (2.322 mmol) of N,N′-dimethyl-1,2-cyclohexanediamine, 2.8 g (11.6 mmol) of 1-bromo-2-(1,3-dimethylbutyl)benzene and 30 ml of toluene. After boiling under reflux for one day, the mixture is poured onto water and 10 ml of a 5% EDTA solution. Subsequently, the mixture is extracted three times with ethyl acetate and concentrated by evaporation under reduced pressure. The oily residue is dissolved in toluene and stirred into n-hexane. After the precipitated crystals have been filtered off with suction, 3.3 g (89% of the theoretical yield) of N-[2-(1,3-dimethylbutyl)phenyl]-5-fluoro-1,3-dimethyl-1H-pyrazole-4-carboxamide are obtained with a purity (HPLC) of 99%. | The present invention provides a metal-catalyzed process for preparation of substituted pyrazolecarboxamides of formula (I) as fungicidally active compounds from 2-alkylhaloaromatics and heterocyclylamides. | 2 |
CROSS-REFERENCE TO PRIOR APPLICATION
[0001] This application is a §371 National Stage Application of PCT International Application No. PCT/EP2009/066511 filed Dec. 7, 2009, which is incorporated herein in its entirety.
TECHNICAL FIELD
[0002] The disclosure relates to a fibrous product, especially tissue paper product, non-woven product or a hybrid thereof, and especially hygiene and cleaning product with at least one ply, the surface of which is partly covered with an embossing pattern. The disclosure also relates to an embossing roll for producing such a fibrous product and to a device and method for producing such fibrous products.
BACKGROUND
[0003] Hygiene or wiping products primarily include all kinds of dry-creped tissue paper, wet-creped paper, TAD-paper (Through Air Drying) paper manufactured by the UCTAD process (Uncreped TAD), by the Atmos process (Voith) or by the NTT process (Metso) and cellulose or pulp-wadding or all kinds of non-wovens, or combinations, laminates or mixtures thereof. Typical properties of these hygiene and wiping products include the reliability to absorb tensile stress energy, their drapability, good textile-like flexibility, properties which are frequently referred to as bulk softness, a higher surface softness and a high specific volume with a perceptible thickness. A liquid absorbency as high as possible and, depending on the application, a suitable wet and dry strength as well as an appealable visual appearance of the outer product's surface are desired. These properties, among others, allow these hygiene and wiping products to be used, for example, as cleaning wipes such as paper or non-woven wipes, windscreen cleaning wipes, industrial wipes, kitchen paper or the like; as sanitary products such as for example bathroom tissue, paper or non-woven handkerchiefs, household towels, towels and the like; as cosmetic wipes such as, for example, facials and as serviettes or napkins, just to mention some of the products that can be used. Furthermore, the hygiene and wiping products can be dry, moist, wet, printed or pretreated in any manner. In addition, the hygiene and wiping products may be folded, interleaved or individually placed, stacked or rolled, connected or not, in any suitable manner.
[0004] Due to the above description, the products can be used for personal and household use as well as commercial and industrial use. They are adapted to absorb fluids, remove dust, for decorative purposes, for wrapping, or even just as supporting material, as is common, for example, in medical practices or in hospitals.
[0005] If tissue paper is to be made out of pulp, the process essentially includes a forming that includes a box and a forming wire portion, and a drying portion (e.g. through air drying or conventional drying on a yankee cylinder). The production process also usually includes the crepe process essential for tissues and, finally, typically a monitoring and winding area.
[0006] Paper can be formed by placing the fibers, in an oriented or random manner, on one or between two continuously revolving wires of a paper making machine while simultaneously removing the main quantity of water of dilution until dry-solids contents of usually between 12 and 35% are obtained.
[0007] Drying the formed primary fibrous web occurs in one or more steps by mechanical and thermal means until a final dry-solids content of usually about 93 to 97% has been reached. In case of tissue making, this stage is often followed by the crepe process which crucially influences the properties of the finished tissue product in conventional processes. The conventional dry crepe process involves creping on a usually 4.0 to 6.5 m diameter drying cylinder, the so-called yankee cylinder, by means of a crepe doctor with the aforementioned final dry-solids content of the raw tissue paper. Wet creping can be used as well, if lower demands are made of the tissue quality. The creped, finally dry raw tissue paper, the so-called base tissue, is then available for further processing into the paper product for a tissue paper product.
[0008] Instead of the conventional tissue making process described above, the use of a modified technique is possible in which an improvement in specific volume is achieved by a special kind of drying which leads to an improvement in the bulk softness of the tissue paper. This process, which exists in a variety of subtypes, is termed the TAD (Through Air Drying) technique. It is characterized by the fact that the “primary” fibrous web that leaves the forming and sheet making stage is pre-dried to a dry-solids content of about 80% before final contact drying on the yankee cylinder by blowing hot air through the fibrous web. The fibrous web is supported by an air-permeable wire or belt or TAD-fabric and during its transport is guided over the surface of an air-permeable rotating cylinder drum, the so-called TAD-cylinder. Structuring the supporting wire or belt makes it possible to produce any pattern of compressed zones broken up by deformation in the moist state, also named moulding, resulting in increased mean specific volumes and consequently leading to an increase of bulk softness without decisively decreasing the strength of the fibrous web.
[0009] To produce multi-ply tissue paper products, such as handkerchiefs, bathroom paper, towels or household towels, an intermediate step often occurs with so-called doubling in which the base tissue in the desired number of plies is usually gathered on a common multi-ply mother reel.
[0010] The processing steps from the base tissue that has already been optionally wound up in several plies are used in processing machines (converting machines) which include operations such as unwinding the base tissue, repeated smoothing of the tissue, printing, embossing, to an extent combined with full area and/or local application of adhesive to produce ply adhesion of the individual plies to be combined together as well as longitudinal cut, folding, cross cut, placement and bringing together a plurality of individual tissues and their packaging as well as bringing them together to form larger surrounding packaging or bundles. Such processing steps may also include application of substances like scents, lotions, softeners or other chemical additives. The individual paper ply webs can also be pre-embossed and then combined in a nip of rolls according to the embossing methods known in the art. Any embossing can lead to embossed elements all having the same height or to embossing elements having different heights. Ply bonding, e.g. by mechanical or by chemical means are other well-known methods mainly used for hankies, napkins and bathroom tissues and household towels.
[0011] The term “embossing” is not restricted to a process of mechanically amending the physical structure of a tissue paper in the converting part of tissue manufacturing. The term “embossing” also includes any amendments of the physical structure of a base tissue paper in the forming or drying part of tissue manufacturing by using structurized sieves, or fabrics, of felts, or belts, or blades (e.g. in line with the Atmos-process, the NTT-process or the CPN-process).
[0012] A known technique to increase the thickness of a paper product is to emboss the paper web. An embossing process may be carried out in the nip between an embossing roll and an anvil roll. The embossing roll can have protrusions on its circumferential surface leading to so-called embossed depressions in the paper web or it can have depressions in its circumferential surface leading to so-called embossed protrusions in the paper web.
[0013] Anvil rolls may be softer than the corresponding embossing roll and may include rubber, such as natural rubber, or plastic materials, paper or steel.
[0014] For manufacturing multi-ply tissue products, especially bathroom tissue and household tissue, three main manufacturing methods for embossing and adhesively bonding of the plies have been established. These are Goffra Incolla/spot embossing, DESL (Double Embossing Single Lamination)/Nested, and Pin-to-Pin/Foot-to-Foot. Other methods for manufacturing multi-ply tissue products are based on a mechanical ply-bonding process without using adhesives, e.g. by mechanical compression of the plies. Before ply-bonding the plies are often embossed in nips of an embossing roll and an anvil roll.
[0015] In the first mentioned manufacturing method, Goffra Incolla, a first web is directed through the nip between an embossing roll and an anvil roll. In this nip, the web is provided with an embossing pattern. Thereafter, an application roll applies adhesive to those parts of the first web at which there are protruding embossing elements in the embossing roll. The adhesive is transported from an adhesive bath via an adhesive transfer roll to the application roll. A second web is transported to the first web and adhesively bonded to the first web in the nip between the so-called marrying roll and the embossing roll. The adhesive bonding takes place at those portions at which the adhesive was applied.
[0016] The second manufacturing method (DESL/Nested) is very similar to the above-described Goffra Incolla method. It includes an additional pair of rolls including a second embossing roll and a second anvil roll. The additional pair of rolls serves to emboss the second web before it is adhesively bonded to the first web using the marrying roll. Typically, the additional pair of rolls is placed close to the first pair of rolls and the marrying roll. Especially when using the so-called Nested-method such close arrangement is important. The Nested-method can be considered as a special case of the general DESL-manufacturing method. For the Nested-method the embossing elements of the first embossing roll and the embossing elements of the second embossing roll are arranged such that the embossed elements of the first embossed ply and the embossed elements of the second embossed ply fit into each other similar to a gearing system. This serves to achieve a mutual stabilization of the two plies. However, for the DESL manufacturing method such correlation between the embossed elements of the first, upper ply and the second, lower ply, does not have to apply. Nevertheless, in a literature the term DESL is often used synonymous to a Nested-method.
[0017] The third manufacturing method (Pin-to-Pin/Foot-to-Foot) is similar to the DESL method. By means of two pairs of rolls both the upper ply and the lower ply are embossed, respectively. Adhesive is applied onto the embossed protrusions of the first ply. The ply bonding however, is not achieved by means of a marrying roll as in the DESL method but is achieved directly by means of the protruding embossing elements of the second embossing roll. In order to achieve this, an exact adjustment of the width of the gap between the first embossing roll and the second embossing roll is required, which is mainly defined by the individual thickness of both webs (upper ply and lower ply). Further, the embossing rolls have to be designed such that at least some of the protruding embossing elements of both rolls face each other. This is the reason why the terminology Pin-to-Pin or Foot-to-Foot embossing is used.
[0018] All above described methods have the following common features: the first embossing roll is formed of a hard material, usually metal, especially steel, but there are also known embossing rolls made of hard rubber or hard plastics materials. The embossing rolls can be a male roll having individual protrusions. Alternatively, the embossing roll can be a female roll with individual embossing depressions.
[0019] The anvil roll typically has a rubber coating. However, structurized anvil rolls, especially rolls made of paper, rubber or plastics materials or steel are also known.
[0020] The applicator roll for adhesive is usually also a rubber roll with a plain smooth circumferential surface, wherein the hardness of the rubber coating is between the hardness of the anvil roll and the hardness of the marrying roll. Commonly used values for the hardness of the rubber coating are 70 to 85 Shore A. When selecting the rubber material its compatibility with the adhesive to be applied has to be ensured.
[0021] The application system for adhesive consisting of applicator roll, adhesive transfer roll and adhesive bath can be designed as a so-called immersion roll system in which the adhesive transfer roll is immersed into the adhesive bath and transports adhesive by means of surface tension and adhesive forces out of the adhesive bath. By adjusting the gap between the adhesive transfer roll and the applicator or application roll, the amount of adhesive to be applied can be adjusted. Application rolls may be structured rolls. Further, adhesive transfer rolls have become known having defined pit-shaped depressions in their circumferential surface. Such adhesive transfer rolls are known as anilox-rolls. Such a roll is usually made of ceramic material or it is a roll made of steel or copper and coated with chromium. Excessive adhesive is removed from the surface of the anilox-roll by means of a blade. The amount of adhesive is determined by the volume and the number of depressions. Alternative application systems for applying adhesives are based on a spraying equipment (e.g. Weko-technique).
[0022] A second possibility to influence the amount of adhesive transferred is the adjustment of the difference in circumferential speeds of the adhesive transfer roll and the applicator roll. Typically, the adhesive transfer roll rotates slower than the applicator roll. The circumferential speed of the adhesive transfer roll is usually between 5% and 100% of the first circumferential speed of the applicator roll. The adhesive bath can be designed as a simple trough, application systems with a blade can also be designed as chamber systems.
[0023] The embossing technologies Goffra Incolla/spot embossing and DESL/Nested, both use an additional roll, the so-called marrying roll for laminating together the plies. The marrying roll commonly has a smooth rubber surface with a hardness of about 90-95 Shore A. A suitable material is e.g. NBR (acrylnitrile-butadien rubber). However, marrying rolls also have become known which, in addition to the rubber coating, are provided with a steel coating. Such steel coating is often provided in form of a steel band spirally wound onto the rubber coating as described in WO2004/065113.
[0024] In case that the single plies individually or together are pre-embossed, a so-called micro-pre-embossing device is used. Such pre-embossing device is often used in combination with the Goffra Incolla technology. Also commonly used is a printing onto the tissue product before or after the ply bonding step. Also known are variants including the application of chemical substances, especially lotions and softeners.
[0025] Another well-known embossing technique comprises a steel embossing roll and a corresponding anvil steel roll (so-called Union embossing). The surfaces of these rolls are being formed in such a manner that deformation of the paper and mechanical ply bonding without using adhesives are achieved within one single embossing step.
[0026] When using one of the above described three embossing methods also for a pin-to-pin technique it is advantageous to provide a control for the tension of the web both before and after the ply bonding because the physical properties of the web and especially the stress-strain characteristic can be changed significantly in the embossing step.
[0027] The embossing not only serves to provide bulk to the fibrous product but also to provide an improved optical appearance to the product. The optical appearance of a product is important for consumer products and also serves to provide a higher degree of recognition to the product. The optical appearance can be improved by combining embossing and coloring steps. Another reason for embossing is to generate higher absorbency or improved perceived softness.
[0028] In the prior art, different embossing techniques have been used to achieve a desired visual effect in embossing patterns. One possibility is to define specific regions in an embossed product in which the dot densities, i.e. the distances between individual, equidistantly arranged embossing spots are different to those of adjacent regions in order to generate a visual effect.
[0029] Another possibility to achieve a visual effect is to arrange individual embossing protrusions such that they form a linear pattern. An example for such linear alignment of individual embossing protrusions is disclosed in U.S. Pat. No. 6,520,330 B1. The embossing pattern shown therein is formed by identical embossing protrusions which have different distances to the neighboring embossing protrusions so that an optical appearance is created.
[0030] A further possibility is to create an optical appearance by selecting different sizes of embossing protrusions. Such patterns are shown in EP 1 253 242 A2 or EP 1 209 289 A1 also using the concept of aligning single embossing protrusions.
[0031] There are several options to provide good optical appearance of an embossed fibrous product. EP 1 047 546 B1 describes a product with a continuous background pattern of embossed depressions and with certain unembossed zones acting as motif elements. The visibility of such elements may be enhanced by providing linear arrangements of dot-like embossed depressions along the motifs.
[0032] A tissue paper product with separate micro-embossed regions and additional linear depressions showing motif elements are known from US 2007/0122595 A1. The linear depressions can either be provided within micro-embossed regions or fully outside the micro-embossed regions and within unembossed areas of the tissue paper product.
[0033] The motif elements according to DE 20 2006 009 274 U1 are formed by unembossed areas within an overall pattern of dot-like embossed depressions evenly distributed over the product.
[0034] The tissue product according to US 2006/0286885 A1 has an embossing pattern with motif elements surrounded by closed linear embossed depressions. Further, the embossed background pattern formed by dot-like micro-embossed depressions is interrupted by macro bosses defining stitch-like patterns to enhance the visual effect of the product.
SUMMARY
[0035] It is desired to provide a fibrous product, an embossing roll, a device, and a method for producing such product so that the optical appearance and the perceived softness of the product can be improved.
[0036] This can be provided by a fibrous product with at least one ply, the surface of which is partly covered with an embossing pattern, wherein the pattern includes at least one first continuous zone being micro-embossed with at least 25 embossing depressions per cm 2 , forming a background embossing area; a plurality of second zones being unembossed and forming at least one motif element; and at least one third zone being largely surrounded by linear depressions and an embossing roll for producing such a fibrous product. Also, an embossing device for manufacturing such a fibrous product and a method for manufacturing such a fibrous product.
[0037] The fibrous product can be especially a tissue paper product, non-woven product or a hybrid thereof, and in particular a hygiene and cleaning product. The fibrous product has at least one ply with a surface which is partly covered with an embossing embossed pattern and is characterized in that the pattern includes a first zone being micro-embossed with at least twenty-five embossing depressions per cm 2 , forming a background embossing pattern, wherein the first zone is a continuous zone. The pattern further includes a plurality of second zones with no embossing depressions wherein the second zones form at least one motif element. Finally, the pattern includes in addition to the second zones at least one third zone being largely surrounded by linear depressions.
[0038] The term “surface” also includes a mechanical amendment of the physical structure of the tissue ply in the third dimension so that the depth of the tissue ply below the surface may also be influenced by an embossing step.
[0039] In other words, the embossed pattern includes three individual zones, wherein the second zones are not provided with embossing depressions. The reason why such second zones are still considered to be part of the embossed pattern lies in the fact that the second zones could be placed at some elevated or recessed level in order to increase the visibility of a motif element represented by the second zones. The first, micro-embossed zone largely determines the perceived bulk of the product. However, the first zone has a double function in that it surrounds the second zones whose outer shapes represent a specific motif element which can be recognized by the consumer. The second zones can also be used to add a technical effect to their visual appearance. Since the second zones have a flat and smooth surface, they contribute to high hand-feel values of the fibrous product. This is why the third zones must not fully lie within the second zones. The at least one third zone is largely surrounded by linear depressions which can be either continuous or non-continuous. Besides a marked optical effect of the third zones, they also have a double function in that they can be used to provide ply-bonding between the embossed ply and one or more further plies of a multi-ply product.
[0040] In particular embodiments, the micro-embossed first zone includes 30 to 160 embossing depressions/cm 2 , especially by 30 to 120 embossing depressions/cm 2 and most particularly by 45 to 100 embossing depressions/cm 2 . These embossing depressions form the background embossing area of the first zone.
[0041] Where the number of embossing depressions is less than 25 per cm 2 it can become difficult to clearly identify the motif of the second zone because the borders between the different zones will become less accurate. If the number of embossing depressions exceeds 160 per cm 2 a single embossing depression will become very small and flat and cannot be clearly recognized as an individual embossing depression. Due to this fact it will become difficult for the consumer to clearly distinguish between the first and the second zone if the number of embossing depressions exceeds 160 per cm 2 . Moreover, such a high number of embossing depressions in the first zone can result in a decrease of bulk of the final fibrous product and in a loss of its absorption properties.
[0042] In certain embodiments, the design of the second zones and the at least one third zone are similar or identical which means that the motif element represented by the second zones thematically corresponds to the motif element formed by the linear depressions of the at least one third zone.
[0043] In order to improve the optical effect of the second zones, some specific measures can be taken either separately or in combination. In the one hand, the visual appearance of the second zones can be improved by using dry-creped paper which is as flat as possible. If a paper produced by a TAD-process is used, the material is much more uneven so that the contrast between the second zones and the micro-embossed impressions of the background pattern of the first zone is smaller. As a result of this, the visibility of the motif elements of the second zones is inferior. A second measure is to adjust the embossing depressions of the first zone such that some of these depressions closely surround and follow the desired contour of the second zones. This can be either achieved by deviating from a fixed arrangement pattern of the micro-embossed depressions. Such micro-embossed depressions can be placed so that one or more lines of micro-embossed depressions fully surround the second zones. A second option is to provide a fixed arrangement of the micro-embossed depression but to provide a sharper and less blurred motif element of the second zones by providing only parts of the micro-embossed depressions along the edges of the second zones. The visual effect is similar to cutting a motif out of a sheet with a fixed raster. This will also lead to certain raster points being suitably cut in order to more accurately follow the desired contour of the motif element.
[0044] Further, it is possible to surround the second zones by macro-embossing depressions which are bigger than the micro-embossing depressions.
[0045] Another possible means to increase the overall visibility of the motif elements is to leave out a margin around the linear depressions around the third zones.
[0046] A further means to improve the optical appearance of the overall fibrous product is to position the embossed depressions of the background embossed area so as to form an optically appealing background pattern. Such background pattern can also thematically relate to the motif of the third zones. To give an easy example, the background embossed pattern can form waves which thematically fit to maritime motifs of the second zones and third zones. Alternatively, the embossed depressions can be rastered in such a way as to form an overall motif element wherein higher dot densities or dot sizes of the embossed depressions represent darker areas of a black and white greyscale motif picture.
[0047] The term non-woven according to ISO 9092, DIN EN 29092 is applied to a wide range of products which, in terms of their properties are located between those of paper (DIN 6730, May 1996) and cardboard (DIN 6730) on the one hand, and textiles on the other hand. As regards non-woven, a large number of extremely varied production processes are used, such as the air-laid and spun-laced techniques as well as the wet-laid techniques. The non-wovens include mats, non-woven fabrics and finished products made thereof. Non-wovens may also be called textile-like composite materials, which represent flexible porous fabrics that are not produced via the classic methods of weaving warp and weft or by looping. In fact, non-wovens are produced by intertwining, cohesive or adhesive bonding of fibers, or a combination thereof. The non-woven material can be formed of natural fibers, such as cellulose or cotton fibers, but can also include synthetic fibers such as polyethylene (PE), polypropylene (PP), polyurethane (PU), polyester, fibers on the basis of polyethylenterephtalate, polyvinyl alcohol, nylon or regenerated cellulose or a mix of different fibers. The fibers may, for example, be present in the form of endless fibers or pre-fabricated fibers of a finite length, as synthetic fibers, or in the form of staple fibers. The non-wovens as mentioned herein may thus include mixtures of synthetic and cellulose fibrous material, e.g. natural vegetable fibers (see ISO 9092, DIN EN 29092).
[0048] The term “hygiene products” and “cleaning products” as used herein include bathroom tissue, household towels, handkerchiefs, facial tissues, napkins, wiping and cleaning products as well as table ware.
[0049] According to a certain embodiment, at least some of the second zones abut the first zone. In other words, such second zones are not surrounded by continuous or non-continuous lines but formed directly within the background pattern of the first zone. In particular embodiments, all third zones and second zones are arranged such that the second zones and third zones are isolated from each other. This means that there is no overlap on the surface of the fibrous product of the second zones and third zones. In the description below, both an example of isolated second zones and third zones and of partially overlapping second zones and third zones will be given in order to more clearly point out the optical appearance of second zones and third zones isolated from each other. Correspondingly, another particular embodiment is characterized in that at least one second zone, or in particular all second zones, and the at least one third zone are arranged such that second zones and third zones partly overlap with each other. However, a full overlap of the second zones and third zones has to be avoided because otherwise the second, unembossed zones are likely to be misinterpreted as the background surface of the third zones without realizing that the second zones independently represent a motif element. Further, the technical effect of the second zones gets lost.
[0050] In certain embodiments, the at least one second zone has a size of at least 0.5 cm 2 , preferably at least 1 cm 2 , more preferably at least 2 cm 2 and most preferably between about 3 cm 2 and about 5 cm 2 , and the at least one third zone has a size of at least 0.2 cm 2 , preferably at least 0.5 cm 2 , more preferably at least 1 cm 2 and most preferably between about 2 cm 2 and about 5 cm 2 . Such ranges provide a good visibility of the motif elements without being too large which can be detrimental to the physical properties of the fibrous product.
[0051] According to a certain embodiment, the total area of all first zones covers 25 to 90% of the total surface of one side of the product, wherein the total area of all second zones covers 5 to 70%, and the total area of all third zones covers 5 to 30% of the total surface of the side of the product. In more certain embodiments, the total area of all first zones covers 35 to 80%, especially 40 to 70% of the total surface of one side of the product, wherein the total area of all second zones covers 10 to 50%, especially 15 to 35%, and the total area of all third zones covers 10 to 25%, especially 15 to 25% of the total surface of the side of the product. Such ranges do not only serve to provide good visibility of the motif elements but also to make sure that the desired physical properties of the fibrous product are achieved. If ply bonding is effected along the linear depressions of the third zones, a total area of such third zones surrounded by the linear depressions should not be too high so that the product is still soft. The coverage of the first zones should not be too small because the embossed background pattern gives the fibrous product a higher perceived volume, as was outlined in more detail above. Also the overall coverage of the second zones should not be above 70% because such unembossed areas are smooth and lead to high hand-feel values but, at the same time, would reduce the perceived softness and bulk of the product. Further, a total surface coverage of all second zones which is too low has a negative effect on the visibility of the motif elements of the second zones.
[0052] The fibrous product may include, besides these three zones, fourth zones, fifth zones or even more zones. Such additional zones are e.g. characterized by a plurality of different heights or by a three-dimensional embossing structure (WO2009/010092) and can be, in particular, isolated from each other.
[0053] According to a certain embodiment, the product includes at least two plies bonded together, wherein ply bonding is especially effected by adhesive, more particularly colored adhesive, and wherein the ply can be bonded together at least partly along the linear depressions of the at least one third zone.
[0054] Reference to at least one ply indicates that the fibrous product can be a single-ply or multi-ply product. Besides the at least one top ply as discussed above, there can be additionally one or a plurality of backside plies. Further, two or more top plies with a partly embossed pattern can be embossed together.
[0055] The backside ply or backside plies can have the same embossing pattern as the top ply or plies, or can be the mirror image of the top ply. The definition of which of the plies is the top ply and which is the backside ply is then arbitrary. In the other cases in which the backside ply does not have the specific arrangement of the embossing depressions forming first, second and third zones, the first ply is then the one according to the particular embodiments of the invention.
[0056] Additionally, the product can also have one or more middle plies non-embossed or embossed separately from the first ply or plies and the backside ply or plies. As a further alternative, the multi-ply fibrous product could include at least one middle ply which is volume embossed. The technique of volume embossing conventional products is known from WO2002/103112, the teaching of which is incorporated herein by reference. A volume embossed middle ply serves to impart a high volume to the product and might be used if a product is desired with the feeling of high volume.
[0057] The ply bonding can be carried out by adhesive. Another possibility to achieve ply bonding is mechanical ply bonding, such as knurling which is usually performed along at least one longitudinal edge of the product. Likewise, edge embossing can be performed along all four sides of the product.
[0058] If the plies are bonded together by adhesive, a conventional application system like a so-called immersion-roll system can be used which was explained above. As regards the adhesive, also conventional adhesive mixtures either colored or not colored can be employed.
[0059] According to a particular embodiment, each ply has a basis weight of 10 to 40 g/m 2 and/or the fibrous product has total basis weight of 15 to 120 g/m 2 .
[0060] In a certain embodiment, the fibrous product is made of creped tissue paper, especially of dry creped tissue paper which has a relatively smooth surface so that the motif elements represented by the second zones has a high visibility because of the high contrast between second zones and first zone or zones.
[0061] In a certain embodiment, the caliper per ply is at least 100 micrometers, preferably at least 120 micrometers and most preferably around 150 micrometers. Determining the caliper value is carried out in line with DIN EN 12625-3 at the final tissue product. Afterwards the caliper per ply is calculated by dividing the measured value by the numbers of plies.
[0062] In the fibrous product, the individual embossed depressions of the first zones can be dots having a cross-sectional shape which is essentially circular or essentially elliptical or oval or essentially square-shaped or essentially polygon and which are arranged regularly. However, the individual embossing depressions can be arranged in a random manner in order to produce an additional optical effect which can be either ornamental or represent more complex motifs by arranging the individual embossing depressions such as to represent a frequency modulated raster element.
[0063] The backside ply or backside plies can be embossed with a second embossing pattern different to the embossing pattern of the first ply or plies, the second embossing pattern can include a micro-embossing pattern. A micro-embossing pattern is a relatively regular pattern of densely arranged small embossed depressions having a density of embossed elements of at least 25/cm 2 . Such a micro-embossing pattern of the backside ply or plies can be selected freely based on functional criteria in order to give the fibrous products certain characteristics in term of overall strength, bulk or smoothness.
[0064] The disclosure also relates to an embossing roll for producing fibrous products. The embossing roll has an embossing surface suitable to run against an anvil roll and is characterized in that the embossing surface includes at least one first zone being a micro-embossing zone with at least 25 micro-embossing protrusions per cm 2 , the micro-embossing protrusions having a first height (H 1 ) over a base circumferential surface of the embossing roll. The embossing surface further includes a plurality of second zones with no embossing protrusions within the second zones, the second zones having a second height (H 2 ) over the base circumferential surface of the embossing roll. Finally, the embossing surface includes a plurality of third zones being provided by continuous or interrupted linear protrusions having a third height (H 3 ) over the base circumferential surface of the embossing roll. In particular embodiments, the third zones are essentially surrounded by the linear protrusions. Besides the three zones, the embossing roll may include fourth, fifth or even more zones. Such additional zones are e.g. characterized by a plurality of different heights or by a three-dimensional embossing structure.
[0065] In particular embodiments, the first height (H 1 ) is between 0.4 mm and 1.4 mm, the second height (H 2 ) is between 0 mm and 2.5 mm, and the third height (H 3 ) is between 0.8 mm and 2.5 mm. In other words, the second zones can have no elevation at all over the base circumferential surface so that the second zones lie in the base circumferential surface of the embossing roll. This corresponds to a product produced by such embossing roll in which the second zones are not recessed or elevated. Although a range is given for the first height and the third height which shows some overlap, it is preferred that the third height exceeds the first height in order to improve the visibility of the motif represented by the third zones.
[0066] In particular embodiments, the embossing roll is characterized by the fact that the third height (H 3 ) of the third zone should exceed the first height (H 1 ) of the first zone by at least 0.2 mm and not more than 1 mm and especially by at least 0.35 mm and not more than 0.6 mm. According to another embodiment, the embossing roll is characterized by a width of the line elements of the third zone of between 0.2 mm and 2.0 mm, especially of between 0.3 mm and 1.5 mm and most preferably of between 0.4 mm and 1.0 mm.
[0067] Moreover, such an embossing roll should have micro-embossing protrusions having a surface of between 0.02 mm 2 and 1.0 mm 2 , especially of between 0.04 mm 2 and 0.5 mm 2 .
[0068] The embossing device for manufacturing a fibrous product includes at least one embossing roll as described above and at least one counter roll (or anvil roll).
[0069] According to a certain embodiment, the embossing device includes a first embossing roll and a second embossing roll arranged downstream of the first embossing roll. The first embossing roll has at least one first zone on its circumferential embossing surface which is provided with micro-embossing protrusions having a density of at least 25 micro-embossing protrusions per cm 2 , and a plurality of further zones with no embossing protrusions. The second embossing roll has a plurality of third zones on its circumferential embossing surface being provided with linear protrusions. The embossing protrusions of the second embossing roll can have a height exceeding the height of the embossing protrusions of the first embossing roll, especially by 0.4 mm.
[0070] In order to manufacture a product with a satisfactory optical appearance by means of such embossing devices with two embossing rolls, the two embossing rolls have to be in register so that the position of the third zones relative to the first and second zones is not arbitrary. The plurality of further zones of the first embossing roll with no embossing protrusions are the second zones as well as regions not covered with a micro-embossing pattern which, in the final product, represent the third zones and, where applicable, an unembossed margin around the linear depressions surrounding the third zones.
[0071] The embossing device as described above can further include a marrying roll. Such marrying roll runs against the second embossing roll for bonding together the at least one top ply and at least one further ply. Such marrying roll is used in the conventional Goffra Incolla type process or in a nested process. However, a marrying roll is not necessary in case of direct bonding together of two embossed plies using the above-described pin-to-pin ply bonding in which the tips of embossing patterns of two plies face each other and are laminated together at such tips. The device can include a further embossing roll running against the second anvil roll for embossing at least one further ply.
[0072] According to a particular embodiment, the embossing device further includes an application roll for applying adhesives. In particular embodiments, colored adhesive is used which can be selected in order to give a specific optical appearance to the product. The use of adhesives is another means to influence the technical properties of the combined product, especially during the ply-bonding process of the fibrous product. Selecting a useful adhesive may result in a fibrous product with a limited stiffness.
[0073] The method for manufacturing a fibrous product, especially tissue paper products, non-woven product or a hybrid thereof and especially hygiene and cleaning product with at least one ply, includes the steps of (a) embossing the at least one first zone, and (b) embossing the at least one third zone, wherein steps (a) and (b) are carried out either simultaneously by directing at least one ply into the nip between an embossing roll and a counter roll or anvil roll, or sequentially by directing the at least one ply through at least two subsequent embossing devices.
[0074] In certain embodiments, the method further includes the step of (c) calendering the second zones in step (a) and/or in step (b). The calendering of those parts of the fibrous product which form the second zones leads to an improved evenness of the surface which contributes to higher hand-feel values.
[0075] According to a certain embodiment, the method is characterized in that in a step (d) the at least one ply and a further ply are laminated at least partly at some of the lines of the third zones by applying adhesives to at least some of the linear protrusions of the at least one ply arranged over the surface of the embossing roll.
[0076] According to another embodiment, the method is characterized by a structurizing step of at least one ply in at least one manufacturing zone directly within the tissue making process, in particular, under wet conditions, and most particularly by using a structurized fabric or belt or felt or a combination of such structurized elements. The structurizing step can be carried out by using the Atmos process, NTT process or CNP process in the wet part or in the drying part of a papermaking machine.
[0077] For laminating together the single webs of material, different types of adhesive can be used. Suitable adhesives are, inter alia, glue on the basis of starch or modified starch like, for example, methyl cellulose or carboxylized methyl cellulose and adhesively acting polymers on the basis of synthetic resins, caoutchouc, polypropylene, polyisobutylene, polyurethane, polyacrylates, polyvinylacetat or polyvinyl alcohol. Such adhesives can also contain coloring agents in order to improve the optical appearance of the finished products. Frequently, water based glues are used for laminating together paper layers.
[0078] Another option to increase the visibility or to enhance the visual appearance of the product is to provide a multi-ply fibrous product which has at least one ply with a color that is different to the color of the other ply or plies. The provision of a selected ply having a different base color can provide interesting visual effects in combination with a first ply representing a motif element covering the motif surface area.
[0079] The fibrous product is characterized by ply-bonding at less points compared to the prior art resulting in an increased flexibility of the plies towards each other, and in a significantly enhanced softness perception. In addition, the fibrous product is further characterized by an improved visual appearance with line elements and dots compared to the prior art whereby missing dots products do not include line elements. Moreover, the fibrous product has a significantly increased bulk compared to prior art products.
BRIEF DESCRIPTION OF THE DRAWINGS
[0080] In the following, embodiments of the invention will be briefly described with reference to the drawings, in which:
[0081] FIG. 1 shows a fibrous product according to a first embodiment;
[0082] FIGS. 2 and 3 show enlarged views of FIG. 1 ;
[0083] FIG. 4 shows a second embodiment;
[0084] FIGS. 5 a to 5 f show cross-sectional views of two embossing rolls and a two ply product produced by means of these two structurized embossing rolls in a pin-to-pin configuration;
[0085] FIGS. 6 a to 6 c show cross-sectional views of two embossing rolls and a two ply product produced with these two structurized embossing rolls in a nested configuration; and
[0086] FIGS. 7 a to 7 c show cross-sectional views of an embossing roll and a marrying roll, and a two ply product produced by means of the so-called Goffra Incolla method.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0087] In the following description of preferred embodiments, the same basic elements will be denoted by the same reference numerals although, throughout different embodiments, specific details of the basic elements might differ.
[0088] FIG. 1 shows a plan view on the main surface of the top ply of a fibrous product. The product might have an identical bottom ply so that, for the sake of simplicity, FIG. 1 is considered to be a view on the top ply of the product.
[0089] The ply 10 is partly embossed and different zones can be distinguished. Firstly, there is a continuous first zone 12 which is provided with a micro-embossing pattern. Micro-embossing means that the average density of the embossing depressions is relatively high and exceeds at least twenty-five embossing depressions per cm 2 . The embossing depressions may have any suitable shape conventionally used for micro-embossed patterns. From the strongly enlarged detail as shown in FIG. 3 it follows that the embossing depressions 14 have a square shaped top surface and could have the shape of a truncated pyramid. The micro-embossing first zone determines some basic technical features of the product like the perceived volume or strength. In the example according to FIG. 1 , the micro-embossing depressions 14 are regularly arranged throughout the first zone. Alternatively, such micro-embossing depressions could have an irregular arrangement which either stresses the shape of the unembossed zones or is selected so as to provide an esthetically appealing effect like undulated patterns or even rastered images which are generated by simulating grayscales of black and white image by adjusting the frequency of the micro-embossing depressions 14 .
[0090] Besides the first zone 12 , the product is also provided with a plurality of second zones 16 which are not embossed. The second zones 16 might lie on the same base surface as the first zone 12 or could be selectively arranged at an elevated or recessed level compared to the base surface of first zone 12 . As can be seen from FIG. 1 , the second zones 16 are shaped so as to show butterflies. It is important to note that the unembossed second zones 16 form motif patterns by their own. The second zones 16 can be relatively flat which improves the perceived hand-feel values of the product.
[0091] Finally, there is a plurality of third zones 18 , which, as can be seen from FIG. 1 , show butterflies of different sizes. The third zones 18 are also not provided with micro-embossing depressions and are additionally formed by a plurality of linear embossing depressions 20 which mainly surround the motif element formed by the third zones. Nevertheless, the specific example of FIG. 1 shows that the linear embossing depressions 20 do not necessarily have to surround only the motif elements. There are embossing depressions referenced to by numeral 22 which additionally provide an optically appealing effect and, from a technical point of view, can be preferably provided within bigger unembossed areas of the third zones in order to stabilize such areas against one or more backside plies not shown in FIG. 1 .
[0092] Further, it can be noted that the linear embossing depressions 20 of the third zones 18 are additionally surrounded by a margin 24 which can be best seen in FIG. 2 and which is not provided with micro-embossing depressions 14 .
[0093] The linear embossing depressions 20 of the third zones can have different lengths and/or widths in order to further contribute to an optically appealing effect of the motif elements shown.
[0094] All or at least a considerable portion of the linear embossing depressions 20 serve to provide ply-bonding between the top ply of the product as shown in FIGS. 1 , 2 and 3 and one or more backside plies.
[0095] Turning to FIG. 3 , part of a second zone 16 of FIG. 1 and the surrounding first zone 12 are shown in an enlarged view. What is interesting to note is the fact that some of the micro-embossing depressions 14 like the example depressions 14 a , 14 b do not have their regular size but are cut such as to follow as closely as possible to the desired contour of the second zone 16 . This serves to increase the sharp visibility of the second zones 16 relative to the first zone 12 . The higher the dot density in the first zone 12 is, the less blurred are the motifs of the second zone. Further factors to increase the visibility of the second zone motif elements is the evenness of the surface of the second zones. To this end, dry creped tissue paper has shown to be especially advantageous to provide a high optical contrast between the second zones 16 and the surrounding first zone 12 .
[0096] In order to increase the visibility of specific motif elements and to provide a strong optical impression, certain further measures can be taken. Firstly, it is possible also to provide linear embossing depressions within the first zone 12 to provide a further motif to be perceived by a user. Further, an irregular background pattern of the micro-embossing depressions 14 can be provided as was discussed in more detail above. Further, some of the micro-embossing depressions might be provided with colored substances which can be applied to the micro-embossing depressions if two separate embossing rolls are used and, in a first step, only the micro-embossing depressions are generated in a first embossing station. In such a case, ink or other colored substances can be selectively applied to the embossed surface in order to increase its visual effect. Finally, colored adhesive could be applied to the linear embossing depressions 20 in order to increase the visibility of these linear depressions.
[0097] In the embodiment of FIGS. 1 to 3 , the motif elements of the second and third zones are identical and second and third zones are strictly separated from each other so there is no partial overlap between these zones.
[0098] FIG. 4 shows a second embodiment of a top ply 10 . Again, there is a first zone 12 with regularly arranged micro-embossing depressions forming a background pattern, second zones 16 in the shape of hearts, and third zones 18 showing angels with hearts. As can be seen from FIG. 4 , some of the second zones 16 a are provided separately, whereas other second zones 16 b overlap with third zones 18 . Further, unlike in the first embodiment as shown in FIGS. 1 to 3 , the motif of the second zones 16 (hearts) is not identical to the motif element of the third zones 18 (angels with hearts). However, the motif elements thematically correspond to each other so that despite of the fact that some of the second zones might be partly overlapped by the third zones, the user still distinguishes the second zones 16 to be specific motifs of their own related to the overall motif of the embossed ply.
[0099] Next, different embodiments of a two-ply product produced by means of two structurized embossing rolls will be explained with regard to FIGS. 5 a to 5 f . All drawings show cross-sectional views through two structurized embossing rolls in order to explain the production of a two-ply product. First embossing roll 50 is used to produce the top ply 10 of the product, whereas the second embossing roll 60 produces the backside ply. For sake of simplicity, it is assumed that the top ply 10 and the bottom ply 30 fully follow the shape of the embossing protrusions on the first embossing roll 50 and the second embossing roll 60 . The first embossing roll 50 has a first zone 52 with micro dots, a second zone 54 which will be referred to as a missing dots zone and a third zone 56 with lines. Correspondingly, the second embossing roll 60 is also provided with a first zone 62 , a second zone 64 and a third zone 66 . In the ply 10 produced, these zones 52 , 54 and 56 correspond to the first zone 12 , second zone 16 and third zone 18 , respectively.
[0100] Between the third zones of the embossing rolls 50 and 60 with the linear protrusions in the embossing rolls, top ply 10 and bottom ply 30 are bonded together. Such ply-bonding in regions 70 can be achieved by means of glue, which can be colored.
[0101] According to the first variant of a pin-to-pin arrangement of both embossing rolls 50 and 60 according to FIG. 5 a , the second embossing roll 60 is an exact mirror image of the first embossing roll 50 and both rolls are operated such that the protuberances of the third zones 56 and 66 exactly face each other so that the ply-bonding and optionally coloring can be easily carried out at these protrusions 68 . Moreover, the first zones 52 and 62 as well as the second zones 54 and 64 also face each other. The linear protrusions have a height H 3 over the base circumferential surface 69 of the first embossing roll 50 which exceeds the height H 1 of the micro-embossing protrusions 53 over the base circumferential surface 69 .
[0102] FIG. 5 b also shows a cross-sectional view through a part of two embossing rolls and two embossed plies. The difference to FIG. 5 a resides in the fact that the second embossing roll 60 is not an exact mirror of the first embossing roll 50 . Nevertheless, the lines elements 68 within lines zones 56 and 66 face each other so that ply-bonding by means of adhesive can be carried out at regions 70 where the tops of the linear depressions in the first ply 10 and the second ply 30 abut each other. The missing dots zones 54 and 64 as well as the micro dots zones 52 and 62 do not face each other. Such staggered arrangement of the micro dots zones and the missing dots zones in the top ply 10 and bottom ply 30 serves to stabilize the two-ply structure because the micro-embossed depressions of one ply prevent the collapsing of the corresponding missing dots zone in the other ply.
[0103] This stabilizing effect can be even improved by using a structure as shown in FIG. 5 c . In this example, the second embossing roll 60 is again not an exact mirror image of the first embossing roll 50 and only the lines elements of the first ply 10 face lines elements of the second ply 30 in order to achieve the desired ply-bonding. The micro dots zones 52 of the first embossing roll 50 faces micro dots zones 62 of the second embossing roll 60 . However, the second embossing roll 60 has no missing dots zone and, corresponding to the position of the missing dots zone 54 in the first embossing roll 50 , there are elevated embossing protrusions 72 in the second embossing roll 60 . Such macro dots or lines 72 act to generate a support structure in the second ply which serves to stabilize, in the fibrous product the missing dots zone 16 , 54 of top ply 10 .
[0104] Instead of the provision of macro dots or lines 72 , the embodiment according to FIG. 5 c can also have micro dots on the second embossing roll 60 in a position corresponding to the missing zone 54 of the first roll. However, using macro dots or lines 72 as shown in FIG. 5 c improves the desired stabilizing effect of this support structure.
[0105] According to a further variant of the pin-to-pin arrangement of two embossing rolls 50 and 60 as shown in FIG. 5 d , not all third zones 56 where the first embossing roll 50 is provided with lines protrusions face a corresponding third zone in the second embossing roll 60 . The linear protrusions 74 do not abut against corresponding linear protrusions in the second embossing roll so that, in the multi-ply product produced by such arrangement of the embossing rolls 50 and 60 , ply-bonding will only be achieved at those third zones of the top ply, where the linear protrusions 68 of the corresponding first embossing roll 50 abut against a third zone 66 with linear protrusions 68 of the second embossing roll 60 . Nevertheless, the application of glue and the optional coloring will take place toward all third zones 56 with lines elements 68 and 74 of the first embossing roll 50 .
[0106] The more bonding points between top ply 10 and bottom ply 30 are provided, the stiffer the resulting product becomes. Therefore, the selective omission of bonding zones serves to adjust the resulting product to the desired softness.
[0107] A further variant of the pin-to-pin arrangement of two embossing rolls 50 and 60 is shown in FIG. 5 e . This embodiment is similar to FIG. 5 c and the difference lies in the fact that the micro dots zone 62 of the second embossing roll has protrusions 63 of differing heights and/or, shapes and/or, sizes and/or, flank angles and/or mutual distances. Accordingly, the micro dots of the second embossing roll 60 are not necessarily in pin-to-pin position relative to the micro dots of first roll 50 .
[0108] The provision of embossing protrusions 63 of different heights, shapes, sizes, flank angles and/or relative distances makes it possible to adjust the position of the micro protrusions such as to improve the contrast to and visibility of the second zones in the product. Another option is to arrange the micro-embossing protrusions such as to provide an optically appealing effect of the micro-embossed background pattern in the second ply 30 .
[0109] A further variant of the pin-to-pin arrangement of two embossing rolls 50 and 60 is shown in FIG. 5 f , wherein the third zones 56 and 66 of the first embossing roll 50 and the second embossing roll 60 are arranged such that the lines elements 68 face each other and ply-bonding and optional coloring can be carried out at these elements. Further, it can be seen that some micro dots 53 of the first embossing roll 50 face micro dots 63 of the second embossing roll 60 . However, other micro dots of the first embossing roll 50 like those referenced to by numeral 76 face macro dots or lines elements 72 of the second embossing roll 60 . Further, the missing dots zone 54 of the first embossing roll 50 faces partly macro dots or lines element 72 on the embossing surface of the second embossing roll 60 , partly micro dots 78 provided on the embossing surface of the second embossing roll 60 and partly a missing dots zone 64 of the second embossing roll 60 .
[0110] The above examples of the arrangement of two structurized embossing rolls according to FIGS. 5 a to 5 f all relate to a pin-to-pin arrangement of two rolls so that ply-bonding was achieved between the highest elevations of the two embossing rolls corresponding to the deepest depressions in the embossed plies. The following embodiments 6 a to 6 c also show cross-sectional views through a part of two structurized embossing rolls and two embossed plies with the difference that the embossing rolls are operating in the nested mode.
[0111] Again, the first embossing roll 50 has a first zone 52 with micro dots, a second zone 54 with missing dots and third zones 56 with linear embossing protrusions. The second embossing roll 60 also has the corresponding first, second and third zones 62 , 64 and 66 . However, the first embossing roll 50 and the second embossing roll are running in register such that the second embossing roll 60 is in nested configuration to the first embossing roll 50 . Therefore, different to the embodiments as shown in FIGS. 5 a to 5 f , adhesive applied to the first ply 10 of the product where it is positioned over the embossing protrusions of lines zones 56 of the first embossing roll 50 will bond the first ply 10 to the second ply 30 in regions 70 where the second ply 30 has no embossed depressions.
[0112] According to the variant as shown in FIG. 6 a , the lines elements of the second embossing roll 60 corresponding to the linear depressions of the bottom ply 30 nest in between the line elements of the first embossing roll 50 corresponding to the linear depressions of the first ply 10 . The same applies to the micro-dots of the second embossing roll 60 which are positioned between the micro-dots of the first embossing roll 50 , whereas the second zones 54 and 64 with missing dots of both embossing rolls face each other.
[0113] The variant of a nested arrangement according to FIG. 6 b corresponds to that according to FIG. 6 a with the only difference that the missing dots zones 52 of the first embossing roll 50 faces macro dots 72 on the embossing surface of the second embossing roll 60 . In this respect, the embodiment according to FIG. 6 b is similar to that according to FIG. 5 c as discussed above. The micro dots or lines 72 serve to produce micro depressions in the bottom ply 30 which stabilize the corresponding second zone in the top ply 10 of the multi-ply product.
[0114] The embodiment as shown in FIG. 6 c is characterized in that the embossing surface of the second embossing roll 60 has no missing dots zone but an extended micro dots zone 63 , wherein the micro protrusions of the embossing roll have different heights and/or, shapes and/or, sizes and/or, flank angles and/or relative distances to each other. Moreover, as can be best seen from the schematically selected shape of the macro protrusion 80 in FIG. 6 c , the macro dots of the second embossing roll 60 can also be provided with different shapes, sizes, flank angles and/or relative distances to each other.
[0115] The second embossing roll 60 further includes a single micro dot 81 positioned between the line elements 68 of the first embossing roll 50 .
[0116] FIGS. 7 a to 7 c show cross-sectional views of the structurized embossing roll 50 and a marrying roll 90 as used in the conventional Goffra Incolla technique. Embossing roll 50 is the same as that e.g. shown in FIG. 5 a or 6 a with micro dot zones 52 , missing dot zones 54 and lines zones 56 . As in the preceding embodiments, the embossing protrusions in the lines zones 56 have a larger height than the micro-embossing protrusions in the first zones 52 . Therefore, glue applied to the highest protrusions of the top ply arranged over the first embossing roll 50 will only receive adhesive in regions 70 corresponding to the highest elevations of the first embossing roll 50 which generate the deepest embossing depressions of the top ply 10 . A second embossing roll is not shown in FIG. 7 a but only the marrying roll 90 having a flat surface. Nevertheless, second ply 30 was embossed in a preceding method step why the second ply 30 has micro-embossing depressions 14 on its surface.
[0117] According to the variant as shown in FIG. 7 a , the micro-embossed second ply 30 is flattened by the marrying roll in those regions 70 of the second ply where first ply 10 and second ply 30 are bonded together. The first zones of the first ply produced by the micro-dots zones 52 of embossing roll 50 face micro-dots 14 of second ply 30 , and unembossed second zones of the first ply also face micro-embossed depressions 14 of the second ply 30 . In absence of any linear depressions of the second ply 30 , there is no pin-to-pin or nested configuration of linear depressions of the first and second plies.
[0118] According to a second variant as shown in FIG. 7 b , the second ply 30 may be provided with three zones including a first zone 12 with micro-embossed depressions, a second zone 16 which is unembossed as well as flattened zones 82 where line elements 68 of the first embossing roll 50 flatten the second ply 30 during the marrying process.
[0119] An alternative embodiment as shown in FIG. 7 c mainly corresponds to that according to FIG. 7 a with the difference that within the first zone 12 of the second ply 30 , the individual micro-embossed depressions 63 have different heights and/or shapes and/or sizes and/or flank angles and/or relative distances to each other. The micro-embossed depressions 63 of the second ply 30 are not necessarily in a pin-to-pin or nested position relative to the first ply 10 .
[0120] In the above description of detailed embodiments, embossing rolls have been described which have embossing protrusions of different heights. However, it should be noted that these embodiments are only one possible example to work the invention. It is also possible to use two subsequent embossing stations wherein the micro-embossed depressions of the first ply 10 are produced first, followed by a second embossing station in which the linear embossing depressions, the application of glue, and the ply-bonding are carried out.
[0121] The fibrous product as described in detail above has an improved softness. Experiments have shown that samples having the three different zones 52 , 54 , 56 as described above have a high hand-feel value. Both the top ply and the bottom ply can include more than one layer and, in order to impart high volume to the product, a volume embossed middle layer can be provided. In order to improve the optical appearance of the product, one or more plies of the product can be colored. | A fibrous product, especially tissue paper product, non-woven product, or a hybrid thereof, especially hygiene and cleaning product, has at least one ply, the surface of which is partly covered with an embossing pattern. The pattern includes at least one first zone being micro-embossed with at least 30 embossing depressions per cm 2 , preferably 30 to 160 embossing depressions/cm 2 , more preferably 30 to 120 embossing depressions/cm 2 , and most preferably 45 to 100 depressions/cm 2 , forming a background embossing area. A plurality of second zones are unembossed and form a motif element. In addition to the second zones, at least one third zone is largely surrounded by linear depressions. Also disclosed is an embossing roll and an embossing device including a method for manufacturing such fibrous products. | 3 |
BACKGROUND OF THE INVENTION AND RELATED ART STATEMENT
The present claimed invention relates to a responsive glass membrane and a glass electrode comprising the responsive glass membrane to which taint is hardly attached and easily detached without destroying an ionic concentration measurement function.
There are multiple kinds of crystalline form for titanium dioxide (TiO 2 , titania) and it has been known that crystalline titanium dioxide of an anatase form produces photocatalytic activity when it responds to visible light. Powerful oxidation-reduction properties and superhydrophilic properties are represented as the photocatalytic activity; disinfection treatment is applied to a wall or a floor of a surgery room in a hospital by coating the wall or the floor with titanium dioxide and irradiating it with the ultraviolet radiation by making use of the oxidizing properties of superoxide ion formed in the degradation of H 2 O, antifog treatment is applied to a side mirror of an automobile or a mirror on a road by coating the mirror with titanium dioxide so that self cleaning can be conducted when it rains by making use of the superhydrophilic properties, or the superhydrophilic properties is also applied to taint prevention of an exterior wall of a building or a sheet for a tent.
Meanwhile, if taint attaches to a responsive glass membrane of an ion selective electrode or a pH electrode, an asymmetry electric potential is produced and an error is caused on a measured value. Then, it requires washing the responsive glass membrane sufficiently by the use of detergent or the like so as to remove the taint attached to the responsive glass membrane every time measurement is conducted in order to keep an accuracy of the measurement. As a result, it is conceivable that washing can be easily conducted if the photocatalytic activity of titanium dioxide is utilized for the responsive glass membrane.
The patent document 1 describes the glass electrode comprising the responsive glass membrane on which surface a titanium dioxide film in a dotted shape is formed and discloses that organohalide is degraded by the titanium dioxide film.
Patent document 1: Japan Patent Laid-open number 2002-14078
However, if a titanium dioxide film is nonuniformly formed on a surface of a glass film and a portion where the titanium dioxide film is formed and a portion where the glass is barely formed are mixed like the glass electrode described in the patent document 1, electrical unevenness would be produced on the responsive glass membrane because the titanium dioxide particulates are negatively-charged. As a result of this, an asymmetry electric potential is generated on the glass electrode, which disturbs accurate measurement.
The present invention provides a responsive glass membrane and a glass electrode comprising the responsive glass membrane to which taint is hardly attached and can be easily detached without hindering a function of measuring the ionic concentration.
SUMMARY OF THE INVENTION
More specifically, the responsive glass membrane in accordance with this invention is characterized by that a thin film containing titanium dioxide of an anatase type is formed on a surface of a glass membrane that makes an ionic response and whole of the thin film is continuously formed to be an integrated body.
In accordance with this invention, since the thin film containing titanium dioxide formed on the surface of the responsive glass membrane is continuously integrated as a whole and whole of the thin film is electrically connected, electric charge does not exist locally and spreads over the thin film even though titanium dioxide is negatively-charged locally. As a result, an asymmetry electric potential is difficult to be produced, which enables to measure the ionic concentration accurately.
The responsive glass membrane in accordance with this invention is not especially limited, and may be both a responsive glass membrane for various kinds of ion selective electrodes and a responsive glass membrane for a pH electrode.
It is preferable that the thin film is porous wherein voids or holes are formed. Porous here comprises voids or holes that are bigger than or equal to several A, angstroms, and through which water molecules or ions can pass.
The thin film may cover the responsive glass membrane without any gap and may be cancellous wherein a gap is partially formed as far as the thin film as a whole is continuous and integrated and whole of the thin film is electrically connected.
The thin film may comprise titanium dioxide alone, or may be mixed with another component, and may contain a transition metal such as cobalt (Co), nickel (Ni) or tungsten (W) in accordance with its usage. In case that these transition metals are added to the thin film, it is possible to reduce any alkali error of the responsive glass membrane. In addition, in this case, it is also possible to reinforce the degree of photocatalytic activity.
The thin film may contain titanium dioxide particulates of an anatase type in addition to titanium dioxide that forms a film structure. If the titanium dioxide particulates of the anatase type are additionally mixed into the thin film and dispersed in the thin film, it becomes possible to adjust or reinforce the photocatalytic activity of the thin film. Impure substances might be mixed into the thin film or crystallization to the anatase type might be insufficient during a process of calcination, for example, in case that the thin film is formed by means of the sol-gel method, however, the photocatalytic activity can be refilled by the additionally mixed titanium dioxide particulates.
Furthermore, if a precious metal ion such as copper (Cu), platinum (Pt), gold (Au) and silver (Ag) is added to the thin film, an oxidation-reduction site is formed and the photocatalytic activity degree can be reinforced. In addition, if a transition metal ion such as iron (Fe) is added, it is possible to degrade and response also at the visible light.
A method for manufacturing the responsive glass membrane in accordance with this invention is not especially limited, however, the responsive glass membrane in accordance with this invention may be manufactured by applying a titanium alkoxide solution to which an additive component such as cobalt or the titanium dioxide particulates of an anatase type is added to an unprocessed responsive glass membrane and then calcinating the responsive glass membrane.
In addition, in order to make the thin film porous, it is possible to manufacture a thin film wherein voids or holes are formed by adding, for example, polyvinyl pyrrolidone (PVP) or the like to a solution of titanium alkoxide, applying the solution to an unprocessed responsive glass membrane and calcinating the responsive glass membrane so as to degrade and remove polyvinyl pyrrolidone. In this case, an additive amount of polyvinyl pyrrolidone can be arbitrarily adjusted in accordance with the usage of the obtained glass electrode.
The glass electrodes comprising the responsive glass membrane in accordance with this invention also is one of the present claimed inventions. The glass electrode in accordance with this invention is not especially limited, and can be represented by various kinds of ion selective electrodes or a pH electrode.
In accordance with this invention, it is possible to make the responsive glass membrane to which taint is hardly attached and easily detached without hindering a function of measuring the ionic concentration.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partially broken view showing a part of an internal structure of a glass electrode in accordance with one embodiment of the present claimed invention.
FIG. 2 is an enlarged view of proximity of the responsive glass membrane 3 in FIG. 1 .
FIG. 3 is a graph showing a measurement result of the electric potential of the sample 9.
FIG. 4 is a graph showing a relationship between a mixed quantity of TiO 2 particles in a titanium dioxide thin film formed on a surface of a responsive glass membrane and a degrading rate of methylene blue.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A pH electrode as being a glass electrode in accordance with one embodiment of the present claimed invention will be explained with reference to drawings.
The pH electrode 1 in accordance with this embodiment comprises, as shown in FIG. 1 and FIG. 2 , a cylindrical tube 2 made of glass and a responsive glass membrane 3 connected to a distal end section of the cylindrical tube 2 .
The cylindrical tube 2 houses an internal electrode 4 and is filled with internal fluid 5 as well. For example, silver chloride electrode is used as the internal electrode 4 , and, for example, a potassium chloride solution whose pH is adjusted to pH 7 is used as the internal liquid 5 .
A lead wire 6 is connected to the internal electrode 4 and the lead wire 6 extends outside from a proximal end section of the cylindrical tube 2 so as to be connected to a pH meter, not shown in drawings.
It is necessary that the responsive glass membrane 3 is made of multicomponent glass containing sizable percentage of lithium (Li) in order to generate enough electro-motive force. The material glass is glass wherein lithium is mixed with, for example, silicate glass, phosphate glass or borate glass. In order connect the responsive glass membrane 3 to the cylindrical tube 2 , a raw material of the material glass used for the responsive glass membrane 3 is molten in a furnace kept at, for example, one thousand and several hundred degrees, and a distal end section of the cylindrical tube 2 is immersed in the molten material glass, followed by drawing it up at a predetermined speed. Next, a distal end section of the glass film can be formed in hemisphere by means of blow molding.
When the responsive glass membrane 3 of the pH glass electrode 1 is immersed in a sample solution, an electro-motive force is generated for the responsive glass membrane 3 in accordance with a pH difference between the internal liquid 5 and the sample solution. The pH is calculated by measuring an electro-motive force as a difference in potential (voltage) between an internal electrode 4 of the pH glass electrode 1 and an internal electrode of a reference electrode by the use of a reference electrode, not shown in drawings. Since the electro-motive force varies with the temperature, it is preferable to calculate the pH of the sample solution by correcting the difference in potential with an output signal value used as a parameter by the use of a temperature element and then to indicate the pH on a pH meter.
In this embodiment, a thin film 7 that contains titanium dioxide of an anatase type and that is continuously formed to be an integrated body is formed on a surface of a distal end section of the substantially hemisphere shape of the responsive glass membrane 3 . The thin film 7 is porous and its film thickness is several hundred nm. Whole of the thin film 7 may cover the responsive glass membrane without any gap, and the thin film 7 may be cancellous wherein a space is partially formed. In addition, the thin film 7 may be of a component with which cobalt or the like is mixed other than titanium dioxide. The titanium dioxide particulates may be mixed into the thin film 7 in addition to titanium dioxide that forms a film structure. An alkali error of the thin film 7 can be reduced if cobalt is mixed into the thin film 7 , and photocatalytic activity of the thin film 7 can be adjusted or reinforced if the titanium dioxide particulates, the metal particulates or the metal ion is mixed into the thin film 7 .
A particle diameter or a crystal density of the titanium dioxide particulates may be appropriately selected in accordance with the usage of the obtained responsive glass membrane 3 .
As a method for forming the thin film 7 on the distal end section of the substantially hemisphere of the responsive glass membrane 3 , in case of using, for example, a sol-gel method; first, alcohol is added to a titanium alkoxide solution so as to prepare a mixed solution, next, water necessary for hydrolysis is added and nitric acid is added as a catalyst to the mixed solution so as to prepare a starting solution. The starting solution is stirred at a constant temperature so as to conduct hydrolysis and polycondensation reaction on alkoxide and hydroxide particulates of titanium are produced so as to make the titania sol. The obtained titania sol is applied to a surface of the glass film by the use of a dip coating method, followed by drying and calcination so as to form the titanium dioxide thin film 7 .
In order to make that the thin film 7 in a cancellous structure, polyvinyl pyrrolidone (PVP) or the like is added to the titanium alkoxide solution and polyvinyl pyrrolidone is degraded during a calcination process so as to be eliminated.
Similarly, in case of mixing cobalt or the titanium dioxide particulates with the thin film 7 , cobalt or the titanium dioxide particulates may be added to the titanium alkoxide solution.
If the light such as ultraviolet ray is irradiated on the responsive glass membrane 3 on which the thin film 7 is formed from a light source such as an LED, a hydrogen discharge tube, a xenon discharge tube, a mercury lamp, a ruby laser, a YAG laser, an excimer laser or a dye laser at a time of cleaning or the like, the photocatalytic activity is induced on titanium dioxide so as to degrade organic matters or the like that attaches to the thin film 7 due to the oxidizing properties and to make a state wherein attached matters can be easily detached due to the superhydrophilic properties, namely a self cleaning function is produced.
As mentioned, while the pH electrode 1 produces the self cleaning function, since whole of the thin film 7 is electrically connected, an asymmetry potential is difficult to be generated on the responsive glass membrane 3 so that a pH measurement ability can be kept in good condition. This will be described in detail with quoting the following data.
Various types of titanium dioxide thin films were manufactured on a surface of the responsive glass membrane of a pH electrode (#9621) manufactured by Horiba Ltd., by means of the sol-gel method, and a potential measurement was conducted three times in the order of pH7→pH4→pH9. Since the potential was stabilized in about 3 minutes, an asymmetry potential at pH7 and the pH sensitivity between pH4 and pH9 were obtained respectively by the use of a value at a time 3 minutes after the initiation of the third measurement. In this case, an electrode manufactured by Horiba Ltd., (#2565) was used as a reference electrode. A result of the potential measurement (sample 9 alone) was shown in a graph in FIG. 3 , and a result of the measurement of the asymmetry potential and the pH sensitivity was shown in Table 1. The asymmetry potential described in Table 1 is based on an unprocessed pH electrode (#962). In addition, P-25 (manufactured by Nippon Aerosil Co., Ltd., particle diameter is 0.02 μm) was used as TiO 2 particles for samples 5 through 9. Sensitivity here is a value wherein a theoretical figure for Nernst response is expressed as 100%.
TABLE 1
Asymmetry
Sample
potential
No.
Thin film structure
(mV)
Sensitivity
1
TiO 2
−11.5
99.5
2
TiO 2 (net-shape by addition of
−7.9
98.9
PVP6.0 × 10 −7 mol %)
3
TiO 2 (net-shape by addition of
−11.4
99.6
PVP4.0 × 10 −6 mol %)
4
TiO 2 + Co8 mol % (net-shape by
−22.2
99.1
addition of PVP4.0 × 10 −6 mol %)
5
TiO 2 + TiO 2 particles 10 mol %
−20.7
99.4
6
TiO 2 + TiO 2 particles 20 mol %
−18.6
99.4
7
TiO 2 + TiO 2 particles 30 mol %
−19.1
99.2
8
TiO 2 + TiO 2 particles 40 mol %
−21.8
99.9
9
TiO 2 + TiO 2 particles 50 mol %
−18.3
99.6
As shown in Table 1, it turned out that the asymmetry potential was small for either sample so that the measurement with high accuracy could be conducted. In addition, it also turned out that the electric potential did not change under usual indoor illumination even though TiO 2 particles are mixed into the titanium dioxide thin film.
In addition, in case that the impure substance is mixed into the responsive glass membrane, the pH response generally deteriorates. However, as shown in FIG. 3 , the pH response time of the pH electrode 1 wherein the titanium dioxide thin film into which TiO 2 particles are mixed is formed on the surface of the responsive glass membrane was by no means inferior to that of a conventional pH electrode.
Furthermore, a degrading performance in case methylene blue was applied to the surface of the titanium dioxide thin film was evaluated by changing a mixing ratio of TiO 2 particles (P-25 manufactured by Nippon Aerosil Co., Ltd., particle diameter is 0.02 μm) in the titanium dioxide thin film formed on the surface of the responsive glass membrane of the pH electrode (#9621) manufactured by Horiba Ltd. The evaluation was conducted by irradiating the Xe light (200˜1100 nm, 8 mWcm −2 (365 nm)) for one hour. The result is shown in a graph of FIG. 4 .
As shown in the graph of FIG. 4 , in case that the mixing ratio of the TiO 2 particles was more than or equal to 5 mol %, the degrading rate increased by more than or equal to about 20% compared with a case wherein no TiO 2 particle was mixed. The methylene blue did not degrade in a general indoor illumination.
As a result, in accordance with the pH electrode 1 in accordance with this embodiment, since the pH electrode 1 does not produce the photocatalytic activity under usual indoor illumination, it does not exercise an influence on a sample and it does not change the electric potential as well, which makes it possible to measure the pH with accuracy. Meanwhile, since the pH electrode 1 in accordance with this embodiment produces the photocatalytic activity if the ultraviolet rays are irradiated, it is possible to degrade the material attached to the response section and to make the material difficult to be attached. In addition, if a little amount of TiO 2 particles are mixed into the titanium dioxide thin film, it is possible to improve the degrading ratio of the material attached to the response section drastically with the above-mentioned function kept.
The present claimed invention is not limited to the above-mentioned embodiment.
The glass electrode in accordance with this invention is not limited to the pH electrode 1 , and may be various kinds of an ion selective electrode such as, for example, a chloride ion, a fluoride ion, a nitrate ion, a potassium ion, a calcium ion, a sodium ion, an ammonium ion, a cyanide ion, a sulfide ion, an iodide ion, a bromide ion, a copper ion, a cadmium ion, a lead ion, a thiocyanate ion or a silver ion. In addition, the glass electrode may be a combined electrode wherein a glass electrode and a reference electrode are integrally formed or a single electrode wherein a temperature compensated electrode is further integrated with the combined electrode.
The shape of the distal end section of the responsive glass membrane 3 is not limited to the substantial hemisphere, and the distal end section may be formed in any shape as long as the shape can produce a function of measuring ionic concentration.
The light source for the ultraviolet rays may be arranged separately from the pH electrode 1 , and the pH electrode 1 itself may comprise a light source for the ultraviolet rays.
In addition, a pH measurement device may be comprised by combining the pH electrode 1 , the comparison electrode, a pH meter and a light source for ultraviolet rays.
Furthermore, it is a matter of course that the present claimed invention may be variously modified without departing from a spirit of the invention.
In accordance with this invention, it is possible to obtain a glass electrode that is imparted with a self cleaning function without disturbing a function of measuring the ionic concentration. | An ion-selective electrode has a responsive glass membrane with an exterior thin film containing titanium dioxide of an anatase type that is continuously formed as an integrated body. The thin film, of several hundred nm in numbers, is electrically connected by an amount of titanium dioxide that will form a continuity in the thin film structure. The thin film can be porous and contain at least one metal selected from cobalt, nickel, tungsten, copper, platinum, gold, silver and iron. Additionally, significantly larger titanium dioxide particles of 0.02 μm in diameter can be further mixed into the thin film. | 6 |
DESCRIPTION OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for combining two or more fluids with variable flow rates, in fixed proportions, over a wide range of flow rates. More specifically, when said fluids are fuel and oxidizer supplied to a combustion engine the present invention provides a means for holding constant the air/fuel ratio in such an engine over its total operating range of power output. Although a specific application to the control of air/fuel ratio for a combustion engine is illustrated, it is obvious that the invention described herein can be employed to control the proportionality of other fluids being mixed at various fluid flow rates. An important feature of the invention is that the accuracy requirement of pressure regulators employed in such mixing is considerably lessened, since the pressure drop is made proportional to the flow rate rather than to the square of the flow rate, as is the case when orifices are used to meter the flowing fluids.
2. Background of the Invention
In combustion engines, the level of noxious emissions and efficiency are strongly dependent on the ratio of air to fuel supplied to the engine. In prior art engines air/fuel control systems there are fundamentally two different systems for providing such engines with appropriate air/fuel mixtures.
The first and simplest employs a carburetor with orifice means for reducing the pressure in the incoming air stream. The pressure of the fuel is regulated by pressure regulator means to be at atmospheric pressure. The reduced pressure of the incoming air stream is then applied to a fuel orifice to suck in the fuel by means of the difference in pressure between the reduced pressure of the incoming air stream and the regulated fuel pressure upstream of the orifice.
In a conventional engine for a motor vehicle the ratio of maximum air inflow to minimum air inflow required is typically 30/1. The reduced pressure in the carburetor venturi is proportional to the square of the flow. The ratio of pressure reduction from maximum to minimum flow is thus typically (30/1) 2 or 900/1. The maximum air pressure reduction at the maximum flow is typically limited to about 2000 pascals to avoid substantial reduction in the maximum air intake of the engine and, hence in the maximum engine power. This means that the minimum pressure reduction will be about 2000/900 pascals or approximately 2 pascals at the minimum engine power. Therefore, accurate control of air/fuel ratio at low power levels requires that the fuel pressure be maintained at the atmospheric pressure level with an error tolerance which is very small compared to 2 pascals.
Examination of the performance of pressure regulators for both liquid and gaseous fuels at the pressures normally employed in engines shows that the error tolerance is typically greater than 20 pascals and frequently more than 100 pascals. This means that at 10% of full power the air/fuel ratio error in such an engine is typically 100%. Studies of power levels employed in urban and highway driving show that a majority of the time power levels of less than 10% of full power are employed. The simple carburetor, as described herein, requires extensive and complex modification for the engine to be operable at low loads, especially at idling conditions, when concern for noxious emissions becomes important. No modification of the carburetor principle described here seems to be sufficient to achieve low levels of noxious emissions from the engine at these lower engine power levels.
A second method for control of the air/fuel ratio in combustion engines involves the direct measurement of air flow, by a suitable sensor, or by inferring the rate of air flow by indirect methods, involving the measurement of a number of engine parameters, such as engine speed, intake manifold pressure, throttle position, and cooling fluid temperature, among others. The measured or inferred air flow is then typically used to control electromagnetic fuel injectors. This latter system is far more complex and only slightly more accurate than the simple carburetor described above.
What is needed and what is provided by the present invention is a new carburetor, or air/fuel combining concept, that reduces the ratio of pressure reduction, from maximum to minimum flow, from 900/1 to 30/1, thereby increasing the tolerance for pressure regulator error by 30 times, and typically raising the minimum pressure reduction from 2 to 60 pascals. This means that at 10% of full power the air/fuel ratio error is typically reduced from almost 100% to less than 10% when the error tolerance of the pressure regulator is approximately 20 pascals.
This invention is of considerable environmental significance. The inventor has had considerable experience in studying the performance of natural gas powered vehicles. One of the more serious deficiencies of these potentially very clean vehicles is the inability of current air/fuel ratio control systems, for such vehicles, to hold air/fuel ratio constant over the range of output power levels required of such vehicles. Since emissions performance is strongly dependent on air/fuel ratio, none of the current vehicles are able to achieve their low emissions potential. The principle problem is the very severe pressure regulator error requirement. The present invention reduces that problem by a factor of approximately 30.
SUMMARY OF THE INVENTION
In the present invention, two or more flowing fluids are combined in fixed proportions, over a broad range of flow rates, by first equalizing the pressure of each fluid, if not already equal, by means of pressure regulator(s) prior to flow of the individual fluids through an individual porous structure, such porous structure being an interconnected pore or capillary duct structure. The diameter of the pores or of the capillary ducts are selected to be sufficiently small, so that viscous forces in the fluids flowing through the porous structures are larger than the inertial forces in the fluids throughout the desired range of flows of the fluids. Inertial forces in the fluid cause the pressure in a fluid flowing through a restriction to be reduced in proportion to the square of the velocity of the fluid, while viscous force cause the pressure to be reduced in proportion to the velocity of the fluid.
In the present invention, therefore, the range of pressure drop is considerably diminished, thereby reducing the accuracy required in equalizing the pressure of the fluids, prior to their individual flow through the porous structure. After passing through the porous structures the fluids are joined in a common chamber, with a common pressure. Thus, the pressure difference across the porous structure in the path of each flowing fluid is identical. Since the flow of each fluid is proportional to the pressure difference, the flow rate of each fluid is in proportion to one another, and depends only on the fluid pass-through area of the respective porous structures. To adjust the constant of proportionality between the fluids, means are provided to adjust the pass-through area of the porous structures. Reducing the pass-through area reduces the flow rate of the corresponding fluid, thus adjusting the constant of proportionality accordingly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a general embodiment of the invention.
FIG. 2 shows the application of the invention to automatically regulate air/fuel ratio in a combustion engine.
FIG. 3 shows a configuration wherein the ratio of fluid proportionality is manually adjustable.
DETAILED DESCRIPTION OF THE INVENTION
The elements of the general embodiment of the invention are shown in FIG. 1. Two or more fluids (in the figure two fluids are indicated) are both drawn together by means of a suction pump (1), which can provide a variable rate of flow, into a common chamber (2) where said fluids are joined. The first fluid (3) is drawn past a porous structure (4) into the common chamber (2). A second fluid (5) is also drawn past a porous structure (8). The pore diameters of the porous structures are chosen to be sufficiently small so that the viscous forces in the fluids (3,5) flowing through their respective porous structures (4,8) are larger than the inertial forces in the fluids. Thus, the pressures in the fluids (3,5) in passing through their respective porous structures (4,8) are reduced in proportion to the flow rates of the fluids. A means for equalizing the pressure of a first fluid (3) and a second fluid (5) is provided by a differential pressure sensor (6) which senses the differential pressure between fluids (3,5) upstream of their respective porous structures (4,8). The output of the sensor (6) is used to adjust a valve (7) to equalize the pressure of a second fluid (5), upstream of its porous structure (8), with that of the first fluid (3), upstream of the first porous structure (4). Since the pressure drop across the second porous structure (8) and the first porous structure (4) are thereby made equal under all flow conditions, the flow rate of the two fluids (5,3) will be proportionate to one another. Further, the ratio of pressure drop at maximum flow to pressure drop at minimum flow will be the same as the ratio of the maximum flow rate to the minimum flow rate.
A sensor (9) of the proportions of the fluids (3,5) in the combined fluids (10) is used to signal the shutter control means (11) to adjust the shutter (12), which blocks a portion of the fluid pass-through area of the second porous structure (8), thereby adjusting the proportionality ratio of the fluids (5,3) to a predetermined ratio.
The shutter control means (13) is used to select the position of the shutter (14) to provide the maximum allowed pressure drop across the first porous structure (4) at the maximum flow.
In FIG. 2, the suction pump (1) is shown to be a combustion engine (13) and the first fluid (3) is air while the second fluid (5) is a fuel. The common chamber (2) is the intake manifold (14) of said combustion engine. The sensor of fluid proportionality (9) is an oxygen sensor (15) in the exhaust of said combustion engine (13) and is an indicator of the ratio of air to fuel. In this instance, the shutter (14) is adjusted to provide the maximum allowable pressure drop at the maximum air flow rate, to result in the maximum allowable power loss in said combustion engine.
In FIG. 3, the shutter control means (11) is manually adjusted without the use of an additional sensor (9) and the system is used to fix the air/fuel ratio under the condition of variable flow at any predetermined level. | A system is described that combines two or more fluids in fixed proportions over a wide range of flow rates, in which said proportions are independent of the rate of flow of the fluids, by causing each of said fluids to experience a drop in pressure which is approximately proportional to said fluid flow. An important application of such a system is to serve as a fuel-oxidizer combiner for a combustion engine to provide a constant ratio of air to fuel over a wide range of engine power output. The invention is especially useful in controlling the ratio of air to natural gas in natural gas fueled engines, where the gas is stored at very high pressures and is normally reduced to atmospheric pressure before being mixed with the air in an air-gas mixer. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] - -
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] - -
BACKGROUND OF THE INVENTION
[0003] The present invention relates to quality assurance instruments for medical radiotherapy equipment used for radiation treatment of tumors or the like.
[0004] Cancerous tumors may be treated by irradiating the tumor with high-energy photons or electrons (henceforth both termed “radiation”).
[0005] Such radiotherapy relies in part on the fact that tumor tissue is more sensitive than normal tissue to such high-energy radiation. Nevertheless, the radiation dose must be carefully controlled to limit the exposure of healthy tissue while ensuring sufficient radiation is received by the tumor.
[0006] Radiation dose may be controlled by a variety of means including shutters for collimating the radiation beam to the area of the tumor, filters for varying the intensity of radiation within the area of the tumor, and control of the exposure duration. An accurate understanding of the energy, flux, and alignment of the radiation beam is essential for such control. Generally, as is understood in the art, radiation energy describes the average energy of the individual photons or electrons whereas radiation flux is number of electrons or photons per unit area per unit time.
[0007] Radiation energy may be determined by calculating changes in flux at two depths within a homogenous medium, for example, a water phantom.
[0008] Radiation flux is normally determined using an ionization chamber or semiconductor detector placed in the radiation beam at a fixed distance from the radiation source. A “build-up” material such as a plastic block may be placed in front of the flux-detector to improve its sensitivity. For the purposes of periodic quality assurance of a radiotherapy machine, the output of the flux-detector may be compared to a base line for the same detector. In this way, precise calibration of the detector to a standard is not required.
[0009] Radiation alignment is normally determined with respect to a visible light field projected along with the radiation showing, for example, an illuminated rectangular area and/or cross-hair pattern. Alignment may be verified by exposing a film marked to show the location of the light field or crosshairs and comparing the exposed film to the markings. Alternatively, as shown in U.S. Pat. No. 4,988,866, a fixture having multiple ionization detectors and multiple light detectors (also called edge detectors) may be used, and the signals from the ionization detectors and light detectors may be compared.
[0010] It is desirable that the radiation therapy machine be checked on a frequent, periodic basis at each of its settings. Such quality assurance checks can be cumbersome and time consuming particularly when multiple pieces of test equipment must be used, for example, as would be required to calibrate a radiotherapy machine that provides both electron beams and photon beams at a variety of energy levels. It is difficult to construct a quality assurance instrument that works for a wide variety of different radiation energies and different radiation modes, e.g. electrons or photons, equally well.
BRIEF SUMMARY OF THE INVENTION
[0011] The present invention provides a radiation beam checker that may verify flux profiles and constancy for a wide variety of radiation energies and modes. Several features contribute to this versatility. First, the beam checker may receive radiation from either of two directions, flipping to receive electrons through one side and photons through the other. In this way, a single set of detectors may be optimized for either of two different radiation modes. Second, rather than relying on a single filtered and unfiltered detector to determine energy level, the present invention may use multiple detectors, each having a different filtration to provide data for a more sophisticated energy discrimination function accurate over a wide energy range. Visual fiducia on both surfaces of the beam checker allow alignment to be determined by flux measurements from the multiple flux-detectors without the need for photosensitive edge detectors that would be required on both surfaces.
[0012] One embodiment of the present invention permits wire-free operation simplifying manipulation of the beam checker without requiring radio communication that may be difficult to establish in the environment of the radiotherapy machine. An additional feature of one embodiment of the present invention is automatic linkage of data to energy levels to minimize necessary operator input. In one embodiment, the present invention may employ a new construction technique for ionization detectors simplifying the manufacture and improving the consistency of multi-detector systems.
[0013] Specifically then, the present invention may provide a test apparatus for both photon and electron radiation, the test apparatus having a housing providing opposed first and second faces holding a set of detectors between the first and second faces. In this embodiment, a first calibrating material for electrons is positioned to intercept electrons passing through the first face to the detectors, and a second calibrating material for photons is positioned to intercept photons passing through the second face to the detectors.
[0014] It is thus one object of the invention to provide a single test unit that may be tailored to two modes of radiation by placing different build-up or filter materials on the opposite faces of the housing and flipping the housing according to the radiation mode.
[0015] The test apparatus may include a quantitative radiation measurement display on a third face of the housing visible when either the second or first face is lying on the surface. The display may change orientation according to whether electrons or photons are being measured to be upright to an operator in either mode.
[0016] Thus, it is another object of the invention to provide a device that retains ease of use in either orientation of the housing.
[0017] One embodiment the invention provides a wire-free test apparatus for therapeutic radiation systems having a housing holding a set of radiation detectors for measuring radiation flux at predetermined locations and a solid state memory for receiving and storing the radiation flux measurements. A battery within the housing powers the radiation detectors and solid-state memories and a port is provided on the housing for downloading the stored radiation flux measurements to a remote computer.
[0018] Thus, it is another object of the invention to provide an easily maneuverable test device unencumbered by connecting cables. It is another object of the invention to provide wire-free operation without the need for radio transmission of data such as can be blocked by the shielding used around radiotherapy machines.
[0019] The housing may include a light field guide on its surface, delineating a region of the housing containing the detectors that should be exposed to radiation. The processing circuitry and memory may be within the housing outside of the region.
[0020] Thus, it is another object of the invention to provide a simple method of minimizing radiation exposure to solid-state memory which is normally sensitive to radiation damage or interference.
[0021] The processing circuitry contained within the housing may communicate with at least some of the radiation detectors to detect the start of a new radiation measurement from signals produced by the radiation detectors and to automatically store the radiation measurements in the solid state memory.
[0022] Thus, it is another object of the invention to provide for simplified data acquisition without the need for complex keyboard control or a permanently attached remote terminal.
[0023] In one embodiment, the invention provides a beam checker for therapeutic radiation comprising a set of spaced radiation flux-detectors producing flux signals and at least one radiation energy-detector providing an energy signal and a storage system for storing a set of energy ranges. Processing circuitry compares at least one of the flux signals to benchmark flux values of an energy range corresponding to the energy signal to provide an indication of any improper operation of the measured radiation source. Generally, the benchmark flux values may indicate flatness, symmetry, or constancy over time.
[0024] Thus, it is an object of the invention to use the energy signal to automatically relate flux measurements to proper benchmark measurements for different energy ranges.
[0025] The radiation energy-detector may be a set of at least three detector elements having different filtrations to provide radiation signals and the energy signal may be derived from an algebraic combination of the radiation signals from the set of detector elements. Alternatively or in addition, the radiation detector may be a set of detector elements, at least one of which element has a “backscatter element” positioned behind it with respect to the measured radiation so that the detector element is sensitive to backscatter, and the energy signal may be derived from an algebraic combination of the radiation signals.
[0026] Thus it is one object of the invention to provide an improved low-profile energy sensor that works over a wider range of energy values than can be achieved with a single filtered detector.
[0027] One embodiment of the invention provides an ionization detector that includes a front and rear plate positioned on a front and rear side of a volume of ionizable gas or other fluid to receive a voltage thereacross to collect the charges resulting from radiation ionizing the gas. The rear plate may be formed of a printed circuit board providing a collector on its front surface and multiple layers, including a middle layer providing a signal trace and a first and second ground flanking the middle layer, where the signal trace may connect to the collector.
[0028] Thus it is an object of the invention to provide improved manufacturability for ionization detectors by using the fabrication techniques associated with printed circuit boards while providing the shielding needed to protect the faint ionization signals.
[0029] These particular objects and advantages may apply to only some embodiments falling within the claims and thus do not define the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a perspective view of the beam checker of the present invention as held in a cradle prior to use showing a first side for receiving photon radiation;
[0031] FIG. 2 is a perspective view of the beam checker and cradle (in partial phantom) together with various cables, a remote computer, and charging unit as may be used with the beam checker; and showing a second side for receiving electron radiation;
[0032] FIG. 3 is a front elevational view of a third wall of the beam checker of FIGS. 1 and 2 as supports a display of radiation energy such as may flip in orientation, depending on the particular radiation mode being detected;
[0033] FIG. 4 is a fragmentary view of a printed circuit board positioned beneath the target markings of the units of FIGS. 1 and 2 , the printed circuit board providing a number of detectors for measuring radiation flux and/or energy;
[0034] FIG. 5 is a cross-sectional view through several detectors of FIG. 4 and front and rear buildup materials of the housing showing passage of electron radiation and photon radiation through different build-up materials (for all detectors) and different filtration materials (for particular detectors) and a backscatter material (for one detector);
[0035] FIG. 6 is an exploded perspective view of one of the detectors of FIG. 4 showing its assembly from a cap placed on exposed traces of a printed circuit board;
[0036] FIG. 7 is a perspective cross-sectional view of the assembled ionization detector FIG. 6 showing the multiple layers of the printed circuit board used to provide shielding of the detected signals;
[0037] FIG. 8 is a block diagram of the circuitry of the detector of FIG. 1 , such as may be placed on the circuit board of FIG. 4 and which employs a microprocessor based processing system to store data within an associated memory for later communication through a port;
[0038] FIG. 9 is a flow diagram showing the calculation of energy for electron radiation;
[0039] FIG. 10 is a figure similar to that of FIG. 9 showing the calculation of energy for photon radiation; and
[0040] FIG. 11 is a flow chart of a program executed by the microprocessor of the circuit of FIG. 8 in implementing the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0041] Referring now to FIG. 1 , the beam checker 10 of the present invention provides a mobile detecting unit 12 having a generally rectangular, box-shaped housing 20 providing a first photon-receiving face 16 opposed to a second electron-receiving face 18 .
[0042] Referring also FIG. 2 , a portion of the photon-receiving face 16 and electron-receiving face 18 is marked with a target 22 defining an area of radiation exposure and thus providing a means for aligning the housing 20 of the mobile detecting unit 12 with a light field or laser crosshair provided by standard radiotherapy machines, as will be described. Typically, the target 22 or 22 ′ is 20 cm by 20 cm and includes a crosshair dividing the target area into equal quadrants.
[0043] Referring to FIGS. 2 and 3 , a first side wall 24 of the housing 20 holds a three-character, 1.2 inch tall, seventeen-segment light emitting diode (LED) alphanumeric display 26 , a reset button 28 and a separate bicolor LED 29 , radiation mode captions and lamps 30 , and a mode select button 32 . During operation, side wall 24 remains visible when either of the photon-receiving face 16 or electron-receiving face 18 of the housing 20 are supported by structure of the radiation therapy machine, for example, a horizontal patient support 34 .
[0044] When photon-receiving face 16 is against the patient support 34 , electron-receiving face 18 is upward facing a source of radiation along axis 36 . The operator may then press the mode select button 32 to illuminate a lamp next to the radiation mode caption denoting “electron” and to indicate to the beam checker 10 that this is the type of radiation being measured. The caption “electron” will be right side up when the housing 20 is appropriately oriented for receiving electron radiation.
[0045] Upon exposure of the beam checker 10 to electron radiation, the alphanumeric display 26 will display a detected energy range using both alphabetic and numeric characters. Typically, the energy ranges will include 6E, 9E, 12E, 16E, and 22E. The number being a measure of energy in MeV and the “E” suffix indicates that the beam checker 10 is checking for electron radiation. The alphanumeric display will be automatically oriented to be right side up, based on the mode selected, when the beam checker is correctly positioned to receive electron radiation as described. This reorientation requires simply a change in the mapping of segments of the alphanumeric display 26 and can be accomplished electronically by the contained processor described below.
[0046] The housing 20 may be flipped as shown by arrow 38 so that photon-receiving face 16 is upward to receive a beam of photons along axis 40 . The operator may then press the mode select button 32 , but this time to illuminate a lamp next to the radiation mode caption denoting “photon” and to indicate to the beam checker 10 that this is the type of radiation being measured. The caption “photon” is inverted with respect to the caption “electron” to be right side up when the housing 20 is appropriately oriented for receiving photon radiation.
[0047] Upon exposure of the beam checker 10 to photon radiation, the alphanumeric display 26 will display a detected energy range using both alphabetic and numbers typically 6X, 18X or 23X with the number being a measure of energy in MV and the “X” suffix indicates that the beam checker 10 is checking for x-ray photons. As before, the alphanumeric captions will be automatically oriented to be right side up based on the mode selected. Thus it will be understood that the alphanumeric display 26 , reset button 28 , LED 29 , radiation mode captions and lamps 30 , and a mode select button 32 may be readily used with either orientation of the housing 20 .
[0048] Referring again to FIGS. 1 and 2 , a second side wall 42 of housing 20 of the beam checker 10 , spanning electron-receiving face 18 and photon-receiving face 16 , provides on its surface a data/power connector 44 , a data-only connector 45 , and power connector 46 . When the mobile detecting unit 12 is placed within the cradle 14 , the side wall 42 abuts an upper face 48 of the cradle 14 so that data/power connector 44 connects with a corresponding data/power connector 52 and power connector 54 on the upper face 48 of the cradle 14 . In this way, data may be communicated to and from the mobile detecting unit 12 and power may be provided to the mobile detecting unit 12 .
[0049] The mobile detecting unit 12 is held in position on the cradle 14 by two guiding pylons 50 extending upward from the cradle 14 and abutting the electron-receiving face 18 and photon-receiving face 16 . Note that in FIG. 2 one guiding pylon 50 is removed for clarity.
[0050] The cradle 14 includes provisions to receive a power cord 58 which may provide line power from a standard wall transformer 59 , or the like, to the mobile detecting unit 12 through power connector 54 . Alternatively, the power cord 58 may be received directly by the mobile detecting unit 12 at power connector 46 .
[0051] Cradle 14 also incorporates two RS-232 connectors 60 and 62 which electrically communicate with data/power connector 52 (connector 60 is opposite connector 62 and not visible in FIG. 2 ). Connectors 60 and 62 allow the mobile detecting unit 12 to be connected to the cradle 14 by means of a standard RS-232 cable 64 connecting between RS-232 connector 60 and data/power connector 44 on the mobile detecting unit 12 when mobile detecting unit 12 is not sitting on the cradle 14 . Connector 62 allows a second cable 66 to connect the cradle 14 (via connector 62 ) to an independent programming and data-logging computer 68 , or the like and thereby connect through data/power connector 52 with the mobile detecting unit 12 . Alternatively, the computer 68 may communicate directly with the mobile detecting unit 12 via cable 66 attaching to data connector 45 .
[0052] Generally, a direct connection between the computer 68 and mobile detecting unit 12 will be used only during an initial calibration procedure when constant reference to the computer 68 will be required. For all other times, the mobile detecting unit 12 will communicate with the computer 68 (for example during periodic downloading of data) via the cradle 14 and the joining of data/power connectors 44 and 52 . While mobile detecting unit 12 is in the cradle 14 , the mobile detecting unit 12 may exchange data with the computer 68 and may receive power for operation and for charging internal batteries as will be described.
[0053] Referring now to FIGS. 1 and 4 , positioned within the housing 20 parallel to, and centered between, photon-receiving face 16 and electron-receiving face 18 is a printed circuit board 70 having a detector zone 72 located beneath the targets 22 and 22 ′. Positioned on the printed circuit board 70 and centered in the detector zone 72 is a central detector 74 a . Positioned on either side of detector 74 a along a longitudinal axis of the printed circuit board 70 are detectors 74 b and 74 c whereas positioned on either side of detector 74 a along a lateral axis of the printed circuit board 70 are detectors 74 d and 74 e . Detector 74 b , 74 c , 74 d , and 74 e are located at midpoints between detector 74 a and the edge of the radiation field as defined by the targets 22 and 22 ′.
[0054] Detectors 74 a - 74 e detect radiation flux and may be, for example, ionization detectors, solid-state detectors, or other detector types known in the art. Detector 74 a provides a measurement of the central flux of the radiation beam and together with detectors 74 b - 74 e provides indication of the variation in that flux over the area of the targets 22 and 22 ′ as may form the basis of a measure of flatness and symmetry. Multiple measurements from detector 74 a over time provides a measure of flux constancy.
[0055] Also positioned on the printed circuit board 70 in the detector zone 72 are energy-detectors 76 a , 76 b , and 76 c . Energy detectors 76 a , 76 b , and 76 c may be located arbitrarily within the detector zone 72 but are preferably equidistant from the detector 74 a to reduce the effects of variations of the beam profile on the their signals. These detectors directly measure radiation flux but include filters and other elements which allow the energy of the radiation beam to be determined from the flux signals. Detectors 74 and 76 will be described in more detail below.
[0056] Referring to FIGS. 4 and 5 , the printed circuit board 70 positions the detectors 74 and 76 between build-up material 80 on electron-receiving face 18 of the housing 20 and build-up material 82 on the photon-receiving face 16 of housing 20 . During use, therefore, electrons 84 will arrive at detectors 74 and 76 after passing through build-up material 80 and photons 87 will arrive at detectors 74 and 76 after passing through build-up material 82 . Each of build-up materials 80 and 82 is optimized for the particular type of radiation it is intended to receive. In the preferred embodiment, the build-up material 80 is a plastic material equivalent to 1.5 centimeters of water optimized for electrons and a build-up material 82 is a plastic material equivalent to 3.5 centimeters of water optimized for photons. More generally, the amount of build-up material 80 and 82 is selected to increase the sensitivity of the detectors 74 and 76 to the particular mode of radiation and to provide even sensitivity of the detectors 74 and 76 (ignoring for the moment any filtration) to the expected energy range of the particular radiation mode.
[0057] Referring specifically to FIG. 5 , detectors 74 a - 74 d are intended to measure radiation flux directly and have no additional filtration. Energy-detectors 76 a , 76 b , and 76 c , however, have additional filter and backscatter elements to allow them to distinguish among different energies of radiation. In the preferred embodiment, detector 76 a has 10 mm of aluminum 86 on its side toward electron-receiving face 18 and energy-detector 76 b has 1 mm of aluminum 88 on its side toward electron-receiving face 18 . Energy-detector 76 c , in contrast, provides no filtration material on its die toward electron-receiving face 18 , but on the side closest to photon-receiving face 16 provides 6 mm of lead. This lead provides backscatter of electrons coming through electron-receiving face 18 , which hit the lead 90 and scatter back into energy-detector 76 . The lead may alternatively be a brass disk.
[0058] The filtration and backscatter element cause each of these energy detectors 76 a , 76 b , and 76 c to produce a slightly different signal. When combined, these signals provide a discrimination of different energies as will be described below.
[0059] Referring now to FIG. 6 , in the preferred embodiment, each of detectors 74 - 76 is an ionization detector of a type in which ionized gas provides a path of conduction between charged and separated plates, and are manufactured using printed circuit board techniques such as those employing a photoresist/etching process or the like.
[0060] In particular, a manufacturing technique of the present invention provides circular disk-shaped collector 92 on the upper surface of the printed circuit board 70 to provide one charged plate. The collector is surrounded by a guard ring 94 , which in turn is surrounded by a high voltage ring 96 leading by trace 98 to a high voltage source. The remainder of the surface of the printed circuit board 70 , in near proximity to the detector 74 or 76 , may include a ground plane 100 .
[0061] A brass cap 102 being a hollow cylinder with an open lower base may be attached at the edge of the lower base to the high voltage ring 96 by solder, or the like. The upper solid base of the brass cap is preferably approximately 0.25 mm thick. A vent port 104 is drilled through the printed circuit board 70 to provide pressure equalization to the inner surface of the brass cap 102 , which holds ionizing air at ambient pressure. Alternatively, the vent port 104 could be drilled through the brass cap 102 . Other materials than brass can be used for the cap as will be understood to those of ordinary skill in the art. A chamber created within the cap and upper surface of the printed circuit board encloses approximately 0.6 cubic cm of air.
[0062] Referring to FIG. 7 , the printed circuit board 70 may be a multi-layer printed circuit board having the upper layer shown in FIG. 6 providing copper cladding forming the collector 92 , guard ring 94 , high voltage ring 96 , and ground plane 100 . Beneath and supporting this upper layer is an insulator 106 and then a ground plane 108 . Beneath the ground plane 108 is another insulator 110 , followed by a signal plane 112 another insulator 109 and finally an outer ground plane 114 . The printed circuit board 70 may be standard copper clad epoxy-impregnated fiberglass.
[0063] Generally, the signal plane 112 includes multiple traces, one connecting to collector 92 by via 116 . The ground plane 100 may be joined by vias 118 and 120 to guard ring 94 and ground planes 108 and 114 , the former which may provides holes through which via 116 may pass. As apparent from FIG. 7 , the traces of the signal plane 112 are thus always flanked on their upper, lower, right and left surfaces by ground planes 114 and 108 providing shielding to the signals detected signals.
[0064] Referring now to FIGS. 4 and 8 , the traces of the signal plane 112 and the ground planes 108 , 100 , and 114 and high voltage traces 98 may pass out of the detector zone 72 to a circuit area 73 also on the circuit board 70 but displaced from the targets 22 and 22 ′ and positioned between radiation shields 124 . The circuit area 73 holds processing circuitry 122 including amplifiers 126 receiving signals from the signal plane 112 . The amplifiers 126 connect to a multiplexing A to D converter 128 providing digitized signals to a processor 130 via an internal bus 132 .
[0065] The processor 130 accesses an internal clock and calendar and communicates with a temperature and barometric pressure sensor 134 to correct for changes of ionization detectors caused by changes in ambient atmospheric pressure and temperature (as is understood in the art), with an audible annunciator 133 , the RS-232 data/power connector 44 , the controls 137 of the first side wall 24 including: the alphanumeric display 26 , the reset button 28 the LED 29 , the radiation mode captions lamps 30 , and the mode select button 32 . The processing circuitry 122 of the circuit area 73 may also include power supply 136 communicating via a jack 138 with the power cord 58 shown in FIG. 2 .
[0066] The processor 130 executes a program stored in memory 140 to process the signals received from the detectors 74 and 76 and to store them in memory 140 as will be described. The program accepts inputs from the temperature and barometric pressure sensor 134 , the RS-232 data/power connector 44 , the reset button 28 , and the mode select button 32 and provides outputs to the LED 29 , RS-232 data/power connector 44 , the alphanumeric display 26 , and the radiation mode captions lamps 30 according to the inputs and the logic of the control program described herein.
[0067] Referring now to FIGS. 2 and 11 , the present invention is used in three distinct phases. In a first phase, the mobile detecting unit 12 is connected to computer 68 by cable 66 and instructed by software in the computer 68 to enter a calibrate mode as indicated by process block 150 . During this calibrate mode, the mobile detecting unit 12 is exposed to radiation from a radiotherapy machine (not shown) at each energy level and for each radiation mode. The energy of radiation is identified via the operator of the computer 68 and the mode identified by the mode select button 32 and matched to an energy signature determined from the measurements of the energy detectors 76 a - 76 c.
[0068] Referring momentarily to FIG. 9 , for electrons, the energy signature value is determined by taking the signal from detector 76 b having 1 mm of aluminum and dividing it by the signal from detector 76 a having 10 mm of aluminum. This fraction is multiplied by the backscatter signal from detector 76 c having a backstop of 6 mm of lead to produce the electron energy signature value 156 .
[0069] For photons as shown in FIG. 10 , the signal from detector 76 c having the 6 mm of lead as a backstop is divided by a signal from the center detector 74 to produce a photon energy signature value 156 .
[0070] It will be understood that other algebraic combinations of these multiple detectors can be used and that generally the energy may be fit to a polynomial function of the signals from detectors 76 and/or 74 .
[0071] The computer 68 then compiles, per process block 152 , an energy table consisting of an entry for each energy and mode providing benchmark flux measurements from each of the detectors 74 a - 74 d and the energy signature value 156 . The energy table is downloaded into memory 140 .
[0072] Referring again to FIG. 11 , in a second phase of operation, the mobile detecting unit 12 is armed automatically and the LED 29 turns green and the indicators display “RDY” for ready. Then unit 12 is placed on the radiotherapy machine in the path of the radiation with the light field of the radiotherapy machine aligned with targets 22 or 22 ′. The operator selects the desired radiation mode corresponding with the orientation of the mobile detecting unit 12 and begins the radiation exposure. Once armed, the processor 130 monitors the signals from the detectors 74 and 76 per decision block 158 until the signals exceed a predetermined threshold indicating radiation is present.
[0073] Once this threshold is passed, at succeeding process block 160 , the energy of the radiation is determined by matching the readings from detectors 74 a and 76 a - 76 c (as appropriate) to the energy signature value 156 stored in the energy table in memory 140 plus and minus a predetermined range. If the energy readings do not match with any energy signature value 156 stored in the energy table, the alphanumeric display 26 shows an error message (“ERR”) and the LED 29 flashes red and there is an audible beep produced by an annunciator 133 . No further readings can be taken until the reset button 28 is pressed whereupon the LED 29 returns to its default color of green.
[0074] Once the energy level of radiation has been determined, the processor 130 compares the benchmark flux measurements associated with the particular entry of the energy table, per decision block 162 , to the signals from the detectors 74 a - 74 d . The flatness and the symmetry of the current flux of the radiation beam is compared to a predetermined threshold value based on the benchmark flux measurements and the constancy of the flux is compared to a predetermined acceptable range also based on the benchmark flux values. Flatness is generally determined by finding the maximum and minimum values of the detectors 74 a - 74 e (values of detectors indicated in the following by the detector number). Then, flatness=(Max(detectors 74 a - 74 e )−Min(detectors 74 a - 74 e )/(Max(detectors 74 a - 74 e )+Min(detectors 74 a - 74 e )). Symmetry is determined by axial=(top (detector 74 b )−bottom (detector 74 c ))/bottom (detector 74 c ) and transverse=(right (detector 74 d )−left (detector 74 e ))/left ( 74 e ). Constancy is determined by the center detector value over time: (detector 74 a (at time x)−detector 74 a (at benchmark time))/detector 74 a (at benchmark time).
[0075] If the current flatness, symmetry of constancy is outside of a predetermined range related to the benchmark value, an error signal is indicated per process block 164 and the alphanumeric display 26 shows an error message (“ERR”) alternating with the type of error (“SYM”, “FLT”, and “CST” for symmetry, flatness and constancy, respectively) and the LED 29 shows red and flashes together with an audible beep by the annunciator. No further readings can be taken until the reset button 26 is pressed whereupon LED 29 returns to its default color of green.
[0076] If the flux measurements are within the acceptable predetermined range, the alphanumeric display 26 shows and indicates the deduced energy level, and the unit resets itself. At process block 166 , the flux values are stored in memory together with a date stamp maintained by the processor 130 as linked to the determined energy level.
[0077] The operator may then proceed through energy ranges and modes stopping only as necessary to flip the mobile detecting unit 12 according to the mode. When the measurements have been made, the operator may install the detecting unit 12 back on the cradle 14 and download the data to the computer 68 for additional analysis or preparation of automatic reports. The memory 140 is sized to hold up to thirty days worth of data so that downloading may be postponed as desired on any given day.
[0078] The third phase of operation is a wired version of phase two for real-time data collection. In this phase, the same functionality exists as is phase two, but beam checker 10 is hardwired either through the cradle 14 or directly to a remote computer 68 allowing real-time data collection and beam checker controls.
[0079] It is specifically intended that the present invention not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come within the scope of the following claims. | An instrument for checking quality of therapeutic x-ray and electron radiation provides modes optimized for both electrons and for photons obtained by physically flipping the unit to interpose the necessary build-up material between the radiation beam and contained detectors. The invention provides an improved method of constructing ionization detectors for improved energy discrimination using such detectors and wire-free operation. | 7 |
BACKGROUND
The present invention relates to a tool for wire fencing. Specifically, the invention concerns apparatus for tightening a span of wire by taking up the slack in the wire.
A large number of devices are known in the prior art for increasing the tension in a wire, rope or similar article. For example, U.S. Pat. No. 1,476,026 issued Dec. 4, 1923 to Barber, shows a device in which a clothesline is engaged between the legs of a U-shaped cleat that extends sideways from an elongated member. When the elongated member is rotated about an axis parallel to the legs of the U-shaped member and midway between them, the clothesline or cable is wound around the legs thereby taking up the slack in the cable and increasing the tension in the cable. At the other end of the elongated member, Barber's device includes a crook that is set over the cable to prevent the handle from rotating and thereby unwinding the cable.
Comparable devices are also shown in U.S. Pat. No. 5,012,559, issued May 7, 1911 to Flannery and in U.S. Pat. No. 5,383,256, issued Jan. 24, 1995 to Wachi et al. The devices of these patents must remain engaged in the lines so long as the increased tension is to be maintained.
If a person wants to increase the tension in a number of spans of wire, such as in a wire fence enclosing a large pasture, it is necessary with the devices of the prior art to use a number of such devices. This is relatively expensive. In addition, because the handle of the device remains in the fence, it would be easy for vandals to disengage the devices of the prior art and steal them.
Inventions consisting of wire tightening devices and tools for their use are also known in the prior art. U.S. Pat. No. 912,960 issued Feb. 16, 1909 to Hestness discloses a wire stretching member and an operating member for its use. U.S. Pat. No. 5,170,536 issued Dec. 15, 1992 to McBroom discloses a tool for tensioning a wire fence around a barb-like article that remains in the fence once the tool has been removed. There are significant limitations in the use of the class of inventions represented by the above mentioned apparatuses. The Hestness' device engages the wire at two points, a looping element and a single stabilizing element. This structure makes the Hestness' invention unstable and prone to disengage from a fence when left on the wire for a significant period of time. The McBroom device is unable to alter the amount of tension at the engagement point on the fence and necessarily introduces a barb into the wire as a means of tightening the fence.
SUMMARY
The present invention provides a stable wire tightening means that is able to introduce variable tensions in a wire and which will not readily disengage from the wire. These qualities allow the invented wire tightening apparatus to minimize problems in the prior art wire tighteners and tools for their use.
The invented apparatus includes a wire tightening device which is able to increase tension in wire fences and a tool for its use. After the wire has been tightened, the tool is removed, leaving the device engaged in the wire.
According to the invention wire tightening apparatus comprises a wire tightening device which includes a wire looping element, at least two wire stabilizing elements, and a base for securing the wire looping element with the wire stabilizing elements.
The wire stabilizing elements interact with the wire in a manner such that when wire is threaded around the stabilizing elements and the looping element, the tightening device engages a length of the wire.
When the wire needs to be disengaged from the device at least one of the stabilizing elements or the looping element is released from the wire to thereby release the wire from the wire tightening device.
The invention also includes a tool for operating the wire tightening device. After engaging the wire tightening device with the wire, the tool is removed such that the wire tightening device remains on the tightened wire.
In a preferred form of the invention the stabilizing elements and looping element of the wire tightening device are positioned on the base in a substantially triangular arrangement.
The present invention overcomes the problems of the majority of similar wire tightening devices by separating the tightening device from the tool. In this way, when the tension must be increased in a number of spans, a single tool can be used to install a number of tightening devices.
Once installed, the devices cannot easily be removed without the use of the tool. In this way, the cost of tensioning a number of spans is greatly reduced, as are the possibilities of theft and vandalism.
The present invention covers a wire tightening device and a tool for its use, a wire tightening device and a tool individually, and a method for using the wire tightening apparatus.
The structure and use of the present invention is described in detail below in relation to the following drawings, in which a preferred embodiment of the invention is shown by way of explanation. However, the drawings should not be considered to limit the scope of the invention in any way.
DRAWINGS
The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may best be understood with reference to the following description, taken in connection with the accompanying drawings in which:
FIG. 1 is a top view showing a wire tightening device of the present invention;
FIG. 2 is a side view of the wire tightening device;
FIG. 3 is a view of a pair of wire tightening devices in engagement with a wire;
FIG. 4 is a top view of a wire tightening tool of the present invention; and
FIG. 5 is a side view of the tool of FIG. 4.
DESCRIPTION
Although the present invention will be described in the context of tensioning a wire fence, the present invention could also be used to increase the tension in a rope, a cable, or a chain.
As seen in FIG. 1, a wire tightening device 10 consisting of a planar triangular base 14 that is substantially rigid and which supports three cylindrical wire engaging and stabilizing elements 12A, 12B and 12C. The wire engaging elements 12A, 12B and 12C are grooved studs which are attached perpendicularly to the base 14. The wire engaging elements 12A, 12B and 12C are attached at points proximal to the 3 points of the triangular base 14 and are arranged to form an isosceles triangle.
As seen in FIG. 2 the wire engaging elements 12A, 12B and 12C are grooved studs that each have a channel 36 that runs around the circumference of the elements and whose nadir occurs approximately half way between the point of attachment and the unattached end of these elements. The channel 36 serves as a receptacle the wire and prevents it from slipping from the wire engaging elements 12A, 12B and 12C.
As best seen in FIG. 3, in which a fence wire 18 is shown as a solid line, the wire engaging elements 12A, 12B and 12C serve as a series of bobbins around which the wire is wound. The wire 18 may be wound around the wire engaging elements 12A, 12B and 12C in a variety of ways in order to introduce different tensions into the wire 18.
The wire 18 may be wound such that wire engaging elements 12A and 12C serve to stabilize a section of wire that has been looped around wire engaging element 12B. This is illustrated in the left hand depiction of the wire tightening element with the wire. In the right hand depiction of the wire engaging device with the wire, the wire 18 may be wound in an alternative manner such that wire engaging elements 12A and 12B serve to stabilize a section of wire that has been looped around wire engaging element 12C. This latter procedure will effect a greater tension by taking up a greater amount of slack in a section of wire.
As seen in FIG. 2, the wire engaging device 10 has a tool engaging element 16, which is reversibly slidable into a groove 34 in the wire tightening tool 20. The tool engaging element is positioned on the base 14 directly below the wire engaging element 12C, and extends perpendicularly from the base in the opposite direction from element 12C. The tool engaging element 16 is a grooved stud that has a channel 38 which serves as a receptacle for the edges of the ledge 32 in order to secure the wire tightening device 10 to the wire tightening tool 20.
As seen in FIG. 4, the wire tightening tool 20 has a handle 22 and an arm 24. The end of the arm 24 which is opposite to the point of attachment to handle 22 has means for reversibly engaging the wire tightening device 10. The means that the wire tightening tool 20 has for reversibly engaging the wire tightening device 10 includes a prong 28 which engages and secures the wire engaging elements 12A and 12B. In addition, the wire tightening tool 20 includes a ledge 32 to support the base 14 of the wire tightening device 10. The anterior edge of ledge 32 includes a groove 34 for receiving the tool engaging element 16.
As seen in FIG. 5, the arm 24 of the wire tightening tool 20 consists of 3 bar elements which may be welded or riveted together to form the arm structure of the tool. Bar element 40 is anchored within the handle 22, and serves as support for bar elements 42 and 44. Bar elements 42 and 44 overlap and their anterior ends serve as means for the reversible attachment of the wire tightening device 10. At the distal end of the bar means 42 and 44, the bars are bent to form a crooked handle or shank 26 immediately prior to the device engaging means. The anterior end of bar means 44 forms the prong 28 of the device engaging means. The anterior end of bar means 42 forms the ledge 32 of the device engaging means. A cavity 30, created by a divergence of bar means 42 and bar means 44 at their anterior ends serves as a receptacle for the base 14 of the wire tightening device 10.
The wire tightening device 10 engages the wire tightening tool 20 by sliding into the appropriate tool engaging means at the distal end of the tool. Once the device 10 has been secured on the wire tightening tool 20, the device is ready to engage a section of wire as illustrated in FIG. 3. The device tightens the wire by threading it around the wire engaging elements 12A, 12B and 12C which act as a series of bobbins which loop and secure the wire.
In order to initiate the tightening process and thread the wire around the device as shown in the example illustrated in the right hand side of FIG. 3, the wire 18 is first brought into contact with the inner edge of wire engaging element 12A. The wire is then threaded around the wire engaging elements by rotating the wire tightening tool 20 in a plane substantially parallel to the length of wire in a manner that engages the outer edge of wire engaging element 12C, which in this example serves as the looping element. The tool is then rotated in the same plane so as to engage the inner edge of wire engaging element 12B. Finally, the wire tightening tool 20 is separated from the wire tightening device 10 by sliding the tool in a direction opposite from the apex of the triangular base 14. The wire tightening device 10 remains on the wire due to the interaction between the wire and the wire engaging elements.
There are many permutations of this device and the accompanying wire looping procedures and it will be apparent that various changes may be made thereto without departing from the spirit and scope of the invention.
With the system of the invention the device can be reused as required. Thus when a fence is broken the device can be retrieved, leaving a bent pattern in the wire. After repairing the fence and stretching during the process, the bent pattern in the wire returns to its original shape without fracturing. The wire rests on the posts with an appropriate tension which is sufficient to create tensioning but not breakage.
There has been described a device for use in tensioning a fence wire as well as tool for using the device and a method of use. The foregoing detailed description is illustrative of one embodiment of the invention. It is to be understood that additional embodiments will be clear to those skilled in the art. The embodiments described together with those additional embodiments are considered to be within the scope of the invention. | A tool for tensioning a fence wire winds the fence wire around a wire tightening device that remains in the fence after the tool has been removed. The wire tightening device includes at least 3 wire engaging elements which are attached to a substantially rigid planar base. The device introduces tension by threading the wire around the wire engaging elements which takes up the slack therein. The tool manipulates the device by bringing it in to contact with the wire and rotating it around the wire. The tool then disengages from the device which becomes a permanent part of the fence. | 8 |
RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 12/115,530, filed May 5, 2008, which claims priority under 35 U.S.C. 119(e) from provisional U.S. Patent Applications No. 60/916,207 filed May 4, 2007, No. 60/938,622 filed May 17, 2007, and No. 60/939,167 filed May 21, 2007, the contents of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure is directed to a transport package for a temperature sensitive payload and a method of use within hostile environments having temperatures outside a desired temperature range for payload protection.
BACKGROUND OF THE INVENTION
[0003] Shipping containers for transporting temperature sensitive payloads typically include insulation materials, such as foam peanuts, expanded foams, etc. Various other containers have employed phase change materials to protect the payload from hotter or colder ambient temperatures during shipping. There is an urgent need for an environmentally friendly or “green” container and method of use for maintaining the payload temperature within a narrow band and which can operate without an electrical power source.
[0004] Many packages and methods are currently employed to ship temperature sensitive products. Often, these packages and methods require specified thermal preparation. For example, known methods of temperature sensitive material product recovery require on site thermal preparation, or just in time delivery of properly thermally prepared packaging. Methods also exist in which a mechanical device is activated, such as a device that evaporates water into a vacuum and uses the latent heat of vaporization to chill and maintain the temperature of a payload. Such systems are complex and expensive. A passive shipping package with no moving parts is particularly needed.
[0005] Temperature sensitive materials such as vaccines are sent to remote locations for use. Often unused materials are wasted for lack of adequate temperature control equipment at the remote location. As the temperature sensitive materials may initially be in usable condition, a method to recover remotely located temperature sensitive materials is urgently needed.
BRIEF SUMMARY OF THE INVENTION
[0006] A transport package is described herein which efficiently maintains payload temperature within a predetermined temperature range during delivery through regions having ambient temperatures outside the desired range. The transport package is used for transporting temperature sensitive materials and thermally protecting the materials from cold and hot ambient temperatures in a manner that does not require a power source or other mechanical devices.
[0007] Aspects of the invention relate to a temperature maintaining packaging system having an outer container, thermal insulation materials and two or more different phase change materials. Methods of using such packages within hostile environments are disclosed.
[0008] Aspects of the present invention also include a package having at least two different phase change materials, with one or more phase change material being thermally conditioned prior to insertion into the container. In some examples of the invention, one or more of the other phase change materials act as a thermal buffer to maintain the payload temperature within a desired temperature range. Prior to package assembly, a phase change material may be cooled or heated to temperatures outside the desired temperature range. With proper selection of the phase change materials, the package can maintain the payload temperature within the desired temperature range throughout the delivery process. Methods of assembling a container and methods of using such a container are also disclosed herein.
[0009] The foregoing has outlined rather broadly the features and technical advantages of the present invention in order that the detailed description of the invention that follows may be better understood. Additional features and advantages of the invention will be described hereinafter which form the subject of the claims of the invention. It should be appreciated by those skilled in the art that the conception and specific embodiment disclosed may be readily utilized as a basis for modifying or designing other structures for carrying out the same purposes of the present invention. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention as set forth in the appended claims. The novel features which are believed to be characteristic of the invention, both as to its organization and method of operation, together with further objects and advantages will be better understood from the following description when considered in connection with the accompanying figures. It is to be expressly understood, however, that each of the figures is provided for the purpose of illustration and description only and is not intended as a definition of the limits of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] For a more complete understanding of the present invention, reference is now made to the following descriptions taken in conjunction with the accompanying drawing, in which:
[0011] FIG. 1 is a perspective illustration of one embodiment of a package utilizing a phase change material combination in accordance with the present invention.
[0012] FIG. 2 is a perspective illustration of a second embodiment of a package utilizing a phase change material combination in accordance with the present invention.
[0013] FIG. 3 is a temperature vs. time diagram showing heat transfer to and from a package in accordance with the present invention during a delivery period.
DETAILED DESCRIPTION OF THE INVENTION
[0014] A phase change material is a substance with a high heat of fusion which, melting and solidifying at certain temperatures, is capable of storing or releasing large amounts of energy. Initially, solid-liquid phase change materials perform like conventional heat storage materials; their temperature rises as they absorb heat. Unlike conventional heat storage materials, however, when phase change materials reach a phase change temperature, i.e., melting point, they absorb large amounts of heat without a significant rise in temperature. When the ambient temperature around a liquid material falls, the phase change material cools and solidifies, releasing its stored latent heat. Certain phase change materials store 5 to 14 times more heat per unit volume than conventional heat storage materials such as iron, masonry, or rock.
[0015] Phase change materials can be broadly grouped into two categories: “Organic Compounds”, including but not limited to propylene and/or ethylene glycols and “Salt-based Products”, including but not limited to Glauber's salt. The most commonly used phase change materials are salt hydrides, fatty acids and esters, and various paraffins, such as octadecane. Certain ionic liquids have also been identified as promising phase change materials.
[0016] One embodiment of the present invention provides an efficient method of packaging realizing a reduction in the use of higher-priced phase change materials. Desirably, the packaging includes water-based phase change materials, which are among the least expensive phase change materials in current use. Water has a transition temperature close to 0 degrees C. Water-based phase change materials are often not suitable for certain temperature sensitive products. Other, generally more expensive, phase change materials may be necessary to avoid thermal damage to the temperature sensitive product. For example, red blood cells are temperature sensitive and should not be subjected to temperatures below 1 degree C. The temperature of sub-cooled water-based phase change materials may be significantly lower. As a result, if water based phase change materials are employed, sufficient insulation is typically needed between the temperature sensitive payload and the water based phase change material.
[0017] Embodiments of the present invention employ a second phase change material to act as a thermal buffer between a water based phase change material and the temperature sensitive payload. In one example, the second phase change material solidifies while protecting the payload from the temperature of the colder or hotter water based phase change material. In one example, the second phase change material is initially in solid form and then used as a heat sink to protect the payload from heat.
[0018] In another embodiment the thermally conditioned phase change material is heated to a temperature above the desired range of protection for the payload. In such an embodiment, the second phase change material again acts as a thermal buffer so as to maintain the payload temperature within the desired range. As a result, it is envisioned that embodiments of the present invention will be utilized to protect a payload against ambient temperatures that are hotter or colder than the payload's desired temperature range.
[0019] Embodiments of the present invention may also protect the payload from ambient temperatures that are both colder and hotter than the desired payload protection temperature range. If the ambient temperature is colder than the desired protection temperature range during one period of the package delivery, some period of time may be necessary in order to precondition the liquid phase change materials.
[0020] The present invention also promotes efficient packaging methods for thermally acclimating phase change materials. For example, a water based phase change material can be placed into the package directly from the freezer or other suitable preparation device. For example, the phase change material can be stored in solid or liquid form and then, along with the temperature sensitive payload, be packaged without having to wait for the phase change material to arrive at a desired packaging temperature.
[0021] The present invention is also directed to a package and method for encasing a payload cavity with phase change materials and insulation. In one example, a water based phase change material is combined with another phase change material to provide thermal protection for the payload. By properly selecting the phase change materials, a package can be configured to provide maximum thermal protection for a temperature sensitive product during delivery. Employing a combination of solid and liquid phase change materials in the container can provide protection from both hotter and colder ambient temperatures during delivery, and a beneficial reduction in the amount of phase change materials can result.
[0022] With reference to FIG. 1 , there is shown an exploded perspective view of a package 10 for shipping a temperature sensitive payload 12 . As depicted, package 10 is prepared for transport by inserting the components and payload 12 into the outer container 14 . The components of package 10 include insulation contained within or defined by an insulation panel 16 and phase change material contained within separated panels 18 . Six phase change material panels 18 and six insulation panels 16 are employed in the package 10 of FIG. 1 . The temperature sensitive payload 12 is received within a payload cavity, defined generally as the interior volume contained within the walls of panels 18 . In the illustrated embodiment, container 14 assumes a generally cubic form. In other embodiments, container 14 may assume alternative forms, including but not limited to cylinders, etc. Container 14 may be corrugated paper or corrugated plastic or other suitable material.
[0023] Insulation panels 16 can include vacuum insulation panels and/or foams and fiber-based materials. A combination of different insulation materials may be used to form the panel 16 .
[0024] While panels 16 , 18 are shown in rectangular form, each panel can assume a variety of different shapes and forms in alternative embodiments of the invention. For example, panels 16 , 18 may be defined as open cylinders with one panel being inserted into the other in a nesting manner. In other examples, panels 16 , 18 may be shaped in relation or allowed to conform to the payload 12 . Panels 16 may be defined by plastic and/or metal shells for containing phase change material therewithin. Phase change material panels 18 may assume different shapes or forms in alternative embodiments. Examples of phase change material panels 18 can include HDPE containers, form fill and seal films, or any other suitable containers sized to be inserted into the package 10 .
[0025] Selection of the phase change materials may include consideration of multiple factors including, but not limited to, the desired protected temperature range, anticipated ambient temperatures during shipment, thermal properties of the different phase change materials, thermal properties of the container and/or insulation panels, and thermal properties of the temperature sensitive product being shipped. The design and sizing of containers for the phase change material panels and the insulation panels would vary depending on these factors as well.
[0026] FIG. 2 illustrates another embodiment of the present invention. In this example, package 10 includes a pair of phase change material panels 18 , 20 placed above and below payload 12 . The payload cavity is thus defined between the four walls of insulation panels 16 and two inside walls of phase change material panel 18 . In this embodiment, the primary heat transfer occurs through the top and bottom portions of package 10 .
[0027] An exemplary package 10 in accordance with the present invention includes phase change materials in different layers relative to the payload. Prior to shipment one or both of the phase change materials can be preconditioned into liquid or solid form. Depending on the anticipated ambient temperature profile during transport of package 10 , an effective combination of solid and liquid phase change materials can be selected. If additional protection is needed, auxiliary phase change materials in solid, liquid, or solid and liquid phase can be added to augment the thermal capabilities of the package 10 .
[0028] In another embodiment, the payload cavity may initially contain a phase change material form that is thermally prepared to be solid, liquid, or solid and liquid based on anticipated ambient temperatures during delivery and the protection requirements of the payload. In yet another embodiment the functions of container 14 and phase change panel 18 may be combined into an integrated structure. In such an example, the container 14 and phase change panel 18 would together be thermally conditioned prior to package 10 assembly. Similarly, the insulation panels 16 and one or more of the phase change material panels 18 , 20 may be combined into one or more structures.
[0029] One embodiment of the present invention includes an outer container into which one or more insulation panels and multiple different phase change material panels are inserted. A payload cavity within the container is sized to receive a temperature sensitive product. In one example, a water based phase change material is combined with another phase change material. The two phase change materials cooperate to provide thermal protection for the temperature sensitive product even, for example, if the water-based phase change material is sub-cooled. For example, a package 10 for shipping blood products may include a first water based phase change material and a second phase change material which is liquid near 4 degrees C. A method of shipping such package 10 would include cooling the water-based phase change material below zero degree C. prior to insertion into package 10 .
[0030] The temperature sensitive payload can be wrapped, encased, or placed adjacent a phase change material and together covered with another phase change material. During shipping, one of the phase change materials may initially solidify the other phase change material without thermal damage to the payload.
[0031] Other embodiments of the present invention include two or more different phase change materials. In one embodiment, a water-based phase change material is utilized along with a non-water-based phase change material. In another embodiment, a phase change material panel protects a temperature sensitive payload against thermal damage from a colder or hotter water-based phase change material. Depending on the desired temperature range, a variety of different phase change materials may be utilized to keep a temperature sensitive product warm or cold during shipment through an environment having substantially different temperatures than desired.
[0032] While the embodiments of FIG. 2 illustrates a water-based phase change material separated from the temperature sensitive payload by an intermediate phase change material, in other embodiments of the present invention a water-based phase change material is positioned between an outer phase change material and the temperature sensitive product.
[0033] FIG. 3 depicts a change of payload temperature during a hypothetical delivery process of a package 10 in a hostile environment. During the delivery process the ambient temperature, shown as line AT, changes to be outside the desired product protection range. In this example, package 10 maintains the payload temperature, shown as line PT, within the desired temperature range for product protection, defined between temperatures, T 1 and T 2 . During a time period between t 1 and t 2 , the ambient temperature of package 10 is higher than the desired range. During such period a solid phase change material panel absorbs heat without a substantial increase in the payload temperature. Similarly, during a time period between t 3 and t 4 , with the ambient temperature lower than the desired range, the phase change material panel would transfer heat to the payload.
[0034] The invention further relates to a method for shipping temperature sensitive products from a first location to one or more remote locations including: preparing at a first location a container having insulation materials and phase change materials; receiving the container at a second location; thermally conditioning and replacing at least one of the phase change materials of the package; and inserting a temperature sensitive product into a payload cavity prior to shipment from the remote location to yet another location. The phase change materials may initially include two different phase change materials.
[0035] Other examples of the invention provide a method for transporting a temperature sensitive product including: receiving a container including multiple phase change materials and insulation, the phase change materials being thermally preconditioned prior to and/or during delivery; thermally conditioning one of the phase change materials to a temperature outside of a desired temperature range for protection of the thermally sensitive product; and placing the temperature sensitive product into the payload cavity prior to shipping the container to another site. In a preferred form, one of the phase change materials is utilized to buffer the temperature of the temperature sensitive product during shipment. As a result, the temperature sensitive product can be protected against thermal damage caused by a phase change material having a temperature outside of the desired temperature range for product protection.
[0036] The present invention is also directed to a transport method where the payload cavity is initially filled with a phase change material prior to transport to a remote location and the payload cavity is cleared prior to delivery from the remote location. In one example, some or all of the phase change material is removed from the payload cavity at a remote location. A temperature sensitive product is then placed into the payload cavity and the container is resealed and delivered to another location. Such an example provides a method for recovering temperature sensitive material from a remote site that does not have adequate thermal control equipment. For example, a remote site may have a small refrigerator but not a freezer. When the package arrives at such a remote location, a flu vaccine clinic for example, some amount of the phase change material is removed from the container and the temperature sensitive material is placed into the container for shipping to another location.
[0037] Another embodiment of a package of the present invention provides phase change materials in different states on different sides of the payload. For example, a phase change material panel 18 in solid form is placed on one side of the payload and phase change material panels 20 are placed on the other sides of the payload. In other examples, two sides can be in solid form while four sides are in liquid form, three sides can be in solid form while three sides are in liquid form, four sides can be in solid form while two sides are in liquid form, and five sides can be in solid form while one side is in liquid form. The panels 18 , 20 on each side of the configuration can be made into two or more panels placed together to make many other combinations of panels possible. Depending on the anticipated ambient temperature profile, the most effective combination of solid and liquid phase change material can be selected. If additional protection is needed and space is available within the payload cavity, auxiliary phase change material in solid, liquid, or solid and liquid phase can be added to augment the encasement phase change materials.
[0038] Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps. | The present invention is directed to a transport package which efficiently maintains payload temperature within a predetermined temperature range during delivery through regions having ambient temperatures outside the desired range. The transport package is used for transporting temperature sensitive materials and thermally protecting the materials from cold and hot ambient temperatures in a manner that does not require a power source or other mechanical devices. Aspects of the invention relate to a temperature maintaining packaging system having an outer container, thermal insulation materials and two or more different phase change materials. | 5 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a seal for a bearing that rotatably supports a shaft. The shaft extends through a housing opening of a housing element that limits, at least partially, a chamber containing a lubricant in form of a lubricating grease or oil. Between the lubricant-containing chamber and the bearing, there is provided a sealing ring that surrounds the shaft and is retained between the shaft and the housing element for protecting the bearing from the lubricant. The sealing ring forms, together with a limiting element, an annular gap.
[0003] 2. Description of the Prior Art
[0004] The seals of the type descried above, are provided, e.g., on lubricant-receiving chambers or receptacles for gear units of, e.g., hand-held power tools. The sealing ring prevents the lubricant, which is provided in the associated gear housing, from directly contacting the bearing and from flowing through the bearing from the gear housing outwardly, e.g., into a motor housing.
[0005] European Patent EP 0 202 702 B1 discloses a seal for a shaft bearing and which includes a swivel ring connected with the shaft for a joint rotation therewith. The swivel ring forms a hub which extends radially outwardly and forms, together with a hub fixedly connected with the housing and extending from the housing opening radially inwardly, an annular gap. This annular gap has a labyrinth-shaped cross-section.
[0006] U.S. Pat. No. 5,876,126 discloses a shaft bearing seal that has a sealing disc retained on an outer ring of the bearing which is fixedly secured to the housing. The sealing disc forms, together with a shaft and a bearing inner ring press-fitted on the shaft, a labyrinth-shaped annular gap.
[0007] The drawback of the known shaft bearing seals consists in that despite the labyrinth-shaped annular gap, in particular at a vertical orientation of the shaft, the lubricant reaches the bearing and can leave the lubricant-receiving chamber through the bearing.
[0008] Such seals are not suitable for hand-held power tools which, e.g., are often used in overhead works and have the shaft oriented vertically for an extended time period in an operational or shut-down condition of the power tool when no lubricant should flow through the shaft bearing.
[0009] Accordingly, an object of the present invention is to provide a shaft bearing seal suitable for hand-held power tools and in which the above-mentioned drawback of the known shaft bearing seals is eliminated, and the bearing is better protected from the lubricant such as grease.
SUMMARY OF THE INVENTION
[0010] This and other objects of the present invention, which will become apparent hereinafter, are achieved according to the present invention by providing a shaft bearing seal of the type discussed above and in which the sealing ring has aeration recesses which connect the annular gap with the lubricant containing chamber. The aeration recesses permit to remove the lubricant, which penetrated in the annular gap during the operation or shut-down of the power tool as a result of a vertical orientation of the bearing, from the annular gap. To this end, a dynamic effect is used which is produced by a rotation of the sealing ring that limits the annular gap on one side, relative to another limitation that limits the annular gap on the second side. The sealing ring can be fixedly connected, e.g., with the shaft for joint rotation therewith, and the limiting element can be fixedly secured to the housing element or vice versa. The aeration recesses aerate the annular gap. The aeration of the annular gap during operation prevents development of underpressure in the annular gap that can cause an aspiration of lubricant in the annular gap or its retention there.
[0011] According to a particular advantageous embodiment of the present invention, the sealing ring is formed by a Hager (impeller-like) disc connectable with the shaft for a joint rotation therewith, and the limiting element is fixedly connected with the housing element. During an operation, the sealing ring rotates together with the shaft, accelerating the lubricant accumulated on the sealing ring. Thereby, in particular with a suitable shape of the sealing ring, the lubricant can be particularly effectively forced out of the annular gap.
[0012] Advantageously, the annular gap is formed between a radially outer rotational surface of the sealing ring and the limiting element. This insures a maximum acceleration of the lubricant that accumulated on the sealing ring during operation. This further optimizes removal of the lubricant from the annular gap.
[0013] Advantageously, the aeration recesses open into the rotational surface of the sealing ring, which insures a particularly good aeration of the annular gap and, thus, an unobstructed delivery of the lubricant out of the annular gap.
[0014] Preferably, the aeration recesses are substantially identical and are spaced from each other by a same angular distance. This insures a uniform removal of the lubricant over the sealing ring circumference.
[0015] Advantageously, there are provided at least three aeration recesses. This permits to achieve a particularly high delivery output of the sealing ring with respect to the lubricant in the annular gap.
[0016] Preferably, the aeration recesses extend from a lubricant containing chamber side end surface of the sealing ring to a bearing-side end surface of the sealing ring. Thereby, the aeration of the annular gap takes place over the entire width of the rotational surface. In addition, thereby, even the region of the annular gap, which is limited by the bearing-side end surface of the sealing ring remote from the lubricant-containing chamber, is aerated.
[0017] It is further particular advantageous when the aeration recesses extend radially inwardly up to a virtual cylinder a diameter (dZ) of which is smaller than an outer diameter of an inner ring of the bearing. Thereby, the side of the bearing adjacent to the lubricant-containing chamber can be completely aerated in the region between the shaft-side inner ring of the bearing and the outer ring of the bearing fixed to the housing. In this region, because of the insufficient sealing, the lubricant exits from the lubricant exits from the lubricant-containing chamber. Complement aeration prevents underpressure in this region. Therefore, with a suitable shape of the sealing ring, in this region also, a substantially complete removal of the lubricant is possible.
[0018] Advantageously, the aeration recesses extend over from 70% to 95% of a sealing ring circumference, and an acceleration element is formed between each two adjacent aeration recesses. With this propeller-shaped design of the sealing ring a particularly high delivery output with respect to the annular gap is achieved.
[0019] It is advantageous when the acceleration element has a side surface adjacent to a rotational direction and inclined toward a bearing axis at an angle. This likewise increases the delivery output.
[0020] Advantageously, the acceleration element alternatively or in addition is inclined toward the bearing axis at the rotational surface of the sealing element, at an angle. In this way, the sealing ring forms, during an operation, a conical rotational body, and an improved lubricant delivery takes place over the circumference of the sealing ring.
[0021] The novel features of the present invention, which are considered as characteristic for the invention, are set forth in the appended claims. The invention itself, however, both as to its construction and its mode of operation, together with additional advantages and objects thereof, will be best understood from the following detailed description of preferred embodiments, when read with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The drawings show:
[0023] FIG. 1 a partially cross-sectional view of a shaft bearing seal according to the present invention;
[0024] FIG. 2 a plan view of the sealing disc of the shaft bearing seal according to FIG. 1 ;
[0025] FIG. 3 a side view of the sealing disc according to FIG. 2 in direction of arrow III;
[0026] FIG. 4 a plan view of another embodiment of the sealing disc of the shaft bearing seal according to the present invention;
[0027] FIG. 5 a side view of the sealing disc according to FIG. 4 in direction of arrow V;
[0028] FIG. 6 a plan view of a further embodiment of the sealing disc of the shaft bearing seal according to the present invention; and
[0029] FIG. 7 a side view of the sealing disc according to FIG. 6 in direction of arrow VII.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0030] FIG. 1 shows a shaft bearing seal 2 which is provided on a grease-containing chamber 4 of a gear housing, not shown in detail, of a hand-held power tool, e.g., in form of a hammer drill or a screw driving tool. The shaft bearing seal 2 is provided on a bearing 6 that is retained in the housing opening 8 of a wall-shaped housing element 10 . The housing element 10 separates the grease-containing chamber 4 from an outer chamber 12 of a motor housing, not shown in detail.
[0031] The bearing 6 serves for supporting a shaft 14 for rotation about an axis A. The shaft 14 projects from the outer chamber 12 into the grease-receiving chamber 4 . The bearing 6 has an inner ring 16 which, e.g., is press fit-mounted on the shaft 14 for joint rotation therewith. The inner ring 16 is rotated relative an outer ring 20 of the bearing 6 by a ball-shaped bearing body 18 . The outer-ring 20 is held fixedly in the housing element 10 and is axially secured with a circlip 22 . Between the inner ring 16 and the outer ring 20 , there are provided sealing elements 24 .
[0032] On the shaft 14 , there is further provided a sealing disc 26 in form of a Hager disc that, e.g., is connected with shaft 14 by a press fit for joint rotation therewith. The sealing disc 26 is held, with respect to the axis A, at an axial height of a limiting element 28 that is formed by a collar section of the housing element 10 , which projects radially inwardly in the housing opening 8 . A circumferential rotational surface 32 , which is defined by radially outer surfaces of the sealing disc 26 , and the limiting element 28 form an annular gap 30 .
[0033] As shown in FIGS. 2-3 , the sealing disc 26 has three acceleration elements 33 which are separated from each other by aeration recesses 34 . The aeration recesses 34 extend over more than 90° of the rotational surface 32 . The acceleration elements 33 form radially outer circumferential surfaces 35 which define the rotational surface 32 .
[0034] Alternatively, the aeration recesses 34 can be formed by a multiplicity of smaller grooves which can be formed on the circumference of the sealing disc 26 (not shown). In each case, the rotational surface 32 is formed by the radially outer surfaces 36 of the sealing disc 26 which upon rotation of the sealing disc 26 in a direction D, form an outer cylindrical surface of the corresponding rotational body.
[0035] The aeration recesses 34 and thus, the acceleration elements 33 extend, as shown in FIG. 1 , over an entire width of the sealing disc 26 from a chamber-side end surface 36 adjacent to the grease-receiving chamber 4 to a bearing-side end surface 28 adjacent to the bearing 6 .
[0036] As shown in FIG. 1 , the aeration recesses 34 extend radially inwardly up to a common virtual cylinder Z having a diameter dZ. The diameter dZ is smaller than the outer diameter dR of the inner ring 16 of the bearing 6 .
[0037] When the respective hand-held power tool is operated or is shut down and the shaft 14 is so aligned that it extends, as shown in FIG. 4 , vertically, the grease can flow from the grease-receiving chamber 4 into the annular gap 30 between the sealing disc 26 and the limiting element 28 and through the annular gap 30 into an intermediate chamber 40 between the sealing disc 26 and the bearing 6 . As a result, the grease directly contacts the sealing elements 24 .
[0038] As soon as the shaft 14 begins to rotate about the axis A, the grease would be accelerated in the annular gap 30 and in the intermediate chamber 40 by the sealing disc 26 and would be transported from the annular gap 30 .
[0039] The aeration recesses 34 , which connect the grease-receiving chamber 4 with the annular gap 30 and the intermediate chamber 40 , insure that both the annular recess 30 and at least a region of the intermediate chamber 40 that extends over the sealing elements 24 , is adequately aerated. In this way, the built-up of an underpressure is prevented, and almost complete removal of grease, which accumulated on the sealing elements, is insured. At that, a grease cone 42 is formed that permanently adjoins the annular gap 30 but cannot penetrate thereinto as long as the sealing disc rotates.
[0040] FIGS. 4 through 7 show alternative embodiments of the sealing disc 26 , with the elements, which perform the same functions, all having the same reference numerals as in FIGS. 1-3 .
[0041] In the embodiment shown in FIGS. 4-5 , the acceleration elements 33 form, with respect to the axis A, an angle (α) on both side surfaces 44 aligned in the rotational direction D.
[0042] In the embodiment of FIGS. 6 and 7 , additionally, the radially outer circumferential surface 35 of the acceleration elements 33 forms, with respect to axis “A” an inclination angle (β), so that the sealing disc 26 forms, upon rotation in the rotational direction D, a conical rotational body, as shown with dash-dot lines.
[0043] Though the present invention was shown and described with references to the preferred embodiments, such are merely illustrative of the present invention and are not to be construed as a limitation thereof and various modifications of the present invention will be apparent to those skilled in the art. It is, therefore, not intended that the present invention be limited to the disclosed embodiments or details thereof, and the present invention includes all variations and/or alternative embodiments within the spirit and scope of the present invention as defined by the appended claims. | A seal ( 2 ) for a bearing ( 6 ) that rotatably supports a shaft ( 14 ) extending through a housing opening ( 8 ) of a housing element ( 10 ) that limits, at least partially, a lubricant-receiving chamber ( 4 ), includes a sealing ring ( 26 ) retainable between the housing element ( 10 ) and the shaft ( 14 ) and forming together with a limiting element ( 28 ) an annular gap ( 30 ), and having aeration recesses ( 34 ) which connect the annular gap ( 30 ) with the grease-containing chamber ( 4 ). | 5 |
FIELD OF THE INVENTION
[0001] The invention relates to a press for producing pellets from powdered material comprising at least one die with a mould cavity replicating the pellet, at least one upper punch and at least one lower punch that interact with the mould cavity to form the pellet, and at least one electric drive for driving the upper punch, and/or the lower punch, and/or the die along a main press axis.
BACKGROUND OF THE INVENTION
[0002] A press for producing pellets from powdered material is for example known from DE 10 2006 020 213 B4, the entire contents of which is hereby incorporated by reference. The die is rotatably mounted on a die table, and an adjusting cylinder is arranged on the die table, the cylinder being in a rotary drive connection with the die by means of a mechanical deflection. With the known press, for example twisted, angled-tooth, or other parts can be produced. Both the main drives for the press punch as well as the drive for rotating the die are hydraulic drives.
[0003] Furthermore, a press for producing a briquette from powdered material is known from DE 10 2010 048 183 A1, the entire contents of which is hereby incorporated by reference, in which several drives act via a mechanical deflection of 90° on transverse punches which interact with the mould cavity of the die along a transverse axis running transverse to the main press axis. The drives for driving the transverse punch can be both electric drives as well as hydraulic drives. Such a mechanical deflection of a drive acting on a transverse punch is also known from EP 2 103 423 A1, the entire contents of which is hereby incorporated by reference. Pellets can be created with such transverse punches which have transverse bore holes or lateral recesses.
[0004] In particular with presses with electric drives for the press axes, there has been no satisfactory solution to date for providing high force in a small installation space. Electric drives require significant installation space. To address this problem, electric drives are frequently arranged at a distance from the die. The mechanical deflections frequently provided in the prior art lead to undesirable control imprecision, a complex design and increased wear. The hydraulic drives provided in the prior art alternatively to electric drives require significant hydraulic complexity, particularly in regard to the hydraulic aggregate, the valves, etc. and are more difficult to control than electric drives. Providing different drives such as electric drives for the main pressing axes and hydraulic drives for the transverse pressing axes leads to imprecision in regard to controlling and the safety design of the press.
[0005] Based on the described priority, the invention addresses the problem of simplifying the press design, reducing the installation space and improving the controlling of the other actuating elements or punches in addition to the upper and/or lower punches that are moved along the main press axis.
BRIEF SUMMARY OF THE INVENTION
[0006] The invention solves the problem for a press of the above-cited type in that the press also comprises at least one movable element acting on the die and/or the mould cavity of the die, wherein at least one electro-hydrostatic drive is provided to drive the at least one movable element.
[0007] With the press according to the invention, pellets consisting of metal powder can be produced for a subsequent sintering process, such as for the production of tools, etc. The press according to the invention can have a die plate with the die in a manner known per se.
[0008] The upper and/or lower punch can be arranged on upper or respectively lower punch plates. The press can possess a press frame in which the aforementioned elements of the press are arranged. The press possesses a suitable filling device by means of which the powdered material is added to the mould cavity in the die. By means of the electric drive(s), the upper and/or lower punch, and/or the die, or respectively a die plate which may have a die, are moved along the main press axis such that the powdered material added to the die is pressed in the mould cavity. Both the ejection process is possible in which the die is arranged stationary, and the upper and lower punch are moved, as well as the withdrawal process in which the lower punch is arranged stationary, and the upper punch as well as the die, or respectively a die plate that may have the die, are moved. The main press axis is for example arranged in a vertical direction.
[0009] The electric drive(s) for the main press axis can for example be electric spindle drives. An electric motor can rotatably drive for example an axially fixed spindle. A spindle nut running on the spindle is moved thereby in the axial direction of the spindles. The spindle nut generally acts by means of a force transmitting apparatus on the upper and/or lower punch plate and moves therewith the upper punch and/or lower punch in the direction of the main press axis which runs at a parallel distance or coaxial to the longitudinal axis of the at least one spindle. The upper punch as well as the lower punch can be moved thereby, or only one of the upper punch and lower punch. For example, two upper and/or two lower of such electric drives can be provided that each act together for example on an upper punch plate and/or lower punch plate. The force transmitting apparatus can for example be a force transmitting bridge running in a horizontal direction, and the spindle nuts are mounted on its opposing ends such that they move the force transmitting bridge in a vertical direction.
[0010] According to the invention, at least one additional movable element is provided which acts on the die and/or the mould cavity of the die, and which is moved by at least one electro-hydrostatic drive. In particular, a plurality of such movable elements and correspondingly a plurality of such electro-hydrostatic drives can be provided. One electro-hydrostatic drive can be provided for each movable element. It is however also conceivable for one electro-hydrostatic drive to drive a plurality of movable elements. According to the invention, one or respectively a plurality of electro-hydrostatically driven additional axes is provided. Electro-hydrostatic drives are known in principle. Generally, they possess a hydraulic cylinder which is actuated by means of a hydraulic pump. The hydraulic pump in turn is driven by an electric motor. In terms of control engineering, electrostatic drives behave like purely electric drives.
[0011] For controlling, the electric motor of the electro-hydrostatic drive can therefore be actuated in the same manner as electric drives provided for the main press axis. A uniform approach in terms of control engineering can therefore be realized in the press. A uniform approach in terms of safety engineering can also be realized due to the use of uniform drive types. According to the invention, the advantages of hydraulic drives, particularly the compact design with a high exertion of force, and the advantages of electric drives, particularly the simple and precise controlling of electric drives, can be combined with each other. The advantages of the two drive types known in principle are used for a press without implementing the respective disadvantages. Mechanical deflections between the electro-hydrostatic drives and the movable elements driven by them can be omitted. The precision of controlling is increased, the design is simplified, and wear is reduced.
[0012] It is also possible for the die of the press to consist of a plurality of components, or respectively segments, for example divided along the direction of the main pressing axis, i.e., for the die to be a so-called parted die. In this case, the components or respectively segments of the die can be driven by the electro-hydrostatic drives provided according to the invention. In this case, the components or respectively segments of the die can form the movable elements per se provided according to the invention.
[0013] The at least one movable element can be at least one adjusting element for adjusting the die and/or at least one punch acting on the mould cavity of the die. The adjusting element can for example be provided to move, e.g. rotate, the die during pressing. The at least one movable element can be movable by means of the least one electro-hydrostatic drive along an axis running at an angle to the main press axis, preferably a transverse axis running transverse to the main press axis. Particularly when the additional movable element is an additional press punch, e.g. transverse bore holes, lateral recesses or undercuts in the pellet can be generated in this manner. The teaching according to the invention very effectively manifests the advantages of small installation space, simple controlling and high control precision, especially for axes running at an angle to the main press axis, e.g. transverse axes.
[0014] Alternatively, it is also possible for the at least one movable element to be an additional upper punch and/or an additional lower punch that can be moved by the at least one electro-hydrostatic drive parallel to the main press axis.
[0015] According to another embodiment, it can be provided that the movement of the at least one electro-hydrostatic drive to drive the at least one movable element, and the movement of the at least one electric drive to drive the upper punch and/or lower punch along the main press axis, are controlled by a common control apparatus. A uniform control is accordingly realized for the electric drives along the main press axis and the electro-hydrostatic drive(s) for the additional movable elements. In particular, a uniform control for all the drives of the press can be realized. Due to the use of electric drives for driving the upper and/or lower punch along the main press axis on the one hand, and the use of electro-hydrostatic drives for moving the at least one movable element, one electric motor can be activated for controlling in both cases.
[0016] The at least one electro-hydrostatic drive, in particular a hydraulic cylinder of the electro-hydrostatic drive, can act on the at least one movable element without mechanical deflection. It is in particular hence possible for no gearing to be provided between a hydraulic cylinder of the electro-hydrostatic drive and the movable element. As already mentioned, electro-hydrostatic drives, in particular their hydraulic cylinders, require less installation space while generating strong force. They can hence be easily integrated in the press, in particular arranged within a press frame. Complex mechanical deflections as provided in the prior art are unnecessary.
[0017] According to another embodiment, at least one hydraulic cylinder—acting on the at least one movable element—of the at least one electro-hydrostatic drive can be arranged spatially separate from at least one hydraulic pump actuating the at least one hydraulic cylinder, and from at least one electric motor driving the hydraulic pump, wherein the at least one hydraulic cylinder and the at least one hydraulic pump are connected to each other by means of a hydraulic feedline and a hydraulic drain line. The hydraulic feedline and hydraulic drain line can in particular be flexible. Such a separation of the actuator and force generator yields particularly flexible installation options for the electro-hydrostatic drive and hence smaller sizes of a press frame and hence a press. Since the hydraulic cylinder is separate from the hydraulic pump and the electric motor driving the hydraulic pump, the flexibility is enhanced with respect to the design and arrangement of the electro-hydrostatic drive. By means of flexible hydraulic lines, the two separate components of the electro-hydrostatic drive can be positioned substantially free from each other. Of course rigid hydraulic lines are also possible.
[0018] It can furthermore be provided that the press has a press frame within which are arranged a matrix plate having the matrix, the at least one upper punch and the at least one lower punch, wherein the at least one electric drive is arranged within the press frame or on the press frame, and wherein the at least one hydraulic cylinder of the electro-hydrostatic drive is arranged within the press frame, and the at least one hydraulic pump actuating the at least one hydraulic cylinder, as well as the at least one electric motor driving the hydraulic pump, are arranged outside of the press frame. Only the one hydraulic cylinder per se requiring a small installation space is therefore arranged within the press frame. The possibly larger drive components for the hydraulic cylinder are positioned outside of the press frame. The at least one hydraulic pump, as well as the at least one electric motor driving it, can for example be fastened to the outside of the press frame.
[0019] According to an additional embodiment, the hydraulic cylinder can be fastened to the die plate. Particularly with this embodiment, the fixed part of the hydraulic cylinder is fastened to the die plate, such as the cylinder housing. The cylinder piston is then movable relative to the fixed part, and hence relative to the die plate, to drive the at least one movable element. A secure and easy attachment of the hydraulic cylinder within the press frame is achieved, particularly when the hydraulic cylinder drives an adjusting element to adjust the die or an additional punch acting on the mould cavity of the die.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] An exemplary embodiment of the invention is explained below in greater detail with reference to figures. They show schematically:
[0021] FIG. 1 A first perspective view of a press according to the invention,
[0022] FIG. 2 A second perspective view of the press from FIG. 1 , and
[0023] FIG. 3 A perspective view of an electro-hydrostatic drive used in the press from FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
[0024] While this invention may be embodied in many forms, there are described in detail herein specific embodiments of the invention. This description is an exemplification of the principles of the invention and is not intended to limit the invention to the particular embodiments illustrated.
[0025] For the purposes of this disclosure, like reference numerals in the figures shall refer to like features unless otherwise indicated.
[0026] If not otherwise specified, the same reference numbers indicate the same objects in the figures. The press according to the invention possesses a press frame 10 with an upper holding plate 12 and a lower holding plate 14 . The upper and lower holding plates 12 , 14 are connected to each other by means of four spacers 16 running in a vertical direction in the portrayed example, and to a bearing element 18 arranged approximately in the middle between the upper and lower holding plates 12 , 14 . In the portrayed example, the bearing element 18 is designed as a single part and possesses a U-profile lying in a horizontal plane, an arrangement and extension plane. The lower holding plate 14 stands on the supporting surface by means of four support legs 20 . Furthermore, the press possesses an upper punch plate 22 with an upper punch (not shown) and a lower punch plate 24 with a lower punch (also not shown). In the portrayed example, a die plate 26 is arranged between the upper punch plate 22 and the lower punch plate 24 with a die (not shown) with a mould cavity for powder, such as metal or ceramic powder, to be pressed between the upper and lower punch. In the portrayed example, the upper punch plate 22 , the lower punch plate 24 , and the die plate 26 are connected to each other by means of vertical guide columns 28 . In the portrayed example, the die plate 26 is directly attached to the bearing element 18 .
[0027] The press according to the invention furthermore comprises two upper electric drives for vertically moving the upper punch plate 22 , and two lower electric drives for vertically moving the lower punch plate 24 . The upper and lower electric drives are each arranged on opposite sides of the press frame 10 . The upper electric drives each comprise an upper electric drive motor 30 , 31 arranged on the upper holding plate 12 and an upper spindle drive. The upper spindle drives comprise in each case an upper fixed bearing 32 , 33 that is fastened in each case directly to the top side of the bearing element 18 . The electric upper drive motors 30 , 31 each rotatably drive an axially fixed upper spindle 34 , 35 . An axially movable upper spindle nut 36 , 37 is arranged on each of the upper spindles 34 , 35 . When the upper spindles 34 , 35 rotate, this therefore generates an axial movement of the respective upper spindle nuts 36 , 37 . The upper spindle nuts 36 , 37 are fastened to opposite ends of an upper, bar-shaped force transmission bridge 38 which is connected in the middle to the upper punch plate 22 by means of another force transmission element 40 . The upper electric drives with their upper electric drive motors 30 , 31 therefore act laterally offset on the upper punch plate 22 , and hence on the upper punch, by means of the force transmission bridge 38 .
[0028] The design of the two bottom electric drives is accordingly identical to the design of the two upper electric drives. Hence the lower electric drives each have a lower electric drive motor 42 , 43 that is arranged on the lower holding plate 14 and rotatably drives an axially fixed lower spindle 44 , 45 . A lower fixed bearing 46 , 47 of each of the lower spindles 44 , 45 is directly fastened to the bottom side of the bearing element 18 . An axially movable lower spindle nut 50 , 51 is in turn arranged on the lower spindles 44 , 45 . The lower spindle nuts 50 , 51 are in turn arranged on opposite ends of a lower, bar-shaped force transmission bridge 52 which is connected in the middle to the lower punch plate 24 by means of another force transmission element 54 . When the lower electric drive motors 42 , 43 rotatably drive the lower spindles 44 , 45 , an axial movement of the lower spindle nuts 50 , 51 arises which is transmitted to the lower punch plate 24 by means of the lower force transmission bridge 52 and the force transmission element 54 such that the punch plate is moved in a vertical direction. In turn, the lower electric drives with their lower electric drive motors 42 , 43 therefore act laterally offset on the lower punch plate 24 , and hence on the lower punch, by means of the lower force transmission bridge 52 .
[0029] In the depicted example, the upper spindle nuts 36 , 37 are connected to the upper force transmission bridge 38 by means of a total of four compensation elements, of which two can be seen in FIG. 1 under reference numbers 56 , 58 . Corresponding compensation elements with an equivalent function are arranged on the rear of the press, hidden in FIG. 1 , opposite the compensation elements 56 , 58 in each case. The lower spindle nuts 50 , 51 are correspondingly connected by means of a total of four compensation elements to the lower force transmission bridge 52 , of which two can be seen in FIG. 1 under reference numbers 60 , 62 . In turn on the rear of the press which cannot be seen in FIG. 1 , there are two additional compensation elements opposite compensation elements 60 , 62 which are identical to the compensation elements 60 , 62 in terms of design and function.
[0030] The elongated compensation elements 56 , 58 , 60 , 62 are rotatably mounted on the upper force transmission bridge 38 , or respectively the lower force transmission bridge 52 , by means of first pivot bearings. The compensation elements 56 , 58 , 60 , 62 are each rotatably mounted on the upper, or respectively lower, spindle nuts by means of second pivot bearings. The pivot bearings of a compensation element in the resting position of the press shown in FIG. 1 are each arranged over each other in a vertical direction. The longitudinal axis of the elongated compensation elements 56 , 58 , 60 , 62 also extends in a vertical direction in this resting state. During a pressing operation, enormous forces arise. These can cause the force transmission bridges 38 , 52 to bend. This bending of the force transmission bridges 38 , 52 leads to a tipping of the compensation elements 56 , 58 , 60 , 62 which is enabled by a rotation of the compensation elements 56 , 58 , 60 , 62 about their pivot bearings and hence, in conjunction with a gap between the spindle nuts 36 , 37 , 50 , 51 and the associated force transmission bridges 38 , 52 , to compensation of a bending of the force transmission bridges 38 , 52 .
[0031] Furthermore in the exemplary embodiment shown in the figures, two additional movable elements are provided, i.e. the additional press punches, indicated by reference numbers 64 , 66 , which are movable along a transverse axis running perpendicular to the vertical main press axis of the upper punch and lower punch and also interact with the mould cavity of the die. In this manner, transverse openings, recesses or undercuts, for example, can be formed in the pellet imaged in the mould cavity. The additional press punches 64 , 66 are each driven by means of an electro-hydrostatic drive. For the sake of illustration, FIG. 3 depicts an enlarged representation of the additional press punch 64 together with the electro-hydrostatic drive which drives it. Of course the other additional press punch 66 and its electro-hydrostatic drive are accordingly designed identically. The electro-hydrostatic drive comprises a hydraulic cylinder indicated by reference number 68 . The hydraulic cylinder 68 is connected to a drive block 74 by means of the hydraulic lines 70 , 72 which can be used as a hydraulic feedline or hydraulic drain line depending on the drive direction of the hydraulic cylinder. The drive block 74 comprises a hydraulic pump which is connected to a reservoir for hydraulic fluid. In addition, the drive block 74 comprises an electric motor which drives the hydraulic pump. By means of the hydraulic pump, the hydraulic fluid is pumped out of the reservoir, for example by means of the hydraulic line 70 used in this case as a feedline, to actuate the hydraulic cylinder 68 , wherein the hydraulic fluid can flow from the hydraulic cylinder 68 back to the hydraulic pump and into the hydraulic reservoir by means of the hydraulic line 72 used in this case as a drain line. It can be seen that the electro-hydrostatic drives, in particular the hydraulic cylinders 68 of the electro-hydrostatic drives, act on the additional press punches 64 , 66 to move them without gearing, particularly without mechanical deflection. Furthermore, it can be seen in FIGS. 1 and 2 that the hydraulic cylinders 68 are arranged within the press frame 10 , whereas the drive blocks 74 are attached to the exterior of the press frame outside of the press frame. The necessary connection for actuating the hydraulic cylinders 68 exists by means of the flexible hydraulic lines 70 , 72 . Of course, a path measuring system for the hydraulic cylinder 68 is also provided. This can be integrated within the hydraulic cylinder or arranged externally. Only a small installation space is required within the press frame 10 with a high application of force. The hydraulic cylinders 68 can be attached via their fixed part to the die plate 26 . Furthermore, the portrayed exemplary embodiment provides a common control apparatus (not shown) which is designed to control both the upper and lower electric drive units to drive the upper and lower punches along the main press axis, as well as to control the electric motors which are provided in the drive blocks 74 of the electro-hydrostatic drives. A uniform approach in terms of control engineering and safety engineering is accordingly realized.
[0032] The above examples and disclosure are intended to be illustrative and not exhaustive. These examples and description will suggest many variations and alternatives to one of ordinary skill in this art. All of these alternatives and variations are intended to be included within the scope of the claims, where the term “comprising” means “including, but not limited to”. Those familiar with the art may recognize other equivalents to the specific embodiments described herein which equivalents are also intended to be encompassed by the claims. Further, the particular features presented in the dependent claims can be combined with each other in other manners within the scope of the invention such that the invention should be recognized as also specifically directed to other embodiments having any other possible combination of the features of the dependent claims. For instance, for purposes of written description, any dependent claim which follows should be taken as alternatively written in a multiple dependent form from all claims which possess all antecedents referenced in such dependent claim. | The invention relates to a press for producing pellets from powdered material comprising at least one die with a mould cavity imaging the pellet, at least one upper punch and at least one lower punch that interact with the mould cavity to form the pellet, and at least one electric drive for driving the upper punch, and/or the lower punch, and/or the die along a main press axis, wherein the press also comprises at least one movable element acting on the die and/or the mould cavity of the die, wherein at least one electro-hydrostatic drive is provided to drive the at least one movable element. | 1 |
BACKGROUND OF THE INVENTION
The invention generally relates to methods for testing for the presence of imperfections in semiconductor specimens and, more particularly to a contactless method for measuring PN junction leakage.
DESCRIPTION OF THE PRIOR ART
Contactless methods for measuring the decay time of bulk semiconductor materials are known in the art. For example, the paper "Contactless Measurement of Resistivity of Slices of Semiconductor Materials" by Nobuo Miyamoto et al, Review of Scientific Instruments, Vol. 38, No. 3, March 1967, page 360, discloses a high frequency capacitively coupled technique whereas the paper "Simple Contactless Method for Measuring Decay Time of Photoconductivity in Silicon" by R. M. Lichtenstein et al, Review of Scientific Instruments, Vol. 38, No. 1, January 1967, page 133, deals with a high frequency inductively coupled technique. Both techniques monitor the amplitude of oscillation of a high frequency carrier which is capacitively or inductively coupled, respectively, to the semiconductor sample while the sample is irradiated with pulsed light. Each pulse of light excites electrical carriers which temporarily increase the loading on the high frequency oscillator and cause a corresponding temporary decrease in the amplitude of oscillations. When the light pulse terminates, the amplitude of oscillations returns to its steady state value at a rate determined by the carrier recombination rate of the irradiated sample.
A more complicated situation exists when one or more junctions are present in the sample under test. High frequency oscillations which are capacitively coupled into the irradiated PN junction-containing specimen are substantially uneffected by the presence of the junctions. That is, the presence of the junctions does not significantly change the loading on the capacitively coupled high frequency oscillator. On the other hand, an inductively coupled high frequency oscillator experiences significant change in loading due to the presence of junctions in the semiconductor specimen under test. However, if the intensity of the pulsed light irradiating the specimen is maintained at relatively high values, consistent with prior art intensity levels, the loading of the inductively coupled oscillator attributable to the leakage associated with the PN junctions is not accurately detectable.
SUMMARY OF THE INVENTION
PN junction leakage in a semiconductor specimen including large scale integration specimens is measured by inductively coupling high frequency oscillations to the specimen while the specimen is subjected to pulsed light of selected intensity. The capacitance of the junction or junctions in the sample is charged to an amount dependent on the intensity of the pulsed light. When each light pulse terminates, the junction capacitance discharges at a rate determined by the existing discharge path impedance.
Each junction can be equivalently represented by a leakage resistor and a rectifying diode connected in shunt across a junction capacitor. The impedance of the diode is small relative to the leakage impedance when the diode is conducting. The impedance of the diode is high relative to the leakage impedance when the diode is not conducting, i.e., when the forward voltage across the diode is insufficient to overcome the conduction threshold.
It has been found that when the intensity of the pulsed light irradiating the junction specimen is set at a value insufficient to charge the junction capacitance to an amount causing forward conduction of the junction diode, the discharge of the junction capacitance following the termination of the pulse light is determined substantially solely by the leakage impedance of the junction. Such a setting of the light intensity is achieved in accordance with the present invention by observing a decay time plot of the discharge of the junction capacitance and reducing the amplitude of the light pulse until the ratio of the initial slope of the decay time plot relative to the terminal slope of the decay time plot portion attributable to leakage discharge is less than about 2:1.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a simplified schematic circuit diagram of a preferred embodiment of the invention;
FIG. 2 is a cross-sectional view of a PN junction semiconductor specimen irradiated by pulsed light;
FIG. 3 is a representative superimposed series of decay time plots produced by the apparatus of FIG. 1;
FIG. 4 shows one of the plots of FIG. 3 in its entirety; .Iadd.and .Iaddend.
FIG. 5 is a plot showing the correlation of decay time data obtained in accordance with the present invention and premature junction breakdown data.Iadd.. .Iaddend..[.; and.].
.[.FIG. 6 is a summarized plot of FIG. 4..].
DESCRIPTION OF THE PREFERRED EMBODIMENT
Production yield in high density large scale integration transistor processing is adversely effected by the presence of crystallographic defects which create "pipes" or undesired pathways between collector and emitter along which impurities diffuse to produce collector to emitter leakage resistance. It is important that such crystallographic defects be detected at an early stage before completion of LSI transistor devices to minimize any production investment in unacceptable devices.
A semiconductor PN junction may be represented by the equivalent circuit consisting of three elements connected in parallel with each other, i.e., a capacitor representing junction capacitance, a diode representing the rectification properties of the junction, and a resistor representing the leakage resistance of the junction. It has been observed that there is a correlation between the existance of collector to emitter "pipes" and high junction leakage. The two effects are related to the same crystallographic defects. According to the present invention, junction leakage is used as a predictor of "pipes".
Referring to FIG. 1, a high density, large scale integrated semiconductor wafer 1 having PN junctions 2 is irradiated by a source of pulsed light 3. The intensity of light 3 is adjustable by control 4. High frequency oscillator 5, preferably operating at a frequency in the range from about 50 to about 200 megahertz, is inductively coupled to wafer 1 via tank coil 6. The resonant tank circuit is completed by capacitor 7. Coil 6 is center tapped to ground to minimize undesired stray noise pick-up in the coil. Oscillator 5 further comprises junction field effect transistor 8 which is coupled to the tank circuit by capacitors 9 and 10 and resistor 11. FET 8 is coupled to positive voltage terminal 12 by radio frequency choke 13 and high frequency bypass capacitor 14. FET 8 is connected to ground via unbypassed resistor 15 and a bias control comprising rheostat 16 and capacitor 17. Rheostat 16 is designated "sensitivity adjust" consistent with its function in optimizing the sensitivity of oscillator 5 to the loading effect of PN junction wafer 1 on the resonant tank circuit comprising coil 6 and capacitor 7.
The amplitude of the carrier oscillations produced by oscillator 5 is modulated upon the occurrence of pulse light from source 3. The amplitude modulated carrier, available at node 18, is coupled by resistor 19 and capacitor 20 to wide band inverting amplifier and detector 21. The detected signal is applied to scope 22 whose trace is synchronized by pulses from source 3 applied via line 23. A synchronizing pulse occurs on line 23 each time that light source 3 is pulsed.
Eddy currents are induced in wafer 1 by the inductively coupled oscillations from oscillator 5. The amplitude of oscillations of oscillator 5 is inversely related to the magnitude of the eddy current losses in wafer 1. The magnitude of the eddy current losses, in turn, is related to the amount of work done by the electric field associated with the induced eddy currents in moving charges through a distance in wafer 1.
Referring to FIG. 2, charges are induced adjacent junction 2 in wafer 1 each time that the wafer receives a pulse of light. The charges are distributed as indicated in FIG. 2 in a direction tending to forward bias the PN junction as is well understood. The photoinduced charges recombine after the termination of the light pulse at rates determined by the RC time constant of the available discharge path. The charges are stored by the junction capacitance whereas the discharge resistance is provided by the forward conduction resistance of the equivalent junction diode (if the stored charges are sufficient to forward bias the diode) and by the leakage impedance of the junction (if the stored charges are insufficient to forward bias the diode). In general, each light pulse charges the junction capacitance by an amount determined by the intensity of the light pulse and the junction capacitance discharges at a relatively fast initial rate if and so long as junction diode is biased into a forward conduction mode. Upon the cessation of the forward conduction of the equivalent junction diode, the residual charge on the equivalent junction capacitance continues to fall but at a significantly reduced rate. In accordance with the present invention, the intensity of the pulsed light is adjusted to induce an initial charging of the equivalent junction capacitance to a value just below the value required to forward bias the equivalent junction diode. As will be discussed later in connection with FIG. 3, such a setting of the intensity of the pulsed light provides a voltage time plot on scope 22 of FIG. 1 which represents substantially solely the leakage characteristic of the PN junctions 2 in wafer 1 which is desired to be measured.
Referring again to FIG. 2, it is necessary that the electric field impressed on wafer 1 by the inductively coupled oscillations from oscillator 5 be directed along a path which causes substantial movement of the negative and positive charges induced by the pulsed light. The work expended by moving the induced charges through a distance along the impressed electric field causes a loading effect on the oscillations from oscillator 5, i.e., the greater the distance of movement of the charges along the impressed electric field, the greater the loading of oscillator 5. The greater the loading of the oscillator, the more easily the recombination rate of the photoinduced charges can be seen above the electrical noise level, on the voltage decay time plot provided by scope 22.
It is believed that the loading effect is maximized in accordance with the present invention by the provision of circular electric fields such as field 24 of FIG. 2 associated with the induced eddy currents created by the inductively coupled oscillations from oscillator 5. Oscillating E-field 24 lies in a plane parallel to the major surfaces of wafer 1 and of junction 2. As a result of this parallel relationship, the positive and negative charges contiguous to junction 2 freely oscillate in opposite parallel directions. It is believed that the distance through which the negative and positive charges travel would be significantly reduced for a given magnitude of electric field if the electric field were of linear rather than circular direction as shown in FIG. 2. A linear electric field could be provided, for example, by a capacitively coupled oscillator in contrast to the inductively coupled oscillator depicted in FIG. 1. A linear electric field would tend to separate the negative and positive charges from each other. Such separation would be resisted with the result that the positive and negative charges actually would travel through relatively short distances and produce insignificant loading effect. In any event, it has been found experimentally that the sensitivity of an inductively coupled oscillator to the decay of the photoinduced charges following each light pulse is significantly greater than the sensitivity of a capacitively coupled oscillator to the same charge decay. It is particularly important to maximize loading sensitivity because reduced intensity of the pulse light is required for increasing the accuracy of the junction leakage measurement as will now be explained in connection with FIG. 3.
FIG. 3 is a representative superimposed series of individual traces produced on scope 22 of FIG. 1 for respective intensities of pulsed light irradiating wafer 1 as shown in FIG. 1. Each of the superimposed traces is characterized by a leading edge 25 which rises in response to the pulsed light to an amplitude directly related to the intensity of the pulsed light. Assuming for the sake of discussion that control 4 is adjusted to produce a relatively high intensity of the pulsed light, the junction capacitance is charged to a relatively high value to forward bias the junction diode. Upon the termination of the light pulse, the junction capacitance discharges at a relatively high initial rate determined by the relatively low forward conduction resistance of the junction diode. The initial relatively rapid discharge is represented by the steeply falling portion 26 of the trace on scope 22. When the discharge has proceeded to a point where the residual charge on the junction capacitance is insufficient to forward bias the junction diode, the remaining discharge proceeds at the relatively low decay rate represented by terminal portion 27 of the time plot. The term "terminal portion" is defined as those portions of the displayed decay time plots which occur at the time when the displayed plot having the highest initial amplitude 25 has decayed to about 20% of its initial amplitude. Said time is represented by dashed line 44.
Dashed line 28 is added to the decay time plots of FIG. 3 for reference purposes to designate the points at which the forward conduction of the effective junction diode ceases. It is to be noted that the slope of portion 26 of the decay time plot is determined primarily by the forward conducting junction diode and is of no interest to the present invention. Moreover, the presence of portion 26 detracts from the accuracy with which desired portion 27 can be measured. It is necessary to eliminate portion 26 in order to provide the best resolution of the portion which relates to the junction leakage characteristic to be measured.
The manner in which portion 26 is diminished in the voltage time plot displayed by scope 22 can be understood by reference to the remaining decay time traces depicted in FIG. 3. If control 4 is adjusted to decrease the intensity of the pulsed light source relative to the intensity producing trace portions 26 and 27, a second trace with lower initial amplitude is displayed having a rising edge portion conforming to trace portion 25 and a trailing edge having a relatively steeply falling initial portion 29 and a less steeply falling terminal portion 30. Similarly, a further reduction in the amplitude in the pulsed light produces a third trace having trailing edge portions 31 and 32. It will be noted that in each of the three traces just described, the intensity of the pulsed light is sufficient to charge the junction capacitance to an initial value overcoming the forward conduction threshold of the junction diode.
Of particular significance is the ratio of the slope of the initial portion of a given trace to the slope of the terminal portion of the same trace. Dotted line 33 represents the slope of the initial trace portion 31 while dotted line 34 represents the slope of the terminal trace portion 32 produced by the lowest of the three pulsed light intensities discussed above. The ratio of the slope represented by dashed line 33 to the slope represented by dashed line 34 is in excess of 20:1. A further reduction in the intensity of the pulsed light from source 3 produces decay time trace 35 whose initial slope is represented by dashed line 36 and whose terminal slope is represented by dashed line 37. In the case of trace 35, the intensity of the pulsed light is insufficient to charge the junction capacitance to a value overcoming the forward conduction threshold of the junction diode. Accordingly, there is no abruptly falling portion of the decay trace attributable to the low discharge resistance presented by a forward conducting diode. Rather, the entire discharge of the charged junction capacitance is through the leakage resistance of the junction which discharge proceeds at the relatively low initial rate represented by dashed line 36 and at the even lower terminal rate represented by dashed line 37.
Further reduction in the amplitude of the pulsed light produces trace 38 which, like trace 35, decays at a very low rate determined by the junction leakage characteristic. Although trace 38 is as accurate as trace 35 in its depiction of the junction leakage characteristic, trace 38 is less desirable than trace 35 inasmuch as trace 38 is of reduced amplitude and more difficult to observe when extraneous noise signals are present in the signal applied to scope 22 by wide band amplifier and detector 21 of FIG. 1. In general, any trace having a ratio of initial slope to terminal slope less than about 2:1 has been found to be useful. The ratio of initial slope represented by dashed line 36 to terminal slope represented by dashed line 37 is about 2:1. Accordingly, in the operation of the apparatus represented in FIG. 1, intensity control 4 is adjusted until there is observed on the face of scope 22 a decay time trace similar to trace 35 where the ratio of the initial slope to the terminal slope is no greater than about 2:1. Preferably, the intensity control is adjusted to produce the maximum pulsed light intensity meeting the aforementioned slope ratio criterion. A sizing of junction leakage then can be obtained making a standard lifetime measurement on the displayed trace, i.e., measuring the elapsed time for the trace to decay to 37 1/2% of its initial value. Such a measurement is facilitated by increasing the vertical gain setting and decreasing the sweep rate setting of scope 22 so that the entirety of the displayed trace can be readily observed as depicted in FIG. 4. The curve of FIG. 4 corresponds to curve 35 of FIG. 3.
Semiconductor wafers having junctions exhibiting unacceptably high leakage are easily recognized in the practice of the present invention in that they will not exhibit the characteristic abrupt reduction (possessed by low leakage wafers) in the initial slope of the decay trace such as may be seen by comparing the slopes of dashed lines 33 and 36 which occurs as the intensity of the pulsed light is reduced through a value which no longer causes the forward conduction of the junction diode.
Experimental evidence has been obtained showing good correlation between junction leakages measured by the decay time trace technique of the present invention and premature junction breakdown voltage measurements on a sampling of .[.258.]. .Iadd.28 .Iaddend.wafers containing PN junctions. Each wafer was subjected to a junction breakdown voltage test and to the decay time trace test of the present invention. Each dot in the plot of FIG. 5 represents the breakdown voltage observed on a given wafer and the time designated "lifetime" for the decay trace obtained from the same wafer to fall to 37 1/2% of its initial (peak) amplitude following the cessation of a light pulse. .[.The experimental results of FIG. 5 can be more easily appreciated by reference to the plot of FIG. 6 which summarizes the data represented in FIG. 5..].
.[.Each point represented by an X in FIG. 6 represents the average value of the points of FIG. 5 surrounding a respective "lifetime" value. For example, the 10 points plotted around the "lifetime" value of 100 microseconds are averaged and plotted on FIG. 6 as point 40. Similarly, the median value of the same ten dots of FIG. 5 are represented by the single circle 41 of FIG. 6. The other points on FIG. 6 are plotted in a similar manner. In the case of point 42 and 43, the median and average values coincide. The number of samples represented by each of the points on FIG. 6 is shown below the respective "lifetime" value. Measurements on a total of 258 wafers are represented in the plots of FIGS. 5 and 6..]. The plotted data shows that the junction leakage measurement provided in accordance with the present invention correlates well with premature junction breakdown voltage, the latter of which is recognized in the art as an indicator of "pipe" defects in transistor wafers.
It will be observed that the technique of the present invention averages the junction leakage behavior of all junctions on a given LSI wafer without requiring any physical contact to the wafer. The non-destructive test nature of the technique allows its use on product wafers at many different times during their fabrication as desired.
While the invention has been particularly shown and described with reference to the preferred embodiment thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention. | An inductively coupled oscillator method for inducing eddy currents in a semiconductor PN junction wafer while irradiating said wafer with pulsed light of selected intensity. The oscillator loading due to the pulsed light modulated eddy current losses is monitored and displayed on an oscilloscope in the form of a decay time plot of voltage amplitude, the plot being a function of the pulsed light intensity and the recombination rate of light-induced electrons and holes on each side of the junctions. The leakage characteristics of the junctions which are desired to be measured are one of the factors determining said rate. Leakage characteristic is made the predominent factor by setting the intensity of the pulsed light to a value which produces a nearly straight line decay time plot on the oscilloscope display. The slope of the line then is a measure of the leakage characteristic. | 6 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 13/267,379 filed Oct. 6, 2011 which claims the benefit of priority for prior Provisional Patent Application No. 61/501,131, filed on Jun. 24, 2011, the entire contents of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] Embodiments of the invention relate to services provided to consumers and operators of wireless networks.
BACKGROUND
[0003] The continued evolution of wireless network technology allows consumers today to communicate with each other by voice, data and text messaging through highly sophisticated network architectures. A consumer can make a phone call, download data and send text messages using a single wireless communication device, such as a smartphone. Typically, a consumer would purchase a plan from a network operator and be constrained by the rules defined in the plan for the duration of the plan period. For example, if the plan's policy does not allow roaming outside of a predetermined region, the consumer would be unable to make any calls from his smartphone once he leaves that region. The consumer may be unaware of the cause of the problem, and cannot easily find help at a time when he cannot make phone calls. As another example, if the plan has a set quota for data usage and the consumer has reached a predetermined threshold (e.g., 90%) of that quota before the end of a billing cycle, the consumer's future data traffic can be throttled (e.g., the Quality of Service (QoS) is lowered) until the next billing cycle starts. With the conventional operator's system, a consumer cannot easily monitor his data usage and cannot easily request his QoS be maintained at the same level throughout a billing cycle. Thus, the conventional operator's system for managing usage, offers, pricing and policy is inflexible and cannot easily adapt to consumers' needs.
BRIEF DESCRIPTION OF THE DRAWINGS
[0004] The present invention is illustrated by way of example and not limitation in the figures of the accompanying drawings, in which like references indicate similar elements and in which:
[0005] FIG. 1 is a diagram of one embodiment of network architecture in which a Core Service Platform (CSP) system may operate.
[0006] FIG. 2 is a diagram of one embodiment of a deployment model for a CSP system.
[0007] FIG. 3 is a diagram of one embodiment of a mobile communication device.
[0008] FIG. 4 is a diagram of one embodiment of a computer system.
[0009] FIG. 5 is an overview of CSP system integration according to one embodiment of the invention.
[0010] FIG. 6 is an overview with further details of CSP system integration according to one embodiment of the invention.
[0011] FIG. 7 is an embodiment of integration between a CSP system and an operator network.
[0012] FIG. 8 is an embodiment of network signal flow.
[0013] FIG. 9 is another embodiment of network signal flow.
[0014] FIG. 10 is an embodiment of integration between a CSP system and a wireless communication device.
[0015] FIG. 11 is an embodiment of a display screen of a CSP device application (CDA) that shows a “My Account” feature.
[0016] FIG. 12 is an embodiment of a display screen of a CDA that shows a “Tell a Friend” feature.
[0017] FIG. 13 is an embodiment of a display screen of a CDA that shows a “Diagnostic Help” feature.
[0018] FIG. 14 is an embodiment of a display screen of a CDA that shows a “Contextual Help” feature.
[0019] FIG. 15A is an embodiment of a display screen of a CDA that shows a “Usage Alert” feature.
[0020] FIG. 15B is an embodiment of a display screen of a CSP device application that shows a “Roaming Alert” feature.
[0021] FIG. 16 is an embodiment of a display screen of CSP operator Web applications.
[0022] FIG. 17 is an embodiment of Custom Relationship Management (CRM) integration.
[0023] FIG. 18 is an embodiment of a process for publishing offer/policy from a CSP system to an operator.
[0024] FIG. 19 is an embodiment of provisioning/order entry integration.
[0025] FIG. 20 is an embodiment of a process for provisioning/order entry integration.
[0026] FIG. 21 is an embodiment of billing integration.
[0027] FIG. 22 is an embodiment of reporting integration.
DETAILED DESCRIPTION
[0028] In the following description, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known circuits, structures and techniques have not been shown in detail in order not to obscure the understanding of this description. It will be appreciated, however, by one skilled in the art, that the invention may be practiced without such specific details. Those of ordinary skill in the art, with the included descriptions, will be able to implement appropriate functionality without undue experimentation.
[0029] FIG. 1 is a block diagram illustrating an embodiment of a network system. In the embodiment shown, a cellular device 100 communicates with an operator network 110 through a base station 102 and a base station controller 104 . Cellular device 100 can be a cellular telephone, a smartphone with data transfer and messaging capability, a tablet computer, a personal digital assistant (PDA), a video-camera, a gaming device, a global positioning system (GPS), an e-Reader, a Machine-to-Machine (M2M) device (i.e., an application-specific telemetry device that collects data using sensors and transmits the data to a destination such as a server over a network), a hybrid device with a combination of any of the above functionalities, or any other wireless mobile devices capable of sending and receiving voice, data and text messages. Cellular device 100 communicates with operator network 110 using wireless protocols, such as Bluetooth, IEEE 802.11-based wireless protocols (such as Wi-Fi), and the like. Cellular device 100 is used by a consumer (equivalently, a subscriber or a user). Operator network 110 is a wireless cellular network that includes a voice network (e.g., a global system for mobile communications (GSM) network), a data network (e.g., a general packet radio service (GPRS) network), and a messaging network (e.g., a short message service (SMS) network). It is understood that operator network 110 can include voice, data and messaging networks that are different from the GSM network, GPRS network and SMS network. In the embodiment shown, the voice network is represented by a network switching subsystem 106 , the data network is represented by a Serving GPRS Support Node (SGSN) 127 , a Gateway GPRS Support Node (GGSN) 107 , and the messaging network is represented by a messaging gateway 108 . It is understood that operator network 110 includes various other network components, which are omitted herein for simplicity of illustration. Operator network 110 allows a user of cellular device 100 to engage in voice, data and messaging communications with devices coupled to operator network 110 through external networks (not shown).
[0030] In one embodiment, base station 102 includes a radio transmitter and receiver for communicating with cellular devices (e.g., cellular device 100 ), and a communications system for communicating with base station controller 104 . Base station controller 104 controls base station 102 and enables communication with operator network 110 . In various embodiments, base station controller 104 can control any number of base stations.
[0031] Network switching subsystem 106 controls voice network switching, maintains a register of cellular device locations, and connects operator network 110 with an external voice network, such as a public switched telephone network, a private voice telephony network, or any other appropriate voice telephony network. In one embodiment, network switching subsystem 106 includes a mobile switching center (MSC) 111 , a home location register (HLR) 113 , and a visitor location register (VLR) 114 . MSC 111 controls, sets up and releases a voice connection using signaling protocols such as signaling system No. 7 (SS7). In some embodiments, MSC 111 additionally tracks the time of a voice connection for the purposes of charging cellular devices, decrementing available usage, tracking monetary balance, monitoring battery status, and other purposes. In one embodiment, operator network 110 may include any number of MSCs. Each of these MSCs serves cellular devices within a network area, which may include one or more base stations and one or more base station controllers. Some of the cellular devices may be registered to use this network area as their “home network,” and some of the other cellular devices may be registered to use other network areas as their home networks. HLR 113 maintains a list of cellular devices whose home network is served by MSC 111 . VLR 114 maintains a list of cellular devices that have roamed into the area served by MSC 111 . When a cellular device leaves its home network (e.g., the network area served by MSC 111 ), the VLR (“target VLR”) of the network (“target network”) to which the device has roamed communicates with HLR 113 in the home network of the device. When HLR 113 has confirmed to the target VLR that it can allow the device to use the target network, the device is added to the target VLR, and the MSC in the target network sets up the communication for the roaming cellular device.
[0032] SGSN 127 and GGSN 102 are two of the main components in the core data network of operator network 110 . SGSN 127 is responsible for the delivery of data packets from and to the cellular devices within its geographical service area. The tasks of SGSN 127 include packet routing and transfer, mobility management (attach/detach and location management), logical link management, authentication and charging functions. GGSN 107 controls data communications switching and connects operator network 110 with an external data network, such as a local area network, a wide area network, a wired network, a wireless network, the Internet, a fiber network, a storage area network, or any other appropriate networks. In some embodiments, GGSN 107 is one of the core components in the core data network of operator network 110 . Although not shown in FIG. 1 , the core data network of operator network 110 may also include various other network switching components. GGSN 107 serves as an interface between operator network 110 and external data networks, and translates data packets into the appropriate formats for the devices on each side. In the embodiment shown, GGSN 107 also performs policy and charging enforcement and control via the functionalities of: Policy and Charging Enforcement Function (PCEF) 122 , Policy and Charging Rules Function (PCRF) 123 and Online Charging System (OCS) 124 . PCRF 123 performs policy control and flow-based charging control. To that end, PCRF 123 authorizes Quality of Service (QoS) resources and operations, e.g., service redirection and other policy-based actions. Ultimately, PCRF 123 resembles a collection controller in that it collects the subscriber's subscription data and allows PCEF 122 to enforce the policies and the charging. OCS 124 facilitates the online charging process by collecting charging information about network resource usage concurrently with that resource usage. OCS 124 also approves authorization for the network resource usage prior to the actual commencement of that usage. The approval may be limited in terms of data volume or in terms of duration. PCEF 122 performs policy enforcement, service data flow detection, and flow-based charging functionalities. The policy control indicated by the PCRF 123 is enforced by PCEF 122 . To that end, the PCEF 122 will permit the service data flow to pass through PCEF 122 only if there is a corresponding active Policy and Charging Control (PCC) rule and if OCS 124 has authorized credit for the charging key used for online charging. Ultimately, PCEF 122 ensures that service is provided with the appropriate QoS and that the subscriber is charged in accordance with the charging rate set for the subscriber.
[0033] Messaging gateway 108 provides short messages transit between cellular devices and other communication devices. Messaging gateway 108 can be a Short Message Service Center (SMSC), a multi-media messaging center (MMSC), or a network node coupled to the SMSC or MMSC. Messaging gateway 108 delivers text messages through operator network 110 to/from external networks via standard protocols such as Short Message Peer-to-Peer Protocol (SMPP) or Universal Computer Protocol (UCP).
[0034] In some embodiments, operator network 110 is coupled to a hosted service platform 120 via a Core Service Platform (CSP) network 170 and a number of network nodes. Hosted service platform 120 serves as a service management platform for wireless communication devices such as cellular device 100 . Hosted service platform 120 may include multiple data centers in multiple geographical locations with each data center including multiple server computers. Hosted service platform 120 includes a number of CSP engines 122 that provide a suite of functions to automate both the sales and support processes towards wireless users. Hosted service platform and CSP network 170 , as well as software hosted thereon, form a CSP system. An overview of the CSP system will be described below in connection with FIGS. 5 and 6 .
[0035] CSP network 170 provides connections between the data centers in the hosted service platform 120 and operator network 110 . In one embodiment, CSP network 170 includes a GGSN 171 that implements PCRF 173 and OCS 174 . Depending on the agreements between the operator/owner of operator network 110 and operator/owner of CSP network 170 , both sets of (PCRF 123 , OCS 124 ) and (PCRF 173 , OCS 174 ) can be active at the same time or at different stages of service deployment. In some alternative embodiments, CSP network 170 does not implement PCRF 173 and OCS 174 . Instead, host service platform 120 collects subscription data, policy and charging information from operator network 110 .
[0036] The network nodes between operator network 110 and CSP network 170 are represented in FIG. 1 as operator network node 130 , network node A 131 and network node B 132 . These network nodes ( 130 , 131 and 132 ) can include switches, routers, bridges, and other network components. There can be any number of network nodes between operator network 110 and CSP network 170 . In the embodiment shown, operator network node 130 communicates with network node A 131 via an integrated connection, while it communicates with network node B 132 via three separate connections for voice, data and text messaging.
[0037] In some embodiments, an operator IT system 150 is coupled to operator network 110 via operator network node 130 . Operator IT system 150 receives subscribers' data and usage from operator network 110 , and provides the functions of Customer Relationship Management (CRM)/care, provisioning/order entry, billing/mediation (or payments), and reporting/data warehouse (DWH) (or business intelligence). Operator IT system 150 also provides a user interface (such as a desktop interface or a Web interface) for a system administrator to monitor and manage these functions. In one embodiment, operator IT system 150 includes a control center that hosts CSP operator Web applications 154 . CSP operator Web applications 154 allow an operator to manage its marketing campaign, offers (equivalently, rate plans), pricing, billing and customer care in an integrated environment. Functionality of CSP operator Web applications 154 will be described later in further detail with reference to FIG. 16 .
[0038] In some embodiments, cellular device 100 stores and runs CSP device application (CDA) 140 . CDA 140 displays alerts and notifications to consumers in response to the consumers' current usage and condition, provides customized contextual offers in real time, and allows consumers to select and purchase wireless products and services from their devices. Moreover, using CDA 140 , consumers can diagnose and solve their own service questions and problems directly from their wireless device. For example, CDA 140 can query multiple sources, including cellular device 100 itself, to perform a diagnosis. Functionality of CDA 140 will be described later in further detail with an example shown in FIGS. 10-15 .
[0039] FIG. 2 is a diagram illustrating an embodiment of a deployment model for the CSP data centers. The CSP data centers can be a cloud-based computing system. In the embodiment shown, two data centers ( 220 and 230 ) are coupled to operator Internet Protocol (IP) network 210 via CSP network 170 and a number of network nodes (e.g., routers). Data centers 220 and 230 are part of hosted service platform 120 of FIG. 1 . Data centers 220 and 230 can be deployed at different locations and each center includes multiple server computers. Some of the server computers can serve as Web servers providing resources that can be accessed by the operator and subscribers. Data centers 220 and 230 can be synchronized in real time, and either data center can carry the full service demand. In one embodiment, dynamic IP routing is established (e.g., Border Gateway Protocol (BGP)) between operator IP network 210 and data centers 220 and 230 , such that failure of one path will allow for automatic routing via the alternative path.
[0040] It is understood that hosted service platform 120 of FIG. 1 can include any number of data centers in any geographical locations. Operator IP network 210 can be part of the data network of operator network 110 of FIG. 1 . In the embodiment shown, operator IP network 210 interconnects GGSN 107 , messaging gateway 108 and the systems of CRM, provisioning/order entry, billing/mediation, and data warehouse (DWH) in operator IT system 150 of FIG. 1 . In one embodiment, operator IP network 210 and CSP network 170 exchange provisioning/order entry data, charging data records (CDRs), reports via standard 3 rd Generation Partnership Product (3GPP) interfaces (Gx, Gy).
[0041] FIG. 3 is a block diagram illustrating an embodiment of a wireless communication device 300 (e.g., cellular device 100 of FIG. 1 ). In one embodiment, wireless communication device 300 is a smartphone. In alternative embodiments, wireless communication device 300 can be a cellular telephone, a tablet computer, a personal digital assistant (PDA), a video-camera, a gaming device, a global positioning system (GPS), an e-Reader, a Machine-to-Machine (M2M) device (i.e., an application-specific telemetry device that collects data using sensors and transmits the data to a destination such as a server over a network), a hybrid device with a combination of any of the above functionalities, or any other wireless mobile devices capable of sending and receiving voice, data and text messages. In the embodiment shown, wireless communication device 300 includes a radio transmitter 302 , a radio receiver 304 , a processor 306 , memory 310 , a subscriber identity module (SIM) 312 , and a display 314 . In some embodiments, SIM 312 is optional and the inclusion of SIM 312 is dependent on the network technology in use. Radio transmitter 302 and radio receiver 304 communicate with a base station (e.g., base station 102 of FIG. 1 ) using wireless radio communication protocols. In some embodiments, radio transmitter 302 and/or radio receiver 304 communicate voice signals, data signals, text signals (e.g., SMS), configuration and/or registration signals, or any other appropriate kinds of signals. Processor 306 executes instructions stored in memory 310 to control and perform the operations of wireless communication device 300 . In some embodiments, memory 310 includes one or more of the following: read-only memory (ROM), flash memory, dynamic random access memory (DRAM), static memory and data storage device. Memory 310 can act as temporary and/or long-term information storage for processor 306 . In one embodiment, memory 310 stores CDA 140 . In one embodiment, display 314 can serve as a graphical user interface (GUI) that displays images and data, such as the screen displays of CDA 140 . The displayed images and data can be retrieved from memory 310 or other local storage, or can be received through radio receiver 304 from a Web server (e.g., the Web servers in the CSP data centers).
[0042] In one embodiment, SIM 312 is a removable module storing an identifying number for wireless communication device 300 to identify the device to the network. In various embodiments, SIM 312 stores an International Mobile Subscriber Identity (IMSI) number, an Integrated Circuit Card Identifier (ICCID) number, a serial number, or any other appropriate identifying number.
[0043] FIG. 4 is a block diagram illustrating an embodiment of a computer system 400 . In one embodiment, computer system 400 can be a server computer within hosted service platform 120 of FIG. 1 . In another embodiment, computer system 400 can be a server computer within operator IT system 150 of FIG. 1 . It is understood that hosted service platform 120 and operator IT system 150 can include any number of server computers. In the embodiment shown, computer system 400 includes a processor 412 , memory 410 , an I/O device 404 , a network interface 402 , a display 414 and a bus 408 . In one embodiment, display 414 can serve as a graphical user interface (GUI) that displays graphics and data to an operator. Some of the displayed graphics and data can be retrieved from memory 410 or other local storage, or received through network interface 402 from a Web server. Processor 412 represents one or more general-purpose processing devices. Memory 410 includes one or more of the following: read-only memory (ROM), flash memory, dynamic random access memory (DRAM), static memory and data storage device. Network interface 402 communicates with an external data network. In an embodiment where computer system 400 is a server computer within hosted service platform 120 of FIG. 1 , memory 410 stores software implementing one or more of the functions of CSP engines 122 , PCRF 173 and/or OCS 174 . In another embodiment where computer system 400 is a server computer within operator IT system 150 of FIG. 1 , memory 310 stores software implementing one or more of the functions of CSP operator web applications 154 .
[0044] FIG. 5 is a block diagram illustrating an overview of CSP system integration according to one embodiment of the invention. FIG. 6 illustrates further details of CSP system integration according to one embodiment of the invention. In the following description, the term “CSP system” 530 refers to the software and hardware infrastructure that manages a suite of services provided to network operators and their subscribers. Thus, referring also to the embodiment shown in FIG. 1 , CSP system 530 includes hosted service platform 120 , CSP network 170 , and the software hosted thereon. CSP system 530 interacts with operator network 110 , operator IT system 150 , and cellular device 100 in real time. In some embodiments, CSP system 530 can also interact with operator network 110 , operator IT system 150 , and cellular device 100 in batch mode. In one embodiment, CSP system 530 is a smartphone service management platform. Through CDA 140 and CSP operator Web applications 154 , CSP system 530 provides or enables the functions of on-device application, self-care, diagnostics, store-front, alert management, policy control, payment handling, offer management, campaign management, analytics, reporting engine, and data rating.
[0045] Referring to FIG. 6 , CSP system 530 provides customized contextual offers based on contextual assessments of a consumer's current “context.” Such “context” includes, but is not limited to, time in contract, loyalty status, data and voice usage, value (or valuation) of customer, time (of a latest data request), location (of a latest data request) and purchase history. The contextual assessments can be made by CSP engines 122 , which run on hosted service platform 120 of FIG. 1 and perform the functions that include, but are not limited to, customer profiling, micro-segmentation, real-time rating and policy, real-time alerts and offers, and targeted recommendations for offers and promotions. CSP system 530 is able to not only identify who the consumer is, but also the consumer's current context, in order to make the right offers at the right time. CSP system 530 formulates offers that the consumer is most likely to purchase and that are most valuable to the operator. The consumer can choose one of the offers and make the purchase from his device at the moment he most likely needs it to maintain his usage level. For example, if the consumer is in the middle of downloading a video to his smartphone and his data usage limit or threshold is reached, he can receive an alert on his smartphone with offers to add more megabytes of data to extend his usage limit. In one scenario where the consumer's usage limit or threshold has not been reached, he can also receive an offer to add more megabytes of data to improve the download speed. The consumer can make the purchase from this smartphone and continue the downloading with no or little noticeable interruption. In one embodiment, the offers can include top-up offers or plan changes, which add more megabytes of data or more usage time to a consumer's existing plan for the current billing cycle, or upgrades, which change the consumer's existing plan to a new plan that is not limited to the current billing cycle.
[0046] Consumers experience CSP system 530 through CDA 140 on their wireless communication devices. CDA 140 provides consumer-side functions that include, but are not limited to: storefront, payment, offers and alerts, self-support, account status, and device diagnostics. Operators experience CSP system 530 through CSP operator Web applications 154 . CSP operator Web applications 154 provide operator-side functions that include, but are not limited to: offer and policy management, campaign and alert management, business and eligibility rules management, product catalog, customer relationship management, merchandising and content management, campaign analytics, retail store activation, customer care application, and reporting. For the operator, this CSP experience translates to the following three main benefits: (1) CSP system 530 provides a retail store on every wireless communication device, thereby increasing Average Revenue per User (ARPU) through real-time contextual selling; (2) CSP system 530 drives support cost towards zero by providing a self-support experience for consumers; and (3) CSP system 530 drives cost of sales towards zero using dedicated on-device channels.
[0047] In order to provide these benefits and reduce time to market, CSP system 530 integrates with four functions of operator IT system 150 . The four functions are: CRM/care 610 , provisioning/order entry 620 , billing/payments 630 and reporting/DWH 640 . CSP system 530 also integrates with two functions of operator network 110 . The two functions are GGSN 107 /PCEF 122 (which represents PCEF 122 implemented by GGSN 107 ) and Messaging Gateway 108 .
[0048] The integration with operator network 110 will be described below with reference to FIGS. 7-9 . The integration with wireless communication devices (e.g., cellular device 100 ) will be described below with reference to FIGS. 10-15 . Finally, the integration with operator IT system 150 will be described below with reference to FIGS. 16-22 .
CSP—Network Integration
[0049] As shown in the embodiment of FIG. 6 , the integration with operator network 110 enables the ability of CSP system 530 to have real-time visibility of usage and take real-time actions. The two network functions with which CSP system 530 integrates are GGSN 107 /PCEF 122 and messaging gateway 108 .
[0050] The network integration enables fast time to market without compromising network integrity or service quality. In one embodiment, the integration is achieved through the use of standard 3GPP interfaces (Gx, Gy) and standard Short Message Peer-to-Peer (SMPP) interface.
[0051] FIG. 7 illustrates an embodiment of the interfaces between operator network 110 and PCRF/OCS 710 . As described above in connection with FIG. 1 , PCRF/OCS 710 may reside within CSP network 170 (e.g., PCRF 173 and OCS 174 ), within operator network 110 (e.g., PCRF 123 and OCS 124 ), or both. In the embodiment of FIG. 7 , it is shown that PCRF/OCS 710 resides outside of operator network 110 (that is, within CSP network 170 ). However, if PCRF/OCS 710 resides within operator network 110 , CSP network 170 can receive relevant information from operator network 110 in real time or near real time. The CSP functions, as described before in connection with FIGS. 5 and 6 , can be embedded within PCRF/OCS 710 . Thus, it is understood that the exact location of PCRF/OCS 710 is not germane to the disclosure herein.
[0052] Referring to FIG. 7 , a standard interface exists between messaging gateway 108 and PCRF/OCS 710 . Message gateway 108 can be a SMS gateway or a Short Message Service Center (SMSC). This interface to messaging gateway 108 can be a standard SMPP interface. This interface allows the system to deliver alerts or notifications to CDA 140 of FIG. 6 and user via SMS.
[0053] The (Gx, Gy) interfaces are defined in accordance with the Diameter protocol. The (Gx, Gy) interfaces are situated between GGSN 107 /PCEF 122 and PCRF/OCS 710 . More specifically, the Gx interface is between PCEF 122 and PCRF for policy, QoS control and redirection. The Gy interface is between PCEF 122 and OCS for real-time usage control and online data charging.
[0054] The following describes a number of scenarios that illustrate the possible use cases in a network system with integrated operator network and CSP functions. Some of these use cases can be combined.
[0055] Case 1: Metering subscriber traffic with no overage allowed and no redirect to portal. In this scenario, a subscriber is assigned a monthly quota of X MB and a threshold is set at Y %. A notification is sent to the subscriber when the subscriber exceeds the usage threshold of Y %. No subsequent session is allowed. Quota is reset at the end of the billing cycle.
[0056] Case 2: Metering subscriber traffic with redirect to offer portal. In this scenario, a subscriber is assigned a static monthly quota of X MB and a threshold is set at Y %. A notification is sent to the subscriber when the subscriber exceeds the usage threshold of Y %. When the subscriber reaches 100% of the monthly quota, the subscriber session is redirected to a portal with specific offers. The subscriber selects a top-up offer and is allowed to continue passing traffic.
[0057] Case 3: Policy to throttle traffic at the end of usage quota. In one scenario, the subscriber can have unlimited usage at a lower speed with a monthly quota at a higher speed. After the monthly quota is consumed, the subscriber's data traffic is reduced (throttled) to the lower speed. In another scenario, a subscriber is assigned a static monthly quota of X MB and a threshold is set at Y %. A notification is sent to the subscriber when the subscriber exceeds the usage threshold of Y %. When the usage reaches 90% (or any configurable percentage) of the monthly quota, the subscriber's data traffic is reduced (throttled) to an externally specified speed (e.g., a speed specified by the operator of the network). When the subscriber reaches 100% of the monthly quota, the subscriber session is redirected to a portal with specific offers. The subscriber can select a top-up offer and be allowed to continue passing traffic at the original Quality of Service (QoS). The subscriber can also pay for a higher speed (e.g., “throttle up”) if the subscriber is accessing a selected service (e.g., an online video) or wants more bandwidth to download a specified song or other type of file.
[0058] Case 4: Day pass. In this scenario, a subscriber is assigned a fixed duration pass. The subscriber maintains its session until expiration of the time quota, at which point the subscriber session gets disconnected. The subscriber is subsequently not able to reconnect until a new pass is purchased.
[0059] Case 5: Usage control around user data volume. In this scenario, a subscriber is assigned a static monthly quota of X MB and a threshold is set at Y %. The subscriber is also restricted to use no more than Z MB of data in a 30-minute sliding window. The subscriber is redirected to a portal if data volume exceeds this restriction. Redirect in this case is one-time only. If the subscriber declines a top-up offer, then the subscriber is reduced (throttled) to an externally specified speed (e.g., a speed specified by the operator of the network) until the 30-minute sliding window is over. (Note that the QoS restrictions are settable.)
[0060] Case 6: Usage restricted to specific Public Land Mobile Networks (PLMNs). This can be combined with other use cases. In this scenario, a subscriber is only allowed to use specific PLMNs. At some point, the subscriber leaves the allowed networks and camps on another network. The subscriber attempts to setup Packet Data Protocol (PDP) context and is blocked by PCRF. Notification is sent to subscriber to offer a targeted roaming package.
[0061] Case 7: Changed QoS on Radio Access Technology (RAT) Change. This use case assumes that the subscribers are allowed (whether as part of the plan or by explicit purchase) to have a specific QoS based on how they are connecting to the network. In one scenario, a subscriber has no QoS restrictions on the 3G network. At some point, the subscriber goes into an EDGE network. Subscriber gets reduced QoS while on the EDGE network. The subscriber is provided with unrestricted speed upon returning to the 3G network. This use case may be combined with other use cases.
[0062] Case 8: Subscriber has no quota limit within home network but has a 100 MB quota while roaming (redirect at end of roaming quota). In this scenario, a subscriber has no set quota while on the home network. The subscriber has a 100 MB quota for roaming. When the subscriber enters a roaming network, a notification update is sent to the subscriber to advise roaming usage. At some point, the subscriber exceeds roaming usage threshold (e.g. 90% of quota). A notification update is sent to the subscriber indicating that roaming limit has been reached. When the subscriber reaches 100% of the roaming quota, the subscriber session is redirected to a portal for additional roaming top-up offers. This use case can be extended to a scenario in which a local area is covered by a group of cellular sites (cells). When a subscriber moves from one cell to another, he is not roaming (switching between networks) but travelling (going to discrete areas in the same network). In one scenario, the subscriber has no set quota while in the home cell, but has a set quota for travelling to other cells.
[0063] Case 9: Detect a subscriber's access to a selected (type of) website or service. In this scenario, through the use of Deep Packet Inspection (DPI), the subscriber's access to a selected (type of) website or service can be detected. The subscriber needs to pay for the access to the selected (type of) website or service. This scenario is similar to another scenario where subscribers would be redirected if they go to a web site or location not explicitly allowed and they need to pay for the access.
[0064] Integration with GGSN/PCEF. FIG. 8 illustrates an example of a signal flow for a use case in which a subscriber is throttled when his quota has been consumed. The signal flow between the GGSN/PCEF and PCRF, as well as between GGSN/PCEF and OCS (or its equivalent), are in accordance with the Diameter protocol. The Diameter protocol is an authentication, authorization and account protocol. The Diameter protocol defines a number of commands, such as capability exchange request (CER), capability exchange answer (CEA), device watchdog request (DWR), device watchdog answer (DWA), credit control request (CCR), credit control answer (CCA), etc. These commands are exchanged between the GGSN/PCEF and PCRF, as well as between GGSN/PCEF and OCS, to communicate policy decision, consumed quota, threshold limit reached, change of policy decision and change of QoS. FIG. 8 shows that when a threshold quota is reached, the OCS issues a notification ( 810 ), and when the quota is consumed, the PCRF makes the policy decision to lower the QoS ( 820 ). The GGSN/PCEF applies the policy decision ( 830 ), which lowers the QoS of the user data traffic ( 840 ). The signal flow of FIG. 8 does not show all of the Diameter parameter details for simplicity of illustration.
[0065] FIG. 9 illustrates an example of a signal flow for a use case in which a subscriber is redirected to a top-up page when his quota has been consumed. FIG. 9 shows that when a threshold quota is reached, the OCS issues a notification ( 910 ). When the quota is consumed, the PCRF makes the policy decision to redirect the subscriber to a top-up page ( 920 ), and the GGSN/PCEF redirects the subscriber to the top-up page ( 930 ), and the user data traffic continues to flow ( 940 ). The signal flow of FIG. 9 does not show all of the Diameter parameter details for simplicity of illustration.
[0066] Because the various Diameter interfaces above have many options, the integration with one GGSN vendor may not be the same as the integration with another. For each make and model of GGSN and Packet Data Network Gateway (PGW), specific GGSN templates can be used. These specific templates include only the parameters and settings that have been proven against the corresponding make and model of GGSN. In terms of Diameter interfaces, only the Access Point Names (APNs) (i.e., the network addresses used to identify one or more GGSNs) that have been proven for the PCRF/OCS and the particular GGSN are used.
[0067] The CSP-integrated PCRF and OCS include an upwards-facing API (also referred to as northbound-facing) and Java Message Service (JMS) queue. These are used for passing usage information and event information to the higher layers of CSP system 530 ( FIG. 6 ) and for issuing instructions from higher layers towards the PCRF and OCS. For example, a PCRF or equivalent instructs the GGSN/PCEF as to the QoS to be applied for a subscriber and the usage to be allowed. When the user has consumed a specific threshold, OCS or equivalent notifies the PCRF or equivalent, which in turn queries the recommendation engine to determine a recommendation to present in a notification and offer to the subscriber. If the user reaches 100% of his allocated quota, then OCS informs the policy and rating engine, which instructs the GGSN/PCEF to change the QoS to throttle the user.
[0068] The use of CSP-integrated PCRF and OCS allows for fast time to market and retains the full value proposition of the CSP solution. However, the higher-layer functions of CSP can integrate with any PCRF and OCS (e.g., an operator's own PCRF and OCS) that can provide the required interfaces for notification and control of the PCRF and OCS functions themselves.
[0069] As the PCRF and OCS may be tightly integrated with CSP system 530 , when a user selects a new plan, that plan can be provisioned through the PCRF and OCS in real time. Thus, the subscriber can be served immediately. It is necessary that the other systems, such as customer care, within the IT infrastructure are aware of the new plan being provisioned. For that reason, as explained later, CSP system 530 interfaces to the operator's provisioning/order entry system. In one embodiment, CSP system 530 may manage the provisioning/order entry of data service upgrades with the CSP-integrated PCRF and OCS.
[0070] Integration with Messaging Gateway.
[0071] CSP system 530 ( FIG. 6 ) can communicate with CDA 140 , as well as other devices if the operator so wishes, via a proprietary or non-proprietary IP-based communication protocol, such as SMS, Unstructured Supplementary Services Data (USSD), Apple® Push Notification Service (APNS) for iOS devices, Android® Cloud Device Messaging (ACDM) for Android® devices, and the like. SMS can be used to wake up CDA 140 when needed. For example, SMS can be sent to a consumer as an alert or notification when data usage limit is reached, payment is overdue, or a promotion relevant to the consumer is available. In one embodiment, the alert and notification can be generated by network elements (such as PCRF/OCS within either operator network 110 or CSP network 170 ), and delivered to the consumer's CDA 140 by CSP system 530 . In a scenario where the operator wishes to recruit existing subscribers to the use of CDA 140 , CSP system 530 can use SMS to signal these subscribers' devices with a link to download CDA 140 .
[0072] In some embodiments, operators have SMSCs to forward text messages to/from external systems. These SMSCs support protocols such as SMPP or UCP. Some operators also use messaging gateways as an interface to the external systems, thereby minimizing direct connections from external systems to the SMSCs. These gateways also support SMPP or UCP, and most also have other APIs that can be made available. In alternative embodiments, the SMSCs may be part of CSP system 530 .
[0073] In some embodiments, CSP system 530 has built-in SMPP client functionality. CSP system 530 can integrate with the operator's messaging gateway 108 using SMPP. In one embodiment, a specific short code can be assigned to CSP system 530 and that short code is zero-rated. Thus, messages between CSP system 530 and the user device will not be charged to the user's account.
CSP—Application Integration on a Wireless Communication Device
[0074] FIG. 10 illustrates an example of CSP device application (CDA) 140 when used on a smartphone device. Although a smartphone is shown, it is understood that CDA 140 can be run on cellular device 100 ( FIG. 1 ) such as a cellular telephone, a tablet computer, a personal digital assistant (PDA), a video-camera, a gaming device, a global positioning system (GPS), an e-Reader, a Machine-to-Machine (M2M) device (i.e., an application-specific telemetry device that collects data using sensors and transmits the data to a destination such as a server over a network), a hybrid device with a combination of any of the above functionalities, or any other wireless mobile devices capable of sending and receiving voice, data and text messages. CDA 140 serves as an interface between the operator and the customer. CDA 140 receives information from CSP system 530 . CSP system 530 , in turn, receives the information from operator network 110 , operator IT system 150 , and CSP network 170 ( FIG. 1 ). CDA 140 can be operator branded and can be built using a combination of multiple programming languages for Web and Mobile technologies, e.g. C++, HTML5, Java, OS-specific native application code, etc., and other mobile Web technologies. CDA 140 is an application (or construct) that is resident and accessed from the device. Customers can be given access to the application in several ways; e.g., by pre-loading on new customer devices at the device OEM, by downloading to existing devices using a link to the appropriate application store, and/or accessed via a mobile Web page sent to the customer.
[0075] While CDA 140 is a device-based application, a majority of its data and experience (e.g., displayed layout and content) are generated and served from CSP system 530 . This provides the ability to dynamically display and change elements of the experience without pushing application updates to the user device. In one embodiment, CDA 140 communicates with CSP system 530 over Hyper-Text Transfer Protocol Secure (HTTPS), which uses multi-layer authentication architecture to validate CDA 140 , handset and user, before allowing access to data and functions such as purchasing upgrades. Alerts and notifications may be delivered to the user device via SMS through the CSP-Messaging integration described above, as well as through Mobile OS-specific notification methods; e.g., APNS for iOS devices and ACDM for Android® devices.
[0076] In one embodiment, the recommendation engine (which is one of CSP engines 122 in CSP system 530 shown in FIG. 6 ) is the CSP's mechanism for creating real-time contextual offers. In the embodiment shown, the recommendation engine analyzes the information collected from CRM, CDRs, campaigns, and the like by data mining and micro-segmentation. The customer micro-segmentation allows an operator to target a certain segment of the subscribers to make offers that are most relevant to those subscribers. The recommendation can be made with respect to a number of factors of contextual assessment, such as time in contract, loyalty status, purchase history, value of customer, and data and time usage. The recommendation engine creates or recommends real-time offers based on results of customer profiling, as well as factors of the contextual assessment and information received from PCRF, OCS and CDRs. Thus, when a consumer's real-time usage reaches a limit and receives a real-time alert, the offers that are created by the recommendation engine and approved by the operator can be delivered to the user device instantly. CDA 140 directly interacts with CSP system 530 . Via CDA 140 , a consumer can choose one of the offered options that are displayed on his device in a user-friendly format. The chosen option can be provisioned to the user in real time and feedback can be sent back to hosted service platform 120 in real time.
[0077] FIGS. 11-15 illustrate examples of the functions provided by CDA 140 according to embodiments of the invention. Referring to FIG. 11 , a series of screen displays of CDA 140 is shown in connection with a top-up offer for data usage. Initially, a home page ( 1100 ) provides a number of options, one of which is “My Account.” By selecting the usage tab in the My Account page, the user's usage for voice, text message and data is displayed on the user device ( 1101 ). The display shows the user's data usage is at 92% of the quota limit. Automatically or by user's selection, a top-up offer page ( 1102 ) including multiple options is shown to the user. Each option is an offer created by the recommendation engine based on the contextual assessment described in connection with FIG. 6 , and approved by the operator. If the user selects one of the options ( 1103 ), a purchase confirmation page ( 1104 ) will be shown on the display. At that point, the usage page ( 1105 ) shows that the user's quota has been increased and the data usage is now at 81% of the quota limit.
[0078] The “My Account” feature allows a user to check his current usage information whenever he wants to. If the user does not take the initiative to check his current usage and limits, he can be notified by alerts of situations that can lower his QoS or disable his network connections. Alerts will be described with reference to FIGS. 15A and 15B .
[0079] In one embodiment, the “My Account” feature also allows a user to monitor the billing; e.g., the amount of money he spent on network services before receiving a billing statement. For example, if the user is roaming and incurring roaming charges, he can monitor the amount of roaming charges in his account by clicking on the “billing” tab on the top right corner.
[0080] Referring to FIG. 12 , a series of screen displays of CDA 140 is shown in connection with a “Tell-a-Friend” feature. Initially, a home page ( 1200 ) provides a number of options, one of which is “Deals.” The Deals page ( 1201 ) shows all of the currently available deals relating to wireless communication services and devices. A user can select a tab to filter the displayed result; for example, deals offered by a particular provider, vendor or operator ( 1202 ). A user can select a “Friends” tab ( 1203 ) to show the deals recommended by his friends. By clicking into a particular offer ( 1204 ), the user can make a purchase in real time or save the offer for later consideration. A purchase confirmation page ( 1205 ) is displayed when the user makes a purchase. The user can share the information about this offer with his friend by clicking a soft button “Send Message” to send a generic or personalized message ( 1206 ).
[0081] Referring to FIG. 13 , a series of screen displays of CDA 140 is shown in connection with a “Help” feature, which performs diagnosis and provides help. In one embodiment, the diagnosis is performed by the user's device, taking into account the information collected by CSP system 530 from many data sources (e.g., PCRF, OCS, CDRs, CRM, etc.). The diagnosis can be performed in the following areas: the user's coverage, subscription, usage, payment, roaming status, and the like. Initially, a home page ( 1300 ) shows that all services are currently available. A user can select a number of options, one of which is “Help,” to explore more information. Clicking into the help page ( 1301 ) automatically activates a diagnostic function. In this example, the diagnostic function finds that the user's payment is overdue. By clicking on the diagnosed problem (payment), the user can go to a page displaying payment options ( 1302 ). The user can make payment by credit and debit cards ( 1303 and 1304 ). A purchase confirmation is shown after the payment is accepted ( 1305 ).
[0082] As shown in the example above, the “Help” feature not only discovers a problem, but also provides a resolution to the problem in a user-friendly way. In another scenario, a user may find out from the diagnosis that he does not have coverage. This diagnosed problem (coverage) can re-direct him to one or more proposed solutions, such as moving down the road 10 miles or purchasing an upgrade to the network coverage.
[0083] FIG. 14 illustrates an example in which a connection problem is automatically detected without the user proactively running the diagnostic function. In this example, the top panel of the display shows that a connection problem has been detected ( 1400 ). The user can click a “Fix Now” soft button and see a list of questions that are relevant to the detected problem ( 1401 ). The user can select one of the questions to find more information; e.g., the user's current status that is relevant to the cause of the detected problem ( 1402 ). In this scenario, a voice test is recommended. The user can run the voice test to test his/her voice connection ( 1403 and 1404 ). For example, the user device can send a message to request a voice network component in the operator network to call the user device. If a problem is found, the user can choose whether to report the problem to the operator ( 1405 ). If the user chooses to report the problem, a report confirmation page ( 1406 ) is displayed. In other scenarios, the user can run a data connection test or a messaging test to request a data server or a messaging server in the operator network to call the user device. This “Help” feature is another example of a contextual action that provides a clear path towards resolution of an issue that a user current has.
[0084] FIG. 15A illustrates an example of a “User Alert” feature. In this example, when a user reaches his quota limit, the top panel of the display shows an alert and a top-up offer ( 1500 ). The alert may show that the user has exceeded his usage threshold but is still within the quota limit, or that the user has reached the quota limit. The user can select a top-up offer from the top panel without clicking into deeper levels of the menu ( 1501 ), or review more plan upgrade options. After the user selects the top-up offer and makes the purchase, a purchase confirmation page is displayed ( 1502 ). As described in connection with FIG. 6 , the top-up offer and upgrade options can be created by the recommendation engine based on contextual assessment of the user's unique situation, and approved by the operator.
[0085] FIG. 15B illustrates an example of a “Roaming Alert” feature. In this example, a user roams into another network (or another area) but his plan does not support such roaming. The display shows an alert and a number of options ( 1530 ). The user can select any of the options to enable the roaming ( 1531 ). Each option is an offer created by the recommendation engine based on the contextual assessment described in connection with FIG. 6 , and approved by the operator. After the user selects one of the options and makes the purchase, a purchase confirmation page is displayed ( 1532 ).
CSP—IT Integration
[0086] Referring again to FIG. 6 , in one embodiment, CSP system 530 integrates with four functions of operator IT system 150 in the areas of CRM/care 610 , provisioning/order entry 620 , billing/payments 630 and reporting/DWH 640 . CSP system 530 integrates with each of the four areas through a corresponding interface. The CRM interface supports rating, policy and offer management, campaign management and customer management and care. The provisioning/order entry interface enables the activation of selected services within the operator systems. The billing interface allows usage information to be shared with CSP system 530 . Thus, a user can see his up-to-the-minute usage via CDA 140 without having to contact customer care. The reporting interface makes available the CSP-generated reports to all necessary functions within the operator.
[0087] The CSP experience provides both the consumer and the operator a number of self-service tools that can be used anytime and anywhere to manage their services. For the consumer, CSP system 530 offers the ability to see, select and purchase new services, as well as perform account management and self-support activities, such as account balance inquires, payment method changes; all from their smartphones (or another wireless communication device) and all in real time.
[0088] For the operator, CSP system 530 provides a suite of tools that enables the creation and management of all of the services and experiences received by the customer. For example, the operator's CRM system 610 can integrate with CSP system 530 to provide details on offers and services that CSP system 530 can recommend to the customer as upsells or standard sales offers, to view current account balances and usage, manage payments and to provide diagnostics to assist the user with self-service resolution of common support issues. CSP system 530 can also integrate with the operator's reporting and data warehouse systems 640 to provide financial, marketing and management reporting.
[0089] In one embodiment, integration between CSP system 530 and operator IT system 150 is based upon the availability of interfaces to selected systems and/or groups of systems. As CSP system 530 uses a model that abstracts its interfaces to the operator platform using an adaptation layer, these interfaces can vary from standards-based Web services APIs to secure file transfers.
[0090] In one embodiment, the interfaces enable not only the integration of CSP system 530 with operator IT system 150 , but also the ability for an operator to manage its marketing campaign, offers, pricing, billing and customer care in an integrated environment. In one embodiment, this integrated environment is presented to the operator via CSP operator Web applications 154 . CSP operator Web applications 154 may be run on a computer in the control center of operator IT system 150 .
[0091] FIG. 16 illustrates an embodiment of a screen display of CSP operator Web applications (e.g., CSP operator Web applications 154 of FIG. 6 ). In this embodiment, the screen display includes a top panel that shows alerts and status 1601 and campaign results 1605 . Alerts and status 1601 allows an operator (or more specifically, the administrators at the operator side) to communicate with each other with respect to the latest updates and status of operator network 110 and operator IT system 150 ( FIG. 6 ). In one embodiment, the main panel of the display is divided into three regions: Create Offers and Policy 1602 , View Customer Activity 1603 and Manage Communications 1604 . Each of the three regions includes a number of task modules 1610 - 1618 that allow the administrators to perform specific tasks. The backend of task modules 1610 - 1618 is CSP system 530 , or more specifically, CSP engines 122 ( FIG. 6 ). When an operator clicks on any of task modules 1610 - 1618 , the operator can be provided with templates and data that are generated by one or more CSP engines 122 . CSP engines 122 generate the templates and data based on the information obtained from operator network 110 and operator IT system 150 ( FIG. 6 ). In one embodiment, access to these task modules 1610 can be role-based; that is, an administrator with a marketing role may be able to access only a subset of task modules 1610 - 1618 while an administrator with a manager role may be able to access all of task modules 1610 - 1618 .
[0092] In one embodiment, some of the task modules, such as pricing workstation 1610 and offers workstation 1611 , allow the administrators to create offers and set pricing. In one embodiment, CSP system 530 can provide offers and pricing templates for the operator to fill in the details. Through subscriber portal 1612 , an operator can design subscriber's on-device experience, also using the templates provided by CSP system 530 . These templates allow the operator to set a pricing plan and package the pricing plan into an offer associated with a policy. The pricing, offer and policy are sent to CSP system 530 to allow CSP system 530 to deliver the right offers with the right pricing to the right subscribers at the right time. CSP system 530 can also provide other templates that can be used by the operator with a click on any of task modules 1610 - 1618 .
[0093] In one embodiment, an operator can view the details (e.g., activities and history) about subscribers through the task module of subscriber details 1613 , and perform operations on their accounts; e.g., activate or deactivate the accounts, change offers, apply promotions and other account administrative tasks. Custom alerts 1614 allow administrators of the operator to configure rules for alert-triggering events. These alerts may be accompanied by automated response to specific events for resolving the condition causing the alerts. The task module of reports 1615 allows the operator to review and analyze subscriber and financial data. For example, the operator can run a report to find out when a particular offer or a particular group of offers have reached a set market share or set usage.
[0094] In one embodiment, an operator can design campaigns to send offers and incentives to specific subscribers using campaign center 1616 . In one embodiment, the offers and incentives can be delivered to CDA 140 on the user device via CSP system 530 ( FIG. 6 ). In one embodiment, CSP system 530 can provide campaign templates for the operator to determine the specific details of campaigns. For example, the operator can decide on a plan and the recommendation engine of CSP system 530 can recommend a segment of subscribers to whom this plan should be offered. Alternatively, the operator can decide on a segment of subscribers and the recommendation engine can recommend a plan to offer to these subscribers.
[0095] In one embodiment, an operator can use customer alerts 1617 to set up an alert for specific subscribers and the rules associated with the alert. The alert can be displayed on the user device to allow a subscriber to take remedial action; e.g., to accept a top-up offer that is delivered with the alert to the subscriber. In one embodiment, the task module of analytics 1618 is backed by the recommendation engine of CSP system 530 . Analytics 1618 allows the operator to identify trends and opportunities based on the subscribers' behavior and campaign results. For example, if the subscriber reaches his usage limit for the first time, analytics 1618 can recommend a top-up offer (which is valid only for this current billing cycle). If this is the fifth time within a five-month period that the subscriber has reached the threshold, analytics 1618 can recommend an upgrade offer such that the subscriber can switch to an upgraded plan and receive a higher quota limit every billing cycle.
[0096] As mentioned before, the integration of CSP system 530 and operator IT system 150 ( FIG. 6 ) enables the functionality of CSP operator Web applications 154 described above. The following describes this integration with respect to CRM/care 610 , provisioning/order entry 620 , billing/payments 630 and reporting/DWH 640 ( FIG. 6 ).
[0097] CRM Integration.
[0098] FIG. 17 is an overview of CRM integration according to one embodiment of the invention. Referring also to FIG. 6 , CSP system 530 includes a CSP CRM API 1701 , which interacts with operator IT system 150 to manage or recommend strategies for CRM and care. Through CSP CRM API 1701 , the operator's CRM system 610 is fed with usage and diagnostic data from CSP system 530 , and CSP system 530 pulls customers profile information and updates from the CRM system 610 . In one embodiment, CSP system 530 integrates with the operator's CRM system 610 in the following areas: Rating, Policy and Offer Management; Campaign Management; and Customer Management and Care.
[0099] CRM Integration Area (I): Rating, Policy and Offer Management (Product Catalog).
[0100] Through the integrated rating, policy and offer management functions, CSP system 530 provides the operator a powerful set of tools to create, edit, approve and manage rate plans and policy actions for consumers. As the front-end interface to an integrated OCS and PCRF facility, CSP's Pricing and Offers engines (e.g., CSP engine 122 of FIG. 6 ) integrate with the operator's Product and Policy Catalog to pull current offers and create new offers and policy rules.
[0101] Depending on the nature of the product deployment, CSP system 530 can replicate offers currently in the operator's product catalog, create and push offers to the operator, or act as the master product catalog for rating. In all of these three cases, CSP CRM API 1701 provides proper synchronization between CSP system 530 and operator IT system 150 , as well as ensuring availability of offers and policies. CSP CRM API 1701 allows CSP system 530 to access and pull offers. CSP CRM API 1701 also facilitates a submit/approve/publish method to push offers to the operator.
[0102] Through CSP CRM API 1701 , CSP system 530 pulls all applicable offers, catalog rules, offer parameters and policy descriptions into an easy-to-use, self-service user interface that the operator's marketing personnel can use to quickly create new offers and promotions. In practice, the process to create and approve an offer touches many internal operator departments and may need some level of internal coordination and process to accomplish. To properly engage with and manage this need, CSP system 530 has an integrated approval workflow to prevent the use of these offers and policies until they are reviewed and approved by the appropriate operator-designated personnel. Once approved, the offers and policies can be pushed to the operator using CSP CRM API 1701 or a similar API.
[0103] A sample product catalog/rating/policy template is shown below.
[0000]
TABLE 1
Sample (Basic Offer) Product Catalog Template
Catalog Area
Field Name
Description
Identification
Offer Code
Operator's offer code used to identify the
offer to CRM and other systems
Offer Friendly Name
Name of the offer that will be presented in the
CDA
Applicable Service Type(s)
Service Type that this offer is applicable to
(voice, data, etc.)
Effective/Expiration
When offer can be used/stops being offered
Date(s)
Compatible Offer Code(s)
Codes of offers that are compatible (allowed
to be purchased) with this offer
Allowed payment types
Payment types (debit, credit card, prepaid)
allowed for plan purchase
Rates
Primary Rating Type
First rating scheme as applicable to service
type (by units of usage, time, destination, etc.)
Rating Amount
Amount charged for rated usage
Secondary Rating Type
Additional rating scheme as applicable to
service type (by units of usage, time,
destination, etc.)
Rating Amount
Amount charged for rated usage
Policy
Policy Conditions
Selected policy conditions, e.g. throttle,
redirect, notify
Policy Actions
Parameter and action when policy condition is
met
Type of Offer
Standard offer, upsell or both.
[0104] In case an API is not or cannot be made available, a manual synchronization process can be used to perform the actions that would be taken by the API. In this manual approach, the operator uses the CSP Pricing and Offer engines to create and publish the appropriate offers and policies. A key to success in this approach will be the creation of business processes that govern the speed and frequency of updates.
[0105] FIG. 18 illustrates an example of an operation sequence that allows offers created by CSP system 530 to be modeled and managed in the operator's product catalog. In one embodiment, CSP system 530 creates an offer/policy template (or zero-rated offer) ( 1801 ). CSP system 530 then submits that offer/policy to the operator for approval ( 1802 ). CSP CRM API 1701 publishes the offer/policy to the operator ( 1803 ). Upon receipt of the offer/policy, operator IT system 150 creates shell offer code and description (e.g., by associating the parameters of that offer (Offer Code, etc.) to the CSP-created offer) ( 1804 ). Operator IT system 150 then propagates the offer/policy to downstream systems ( 1805 ). Thus, all downstream systems that are fed from the product catalog (Care, Finance, Reporting, etc.) receive information and updates during the normal course of business. Through CSP CRM API 1701 , operator IT system 150 also publishes the approval to CSP system 530 ( 1806 ). Upon receipt of the operator's approval ( 1807 ), CSP system 530 makes the offer/policy available for use by the customers ( 1808 ).
[0106] CRM Integration Area (II): Campaign Management.
[0107] In one embodiment, CSP system 530 includes Customer Alerts and Campaign engines (e.g., one or more of CSP engines 122 of FIG. 6 ), which use offers generated by the Pricing and Offer engines (e.g., one or more of CSP engines 122 of FIG. 6 ) to provide customers with automated and operator-generated upsell offers. The Customer Alerts engine allows the operator personnel to create and set automated alerts that provide customers notification of key lifecycle events, e.g. reaching a usage threshold, approaching a bill cycle date, accessing a non-included service such as roaming. Included in these alerts can be contextually relevant upsell offers that allow the customer to continue using services. The Campaign engine allows the operator's marketing personnel to either use CSP's integrated recommendations engine (one of CSP engines 122 shown in FIG. 6 ) to identify targeted lists of customers for receiving promotions, or to upload a pre-segmented list.
[0000]
TABLE 2
Integrations Supporting Campaign Management
Required Function
Description
Addressed in Integration Area
Usage data
Provides campaign analytics and
Network
recommendation
Notifications
Sends SMS messages to customers that
have received a campaign
Service offers and
Offers that have been approved for use
Rating and Policy (Product
upsells
as campaigns and upsells
Catalog)
Opt-In
Customer's preference to receive alerts,
Customer Profile
notifications and campaigns from the
Operator
Personalization
Information to create a more personal
campaign as well as validate that the
campaign is sent to the right consumer
Report and Source
In the case that the Operator uses their
Data Warehouse
Data
own pre-segmented list of target
customers.
[0108] CRM Integration Area (III): Customer Management—Customer Profile.
[0109] CSP system 530 is designed to address the sensitivity of the operator's customer data and the number of regulatory and legal issues. Integration between CSP system 530 and the operator's CRM customer profile is needed to enable several functions: authentication of CDA 140 , personalization of offers and alerts, and knowledge of customer offers for recommendations and account management. In all cases, CSP system 530 looks to the operator's CRM system 610 as the master record for all customer data.
[0110] To protect end-customer data, all of the end-customer data is stored within the CSP customer database and managed in a manner that enables it to be secure and auditable at all times. Any changes made to the customer data are tracked using an audit trail that can be made available for reports, audits, etc. In addition, the CSP data centers can be deployed in specific geographical locations to accommodate data security, privacy and location requirements.
[0111] The integration that is required to store and update this data inside CSP system 530 can be accomplished using an API (e.g., CSP CRM API 1701 of FIG. 17 ) that enables data to be pulled from the operator's CRM system 610 using a commonly used and relatively unchanged key. In one embodiment, the key can be the International Mobile Subscriber Identity (IMSI) followed by the Mobile Station International Subscriber Directory Number (MSISDN). Depending on the nature of the product deployment, customers may be allowed to update their data through the CDA 140 , e.g. change billing methods, addresses, etc. In this case, the same approach is recommended to update customer data inside the operator's systems.
[0112] Since the customer profile data feeds CSP's customer database and contains all of the customer's current plan information, the CRM integration also enables changes made outside of CSP system 530 to be reflected in the CDA 140 and CSP system 530 . Thus, any changes to rating or policy parameters can be properly synchronized between CSP system 530 and the operator. To that end, changes made within the operator's customer care and/or retail ordering systems are pushed (recommended) or pulled periodically from the operator's CRM system 610 to CSP system 530 . The CRM integration allows CSP system 530 to be constantly up-to-date with the operator's systems. In one embodiment, the API (e.g., CSP CRM API 1701 of FIG. 17 ) allows customer data to be rapidly accessed and updated. This is necessary because customer profile data is used in the display of account management functions, as well as a key input into the CSP recommendations engine.
[0113] In one embodiment, CSP system 530 uses the following information in the customer profile for CRM integration:
[0000]
TABLE 3
Customer Profile Fields and CSP Functions that Use These Fields
Field Name
Description
Authentication
Recommendation
AccountMgt
IMSI
Customer's IMSI
x
MSISDN
Customer's phone
x
number
Customer Name
Customer's billing
x
x
name
Billing Account
the Operator's
x
x
Number
billing account for
customer
Contract Date
Original contract
x
x
(tenure)
date or tenure of
customer
Current Plan Type
Prepaid or
x
x
postpaid
Current Voice Plan
Current plan
x
x
Current Data Plan
x
x
Current Messaging
x
x
Plan
Current “other” Plan
Current non-
x
x
mobile or other
service plan
Bill Cycle Date
Postpaid bill cycle
x
x
date or prepaid
expiration date
Previous Voice Plan
Most recent
x
x
Previous Data Plan
changed plan
x
x
Previous Messaging
x
x
Plan
Previous “other”
x
x
Plan
IMEI/Device Type
Device type
x
x
identifier or IMEI -
the latter is
preferred
Opt-In Status
Customer's
x
election to receive
notifications
Campaign Opt-In
Customer's
x
Status
election to receive
campaigns and
promotions
Current campaign
Campaign
x
customer is
currently attached
to (if any)
[0114] CRM Integration Area (VI): Customer Management—Customer Care.
[0115] CSP system 530 has a number of customer management capabilities that can be useful to the operator's customer care and customer management teams.
[0116] In one embodiment, CSP system 530 does not directly push data into the operator's CRM system 610 . Rather, it assumes that integrations are already in place within the operator's infrastructure to pass information, for example, from the product catalog, provisioning/ordering and similar systems to the CRM system 610 . If a direct push integration to the CRM system is necessary, CSP system 530 can provide information via an API to the CRM system 610 on a per-event or time-basis.
[0117] In one embodiment, CSP system 530 can, via an API, allow the operator's CRM system 610 to provide diagnostic, current offer and current usage data. Since CSP system 530 is both the rating and policy management engine, a customer current usage and policy status, e.g. throttled or not throttled can be made available to the CRM system 610 . One key component of the CSP system 530 is the ability to push advanced service and network-level diagnostics to the handset and provide the user timely and actionable feedback to solve issues.
[0118] While one of the key attributes of the CSP system 530 and CDA is the ability to allow a customer to perform a majority of account management and self-support issues, it may be unavoidable that sometimes the customer will call customer care. When the customer does call customer care, the customer care agent (or a technical support representative) can, via the API, pull diagnostic information into their normal systems and provide assistance to the customer. In the case where the CRM system cannot integrate to an external data source, CSP system 530 can be setup to launch-in-context (LIC) along with the customer care representative's existing tools.
[0119] Provisioning/Order Entry Integration.
[0120] Prior to the description of provisioning/order entry integration, it is useful to differentiate between order management and provisioning/order entry functions. Order management functions aggregate customer selections for offers, payment methods and any other updates and pass that information to a provisioning/order entry system that allows access to those ordered services on the network.
[0121] Since CSP system 530 may be the master rating and policy engine, it can enable access to the selected services and then integrate with the order management system to feed data to downstream systems, e.g. care, reporting and CRM. This integration assumes the existence of interfaces between the order management and related downstream systems (e.g., CRM and reporting) to manage activities such as customer activation, service changes, device changes and updating financial and marketing reports.
[0122] FIG. 19 is an overview of provisioning/order entry integration according to one embodiment of the invention. Referring also to FIG. 6 , CSP system 530 includes a CSP provisioning/order entry API 1901 , which interacts with operator IT system 150 to manage service provisioning/order entry. In one embodiment, CSP provisioning/order entry API 1901 defines service offer codes (SOCs) for offers that are applicable to one or more customers. When the customer selects an offer, CSP system 530 provisions the selected service against the SOC code. The selected offer is then propagated to other systems (e.g., CRM and billing). Through CSP provisioning/order entry API 1901 , CSP system 530 can be notified of changes to customer profile, and CSP-created offers can be pushed to the product catalog.
[0123] In one embodiment, CSP system 530 is provided with the appropriate identifiers for all available provisioned services. These codes (and associated parameters) are known as service offer codes (SOC) and can be used by CSP system 530 to inform the provisioning/order entry system to allow a customer access to their selected offers. For data services, CSP system 530 can provision service access on its integrated PCRF based upon the customer's selections, and submit, via CSP provisioning/order entry API 1901 , the appropriate SOC, any relevant parameters and a customer identifier (IMSI or MSISDN) directly to the provisioning/order entry system for fulfillment. In parallel, CSP system 530 can send the same information via a Web services interface to the operator's order management system for further processing and population of downstream systems. In an alternative embodiment, the operator can choose to provision its PCRF with the same information as CSP system 530 .
[0124] FIG. 20 illustrates an example of an operation sequence that provisions the offers selected by customers. In one embodiment, CSP system 530 validates offer rules and restriction ( 2001 ), and signals CDA 140 to display offers ( 2002 ). When the customer selects an offer ( 2003 ), CDA 140 captures the offer and order information ( 2004 ). In response, CSP system 530 enables access to selected services ( 2005 ). At this point, CSP system 530 generates and sends the order to operator IT system 150 via an API (e.g., CSP provisioning/order entry API 1901 ) ( 2006 ), and in parallel, signals CDA 140 to display service confirmation ( 2010 ). When operator IT system 150 receives the order from CSP system 530 ( 2007 ), it updates CRM and customer profile ( 2008 ) as well as downstream systems ( 2009 ). After CDA 140 displays service confirmation ( 2010 ), the customer can start using the selected services ( 2011 ). CDA 140 can further display updated details in My Account (e.g., the My Account feature shown in FIG. 11 ).
[0125] CSP system 530 also offers the ability to offer and provision other mobile (voice, messaging) and non-mobile services (DSL, insurance) that are not rated by CSP system 530 . In this case, CSP system 530 can, using the same mechanisms noted above, provide the provisioning/order entry and ordering systems the appropriate SOC (or equivalent) code, allowing the appropriate network elements (e.g., HLRs) and IT platforms (CRM) to be updated. To that end, all of the products and services offered by the operator need to be provided to CSP system 530 , placed in the product catalog and synchronized.
[0126] As previously noted, CSP system 530 receives information about a customer's current services and selections from the customer profile database. If a change is made to the customer's plans or services via the Care or Retail system, these changes and their associated provisioning/order entry changes are sent to CSP system 530 .
[0127] Billing Integration.
[0128] In one embodiment, CSP system 530 integrates with the operator's billing system in the following areas: Rating of Data Usage, Self-Service Account Management and Risk Management and Payment.
[0129] FIG. 21 is an overview of billing integration according to one embodiment of the invention. Referring also to FIG. 6 , CSP system 530 of FIG. 6 includes a CSP billing API 2101 , which interacts with operator IT system 150 to manage billing and payments. In one embodiment, through CSP billing API 2101 , CSP system 530 pushes rated data CDRs to billing/mediation system, and billing/mediation system pushes rated voice and SMS to CSP system 530 . CSP system 530 is integrated for credit/debit processing. CSP system 530 can push payment details to operator's billing/mediation system. The operator's billing system does tax, invoice and collection.
[0130] Billing Integration Area (I): Rating of Data Usage.
[0131] In one embodiment, a CSP-integrated OCS can be used to rate data usage for customers that are managed by CSP system 530 . The rates and policies used by the OCS can be stored and managed by CSP system 530 .
[0132] In one embodiment, CSP system 530 can rate usage and calculate charges on a per session basis. Depending on the nature of the product deployment, CSP system 530 can either store, aggregate and format usage into an invoice-ready format, or send rated, per-session usage to the operator's CRM or other system. If the former, CSP system 530 can provide the invoice-ready data feeds to a mutually agreed sFTP site for the operator to pick up and include into its billing process a set number of days prior to the close of the billing cycle.
[0133] In the latter option, CSP system 530 can post, on a per-session basis, aggregated usage including the customer identifier (IMSI or MSISDN), plan code and total usage. In one embodiment, this integration will be managed through the use of an API (e.g., CSP billing API 2101 ) that can directly feed the operator billing system. A known analogue to this type of integration is one where a third party provides a “bill on behalf of” service to an operator. In this case, CSP system 530 will be charging data usage on behalf of the operator and providing that rated usage for use by downstream financial systems (e.g., taxation) as well as CRM and reporting systems. If an API cannot be made available, these data can be posted to a sFTP site.
[0134] Billing Integration Area (II): Self Service Account Management.
[0135] A key feature of the CDA 140 is the ability for the customer to view, in real time, current service usage. In an embodiment where CSP system 530 is rating data and the operator is rating voice and SMS, it is necessary to integrate with the operator's usage management systems to get rated and/or aggregated usage for those services. Depending on the operator system that sources this data, a push API or sFTP file transfer can be used to get these data. A key factor in determining how to perform this integration is how fast the usage information can be made available via the interface. If there is a delay greater than a pre-defined time period (e.g., 15 minutes between usage completion and CDR delivery), a secondary method may be used to enable the “real-time” nature of the CDA 140 account management function. In this case, the customer profile integration may be a candidate to pull current, aggregated usage.
[0136] Billing Integration Area (III): Risk Management and Payment.
[0137] Depending on the nature of the product deployment, CSP system 530 can also integrate with the operator's risk management and payment systems. The integration with these services is highly dependent on the service used and where it sits within the operator infrastructure. The ideal integration with CSP system 530 is to use an existing interface, e.g. the customer profile to determine the risk score for a customer and use that along with the catalog rules sourced from the product catalog integration to determine payment risk.
[0138] In addition, CSP system 530 can, as part of the order management and provisioning/order entry transaction, send a payment type and payment details. This is necessary if the operator wants to enable prepaid or credit card payments for services purchased via CDA 140 . In this case, the integration is also highly dependent on the target system and its location within the operator infrastructure. Typically, CSP system 530 can interface with but does not actually store or process any payments.
[0139] Data Warehouse/Business Intelligence Integration.
[0140] FIG. 22 is an overview of data warehouse integration according to one embodiment of the invention. Referring also to FIG. 6 , CSP system 530 of FIG. 6 includes a CSP reporting API 2201 , which interacts with operator IT system 150 to manage data warehouse. In one embodiment, through CSP reporting API 2201 , CSP system 530 can push reports to operator IT system 150 using a sFTP interface or a similar interface. The sFTP interface can be over the Internet. In some embodiments, a Virtual Private Network (VPN) can be used for additional security.
[0141] In some embodiments, CSP system 530 provides over twenty reports for use by an operator, such as daily subscriber report, usage detail reports, reports on charges of all kinds, and the like. Reports can be generated daily and/or monthly, and delivered to the operator.
[0142] Thus, a method, system and apparatus for a Core Service Platform (CSP) has been described. It is to be understood that the techniques shown in the figures can be implemented using code and data stored and executed on one or more electronic devices (e.g., an end station, a network element, etc.). Such electronic devices store and communicate (internally and/or with other electronic devices over a network) code and data using non-transitory machine-readable or computer-readable media, such as non-transitory machine-readable or computer-readable storage media (e.g., magnetic disks; optical disks; random access memory; read only memory; flash memory devices; and phase-change memory). In addition, such electronic devices typically include a set of one or more processors coupled to one or more other components, such as one or more storage devices, user input/output devices (e.g., a keyboard, a touch screen, and/or a display), and network connections. The coupling of the set of processors and other components is typically through one or more busses and bridges (also termed as bus controllers). The storage devices represent one or more non-transitory machine-readable or computer-readable storage media and non-transitory machine-readable or computer-readable communication media. Thus, the storage device of a given electronic device typically stores code and/or data for execution on the set of one or more processors of that electronic device. Of course, one or more parts of an embodiment of the invention may be implemented using different combinations of software, firmware, and/or hardware.
[0143] It is to be understood that the above description is intended to be illustrative and not restrictive. Many other embodiments will be apparent to those of skill in the art upon reading and understanding the above description. The scope of the invention should, therefore, be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. | A system and method for managing wireless devices in a wireless network that performs operation comprising: receiving a diagnostic request to analyze a problem associated with a wireless device operating in the wireless network; retrieving contextual information associated with the wireless device from a database of the wireless network; determining at least one solution for the problem associated with the wireless device based on the contextual information; transmitting the at least one solution; and receiving a confirmation that the problem has been resolved. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to an indoor, miniature simulated golf course game. It has a particular configuration of a plurality of fairway driving areas between the tees and the greens. The fairways, between the holes and tees, provide sequential visual activity segments with intermediate golf ball target areas between the tees and the greens. The intermediate golf ball target areas are constructed in proportional size to the distance of the intermediate target zone area from each respective tee.
The game also simulates a golf course by selective choice of carpet materials to simulate the ball interacting resistive properties of various parts of the golf course. For example, the greens are made from short, tighter fabric with short, densely placed carpet tufts to accelerate the movement of the golf ball as if on a green. Also, the fairways have tightly packed fabric, but with higher strands to add resistance and slow down the movement of the golf ball. Finally, the areas which simulate roughs with bushes, sand traps or water traps are made from looser fabrics to slow down and stop the movement of the golf ball. Therefore the speed of the golf ball is affected by the various fabrics to simulate the various speeds and entrapments of the golf ball throughout the golf course.
DISCUSSION OF THE PRIOR ART
Various attempts have been made to design miniature golf courses which provide a playing field on a small scale, but these courses do not simulate the material of the terrain as a function of the speed and travel of the golf ball. Nor do these golf course games provide a means of testing visual acuity, such as is provided by the present invention with intermediate target zones which increase in size as the size from the tee to the intermediate target zone increases. Such prior art golf games are noted in U.S. Pat. Nos. 1,503,720 of Strasser, 1,591,095 of Meyer, 3,671,042 of Garber, 3,604,710 of Jacobs, 3,427,030 of Ward, 3,649,027 of Vallas, 3,892,413 of Rotolo, 3,904,209 of Thomas, 3,534,961 of Tiley, 4,019,748 of Healey and 4,673,183 of Trahan.
SUMMARY OF THE INVENTION
The plan of the course of the present invention may be accomodated to various sites of varying terrain. It is well suited for an indoor site of limited size for indoor use.
The plan of the course may be easily constructed with varying carpet materials, which are selected to affect the movement and speed of the golf ball so as to simulate different playing conditions.
For example, thick but loosely strung tufts of carpet are provided to simulate water, sand and rough hazards. These thick but loosely strung tufts of carpet constituite a retention means capable of slowing down and partially retaining the golf ball as it travels towards its intended destination. In addition, the terrain may be three dimensional by providing concrete free-form bases for the carpeted surfaces. An advantagous characteristic, according to the invention, is that three dimensional curvature of the terrain aids in directing the golf ball towards its destination.
The present invention is intended to simulate the surface characteristics of the golf course on a minitaure scale, so that the golf ball increases its speed or slows down, depending upon what characteristic terrain it encounters during its path of travel.
For example, the looser but taller strands of carpet tufts simulating the water, sand or rough hazards will by virtue of the height of the tufts and the density of the placement of the tufts, slow down and capture the ball, interrupting its movement, as occurs in a real golf game when the golf ball strikes water, sand or bushes in the rough.
On the other hand, shorter tufts, which are more densely placed, are provided to simulate the grass of the fairways. Since the strands are shorter, they do not have the height to fully capture the balls and interrupt their travel. However the tufts will by virtue of their height and density slow down the movement of the golf ball.
Furthermore, the carpet simulating the densely packed greens with the holes will be short and very densely packed, to allow the golf ball free movement without substantially slowing down the golf ball during putting on a green.
Another feature of the invention is that the fairways are generally designed with angled dog leg configurations, so that a golf ball has to be hit around a corner. To test the player's visual acuity to land a golf ball at a particular elbow of a dog leg shaped fairway, intermediate target zone or scoring zones, generally circular, are provided. As a result, a player cannot by sheer force unsafely hit the golf ball through the dog leg by bouncing it against the terrain features in contravention of typical golf ball travel flow.
By providing the intermediate target areas, the game requires the golf player to accurately land on the intermediate target area before proceeding to the green at the end of the fairway.
To increase variety and to simulate differing lengths of fairways in real life, the diameter of each circular intermediate target area varies in proportion to the length which the intermediate target area is located away from the tee at the beginning of each fairway. For example, if the intermediate target area is 22 feet from the tee, then the diameter of the intermediate target area is a fairly large 22 inches in diameter. On the other hand, if the intermediate target area is only 8 feet from the tee, then the intermediate target area is only 8 inches in diameter.
Therefore, the larger the intermediate target area, the greater its distance is from the tee. This requires a player to test his or her visual acuity, because the perceived visual size of the intermediate target area increases or decreases in proportion to its distance from the respective tees. It also simulates the apparent visual decrease in size of the elbows of the dog legs as they are farther away from the view of the player, similar to a vanishing line in perspective. As a result, the intermediate target areas appear uniform in size, even as they are farther away and larger than closer intermediate target areas.
DESCRIPTION OF THE DRAWINGS
Other characteristics and advantages of the invention will become more apparenty from the following description of the drawings, in which:
FIG. 1 is a top plan view of the miniature, simulated golf course game.
FIG. 2 is a close-up perspective view of a portion of the golf course as shown in FIG. 1.
FIG. 3 is an illustration of the stippled codes for the various simulated terrain materials.
FIG. 4 is a close up top plan view of a sample simulated tree.
FIG. 5 shows several close-up side sectional views of the various carpet tufts constituting various natural surface components.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, the simulated miniature golf course game is comprised of a series of carpeted miniature tees T1 to T18 inclusive, fairways F1 through F18 inclusive, and greens G1 through G 18 inclusive, with holes H1 through H18 inclusive, interspersed by simulated water hazards W1 through W3 inclusive, sand hazards S1 through S18 inclusive and rough hazards R1 through R18 inclusive.
As noted in FIG. 2, the various rough hazards, such as R2, may be three dimensional to simulate three dimensional terrain. This is accomplished by using three dimensional bases, such as concrete or wire impregnated ferro-cement netting, under the various carpeted surface features, such as green G3, sand hazards S3B, S3C and S3D and rough hazard R2.
As noted in FIG. 3, the various terrain features such as sand, water or simulated terrain are noted in the drawing FIGS. 1-5 with stippled gradations of inked lines and tones.
FIG. 4 is a top plan view of a specimen simulated tree, the leaves of which are made from artificial silk or lichen.
FIG. 5 shows side elevational sectional views of the various tufts of carpet, which simulate various terrain and function to slow down or accelerate the travel of the golf ball. As noted, FIG. 5 depicts the carpet tufts of green G1 with a low rolling resistance, b virtue of the densely packed, short tufts. Fairway F1 is depicted with higher, but less densely packed tufts to generally allow free movement of the golf ball. Furthermore sand hazard S1 is constituted from taller, looser tufts spaced farther apart to interrupt the travel of the ball and retard its movement, capturing it as a retention means, such as how a sand trap interrupts the travel of a golf ball.
Referring now also to the drawing FIGS. 1 and 2, each fairway, such as F1, is shaped like a dog leg thus having first and second axial directions angled with regard to one another with an elbow portion. Within the elbow portion of fairway F1 there is located intermediate target area I1, generally circular, the diameter of which is proportional in inches to the extent of the distance from tee T1 to intermediate target area I1. In this case, the intermediate target area I1 is 27 inches in diameter, since the center of it is located 27 feet from tee T1.
Likewise, where intermediate target area I8 is only 14 feet from tee T8, therefore intermediate target area I8 is only 14 inches in diameter. Since intermediate target area I8 is smaller, its distance from tee T8 is proportionally smaller than the distance of larger intermediate target area I1 is from tee T1 thus each circular intermediate target area has a predetermined ratio of a sized diameter directly proportional to a predetermined sized distance of said circular intermediate target area from the tee of its respective said fairway. The ratio of said sized diameter of each said circular intermediate target areas to the respective said distance of said circular intermediate target area from its tee being identical to each ratio for each other of said sized diameter of each other circular intermediate target areas to each other of their respective distance of said circular intermediate target areas from each of their respective tees. It is also to be noted that green G1 contains hole H1 into which the golf balls are hit into for the play for that particular hole H1.
Also, rules are promulgated such that a person who lands directly upon intermediate target area I1 from tee T1 is entitled to have one stroke subtracted from the score of play of the simulated golf game. This presents a further incentive for the player to accurately hit the ball to the intermediate target area I1, without trying to hit the ball through the dogleg of fairway F1 in an overly brisk manner to green G1 in an unnatural, careening travel of the ball to tee T1, which does not simulate the incremental hitting of the ball in real play of a full size golf course from a tee to an elbow of a full length doglegged fairway.
The drawings FIGS. 1 and 2 depict typical holes of a simulated golf course plan, but it is be understood that each simulated golf course as embodied in the present invention may have varying unique characteristic features, according to the terrain sought to be simulated on a miniature scale.
For example, a generally flat coastal type golf course may be simulated with more intricate sand and water hazards, whereas a topographically varied hillside or mountainous course may be simulated with more obstructive rough terrain hazards, depending upon the geographic type of golf course to be imitated.
The carpeted surfaces may be pile fabric such as indoor-outdoor carpeting with short, densely packed tufts of carpeting for greens G1 through G18 inclusive, where appropriate. The smooth surface of the indoor-outdoor carpeting with provide little friction to slow down the golf ball upon simulated green G1. On the contrary, normal household everyday use carpeting may be provided for fairways F1 through F18 inclusive, to generally permit smooth travel of the golf ball, while applying a signifigant amount of friction to slow down the golf ball as it travels toward intermediate target areas I1 through I18 inclusive, or from intermediate target areas I1 through I18 inclusive toward greens G1 through G18 inclusive, having holes H1 through H18 inclusive. Finally, hazards such as sand hazards S1 through S18 inclusive or water hazards W1 through W3 are constituted from very plush carpeting with tall tuft strands which are loosely spread apart to act as a retention means to physically slow down and capture the golf balls, as water and sand hazards do in real life.
Capturing of the ball in hazards W1-W3 or S1-S18 will be attained by slackening the speed of the ball from the increased friction of the tall loose tuft strands of hazards W1-W3 or S1-S18 upon the golf ball, since the taller, looser tufts of carpeting will slacken the travel of the ball, and urging the tufts themselves against and around the golf ball.
The looseness of the tuft strands of the hazards W1-W3 and S1-S18 partially form depressed cavities into which the bottoms of the golf balls travel, exerting pressure upon the golf balls to capture them, simulating the capturing of a golf ball within a real water hazard or real sand trap. As the golf balls further travel slowly within the hazards W1-W3 or S1-S18, they are retained until stopped from motion by the pressure of the tall loosely packed tufts upon the ball.
It is noted that the collection of tall strands in the simulated hazards W1-W3 or S1-S18 begin to mesh and converge together in front of the ball travelling laterally against the tall tuft strands, as the advancing golf ball comes in contact with the plurality of tall tuft strands in front of it.
For safety reasons, no airborne strokes of the golf ball are permitted. The circular intermediate target areas comprise the simulated miniature golf course a plurality of visually distinguishable scoring zones of different values, with the different valued scoring zones corresponding to a reduction of a score of a player by a scoring stroke when a golf ball lands on one of the plurality of visually distinguishable scoring zones. Because of the fact that a player substracts a stroke if the player hits the golf ball to one of the proportionately sized circular intermediate target areas I1 through I18, there is an incentive to safely and accurately hit the ball only upon the surfaces of the fairways F1-F18, as indicated by white areas with the dot-and-dash lines indicated the imaginary distances from the tees T1-T18 to intermediate target areas I1-I18.
With the foregoing in mind, it is apparent that the any embodiment resulting routine experimentation of the teachings of this invention shall be deemed to be within the scope of this invention as noted in the appended claims. | An indoor miniature golf game is provided with a plurality of fairways and greens. Sequential visual activity segments with intermediate target areas are provided on the fairways between the tees and the greens. Various materials both visually and physically simulate the accompanying landscape, so that the golf ball travels quickly over the greens, but is slowed down and caught by rough or water simulated areas. | 0 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to the following applications, which were filed of even date herewith and are assigned to the same assignee as this application:
PARALLEL PIPELINED IMAGE PROCESSOR--Capo et al.;
IMAGE DATA PROCESSOR--Klein et al.;
METHOD AND APPARATUS FOR EFFECTING BACKGROUND
SUPPRESSION OF IMAGE DATA--Klein et al.;
METHOD AND APPARATUS FOR EFFECTING SPOT/VOID FILTERING OF IMAGE DATA--Klein et al.;
METHOD AND APPARATUS FOR SCALING IMAGE DATA--Klein et al.;
APPARATUS FOR IMAGE DATA TRANSPOSITION AND COMPRESSION/ DECOMPRESSION--Klein et al.;
METHOD AND APPARATUS FOR TRANSPOSING IMAGE DATA--D'Aoust et al.;
METHOD AND APPARATUS FOR LOSSLESS COMPRESSION AND DECOMPRESSION OF IMAGE DATA--Klein et al.;
DIAGNOSTIC SYSTEM FOR A PARALLEL PIPELINED IMAGE PROCESSING SYSTEM--D'Aoust et al.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the processing of video image data and, more particularly, to a method and apparatus for the processing of video image data associated with a document imaging system.
2. Discussion
Financial documents, such as checks or drafts, usually contain a plurality of characters printed in magnetic ink which are typically read by a sorter which automatically sorts these documents into a plurality of bins. Prior to sorting, these documents are physically handled by a plurality of individuals, each of who enters the dollar amount associated therewith upon the document by the use of specialized amount entry equipment. Additionally, these individuals physically enter any corrections, associated with the reading of the magnetic code, upon each of the sorted documents.
These prior techniques of utilizing a plurality of individuals to process financial documents, in the aforementioned manner has proven to be relatively costly and inefficient in that many of these documents have been lost or destroyed during their physical handling by these individuals. The speed associated with the processing of the documents is also limited to the processing capabilities of the individuals and the particular mechanical amount entry equipment used by them.
SUMMARY OF THE INVENTION
Apparatus is provided, in accordance with the teachings of the present invention, for detecting a dimension of a generally rectangular document in a system in which the document is carried over a track to a station where the document is scanned by a sensor. The sensor creates a digital image thereof in the form of an array of pixels arranged in rows and columns. The document is scanned in a given direction over a scan line which includes a portion of the track as well as the document. A detector generates an output in response to a predetermined consecutive number of pixels having values exceeding a given threshold. This threshold is chosen so that those pixels exceeding the threshold should be associated with the track. In the preferred embodiment, the threshold is chosen so that the track pixel values generally correspond with white or background levels. A document presence signal is generated in response to the presence of the document in the station. Circuit means are used to store pixel position information and provide an output which is related to the detected dimension of the document in response to outputs from the detector and document presence signal.
In the preferred embodiment, the document is scanned vertically across the width thereof and the selected dimension that is detected is the height of the document.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of the present invention, relative to the advantages thereof, reference may be made to the following detailed description taken in conjunction with the accompanying drawings in which:
FIG. 1 is a block diagram of a typical financial document sorting system containing image processing apparatus made in accordance with the teachings of this invention;
FIG. 2 is a block diagram of the image processing apparatus of the preferred embodiment of this invention;
FIG. 3 is a block diagram of the storage RAM and window shift register shown generally in FIG. 2;
FIG. 4 is a block diagram of the input/output controller shown generally in FIG. 2;
FIG. 5 is a block diagram of the normalization subprocessor block shown generally in FIG. 2;
FIG. 6 is a flowchart detailing the steps associated with the background suppression subprocessor block unit shown generally in FIG. 2;
FIG. 7 is a diagram showing the contents of the window which is shown generally in FIG. 2;
FIG. 8 is a block diagram of the background suppression subprocessor block shown generally in FIG. 2;
FIG. 9 is a block diagram of the histogram counter control shown generally in FIG. 8;
FIG. 10 is a flowchart detailing the computation of a new gradient and threshold which is shown generally in FIG. 6;
FIG. 11 is a block diagram of the edge detector assembly shown generally in FIG. 8;
FIG. 12 is a block diagram of the thresholding enabler shown generally in FIG. 8;
FIG. 13 is a block diagram of the threshold selector shown generally in FIG. 8;
FIG. 14 is a block diagram of the remapper shown generally in FIG. 8;
FIG. 15 is a block diagram of the background graylevel updater shown generally in FIG. 8;
FIG. 16 is a block diagram of the scaling subprocessor block shown generally in FIG. 2;
FIG. 17 is a flowchart detailing the steps associated within the scaling processor shown generally in FIG. 16;
FIG. 18 is a block diagram of the document height detection subprocessor block shown generally in FIG. 2;
FIG. 19 is a block diagram of the spot/void subprocessor block shown generally in FIG. 2; and
FIG. 20 is an illustration of the image processors of this invention arranged in a pipelined manner.
DETAILED DESCRIPTION
1. Document System Overview
Referring now to FIG. 1, there is shown a financial document sorting system 10 having a typical document sorter 12 which, in the preferred embodiment of this invention, is a model DP1800 sorter which is manufactured by the Unisys Corporation of Blue Bell, Pa.
Sorter 12 contains a track 14 into which a plurality of financial documents 16 traverse through and reside within, and further contains a typical magnetic character reader 18 and a typical magnetic character reader controller 20. Additionally, sorter 12 contains a document holder 22, a camera assembly 11, and the image processor 24 made in accordance with the teachings of the preferred embodiment of this invention.
Controller 20 is coupled to the reader 18 by signals on the bus 26, to a host computer 28 by signals on the bus 30, and to the image processor 24 by signals on the bus 32. The computer 28 is coupled to an image storage module 34 by signals on the bus 36 and the image storage module 34 is also coupled to the image processor 24 and to a plurality of workstations 38 by signals on the busses 40 and 42 respectively. Additionally, camera system 11 is coupled to the image processor 24 by signals on bus 82.
In operation, documents 16 sequentially traverse in close proximity to reader 18 which reads a typical magnetic code appearing upon each of the documents 16. This code is then sent to the computer 28, by signals on the bus 30, for storage therein and to the image processor 24, by signals on the bus 32. As each of the documents 16 further travels within the track 14, they pass in close proximity to the camera system 11 which captures the image of the document 16 and outputs a digital representation of the image on bus 82 to the image processor 24. This digital representation comprises a plurality of image pixels having an intensity represented by a number between 0 and 255. Image processor 24 then processes this digitized image thereof and sends this processed image, by signals on the bus 40, to the image storage module 34 for storage therein. After passing by the image processor 24, each of the documents are then sorted, by sorter 10, in the usual way and are held within the document holder 22.
After a typical block of the documents 16 have been sorted in the aforementioned manner, the workstations 38, by signals on the bus 42 sequentially request the aforementioned document images from the storage module 34. These images are then downloaded to the workstations 38, by use of signals on the bus 42, along with their associated magnetic code data obtained from host computer 28.
After these images are captured by the workstations 38, individual operators electronically enter the dollar amount associated with each document and electronically resolve any difficulties associated with the reading of the magnetic code thereon by entering and storing the needed corrections for each document image. Each digitized image and its dollar amount and associated corrections then form a single computerized record which is then sent to the storage module 34, by use of signals on the bus 42, where it may be later accessed for use in automatically placing the dollar amount and corrections upon the sorted documents 16. Therefore, the aforementioned document sorting system 10 substantially eliminates the physical handling of the plurality of documents 16 when the associated dollar amount is placed thereon thereby increasing the efficiency and timeliness of the overall document sorting system 10.
Referring now to FIG. 2, there is shown image processor 24 arranged in accordance with the principles of the preferred embodiment of this invention, and including a random access storage memory (RAM) 50, a 5×5×8 bit shift register window assembly 52, a document height detection subprocessor 54, an input/output controller 56, a normalization subprocessor 58, a background suppression subprocessor 60, a spot/void subprocessor 62, and a scaling subprocessor 64.
Specifically, the document height detection subprocessor 54 is coupled to the input/output controller 56 by signals on bus 66 and is further coupled to the storage RAM 50 and to the shift register window assembly 52 by signals on bus 68. The input/output controller 56 is coupled to the storage RAM 50 and to the shift window assembly 52 by signals on bus 70 while also being coupled to the subprocessors 58, 60, 62, and 64 by signals on bus 72.
The shift register window assembly is additionally coupled to storage RAM 50 by signals on bus 74 and is coupled to each of the subprocessors 58, 60, 62, and 64 by signals on bus 76. Additionally, the subprocessors 58, 60, 62, and 64 are coupled together by signals on bus 78 which represents a functional output associated therewith, while the document height detection subprocessor 54 produces a document height output on bus 80.
Input video data is coupled to the storage RAM 50 and to the input/output controller by signals on bus 82 while the input/output controller further has an input bus 84 which is coupled thereto and which contains externally placed parameter data and command inputs which may emanate from host computer 28 through busses 30 and 32 (FIG. 1).
Generally, the normalization subprocessor 58 is used to correct image data defects associated with such things as a non-uniform photo-cell responsiveness of the camera system 11 or non-uniform document illumination across a segment of a document being scanned during the acquisition of input video data which is placed upon bus 82 by system 11.
The background suppression subprocessor 60 is used to eliminate unwanted scenic or patterned background information from the image of a scanned document, while retaining printed and written information with the image associated with signals on the bus 82. The background suppression subprocessor 60 provides for uniform background, increased image contrast, and increased image uniformity associated with the video data placed upon bus 82. The spot/void filtering subprocessor 62 is used to eliminate small white and dark anomalies which adversely affect the quality and compressibility of the image represented by signals on the bus 82, while the scaling subprocessor 64 allows the image to be scaled relative to the resolution of the image by using one of a plurality of algorithms. The document height detection preprocessor 64 finds the highest and lowest points of transition from the image of the document to the image of the background thusly finding or identifying the overall height of the document whose image is represented by signals on bus 82.
The input/output controller is used to receive externally placed commands and parameter data associated with the processing of the subprocessors 54, 58, 60, 62, and 64 and is further used in the normalization function to allow a remotely located controller (e.g. host computer 28) to sample the input video signals upon the bus 82. The input/output controller, by means of signals on bus 72, selects one of the subprocessors 58, 60, 62, or 64 to be activated in response to external command inputs upon bus 84.
The shift register window assembly 52 is used as a repository for image pixel data and is used in the performance of the various functions associated with subprocessors 58, 60, 62, or 64. In the preferred embodiment of this invention, shift register window assembly 52 has a dimension of 5×5×8 bits, since each of the pixels associated with the video image upon the bus 82 is up to eight bits in length, and since the operations associated with the subprocessors 58, 60, 62, and 64 are performed upon a 5×5 pixel array.
2. Storage RAM and Pixel Window Assembly
Referring now to FIG. 3 there are shown further details of the storage RAM 50 and the shift register window assembly 52 of FIG. 2. Specifically, the storage RAM 50 contains a plurality of random access memory units 90(a-d), each of which contain a storage capacity of approximately one column of image data, each column having 532 addressable storage locations therein. Each of the column storage locations is capable of storing eight bits of data therein.
Each of the random access memory units 90(a-d) is coupled to an associated multiplexer 92(a-d) by signals on buses 94, 96, 98, and 100, respectively. Additionally, the storage RAM 50 contains an address generator and read/write controller assembly 102 which is coupled to random access memory units 90(a-d) by signals on bus 104 and to the input/output controller 56 by signals on bus 106. Controller 56 places typical write enabling signals on bus 106 to controller 102. Address generator and read/write controller assembly 102 is coupled to an end-of-scan input signal 108 from camera system 11 by signals on us 82 and its use will hereinlater be explained.
Further, each of the multiplexers 92(a-d) is coupled to input/output controller 56 by signals on bus 112, which provides a multiplexer enablement or selection signal, and each of the multiplexers 90(a-d) are further coupled at another input associated therewith to the input/output controller 56 by signals on bus 110.
Shift window register assembly 52 contains a plurality of registers 114(1-e). Specifically, register 114(a) is coupled to the video input represented by signals on bus 82, and the register 114(b) is coupled to memory 90(a) and to multiplexer 92(b) by signals on bus 116. Register 114(c) is coupled to memory 90(b) and to multiplexer 92(c) by signals on bus 118, while the register 114(d) is coupled to memory 90(c) and to multiplexer 92(d) by signals on bus 120. Register 114(e) is coupled to memory 90(d) by signals on bus 122. Video data, present on bus 82, is also coupled to an input of multiplexer 92(a).
In operation, video data on bus 82 is initially input into multiplexer 92(a) (along with image processing data, on bus 110, which were originally input to the input/output controller by signals on the bus 84 of FIG. 2). Multiplexer 92(a) is then directed by the input/output controller 56, by means of signals on bus 112, to output either the video data that is present upon the bus 82 or the image processing data appearing upon the bus 110 to the memory 90(a) by signals on bus 94. The data represented by the signals on bus 94 is then input into memory 90(a) and is subsequently output therefrom to register 114(b) and to the multiplexer 92(b) by signals on bus 116. Additionally, the video data associated with bus 82 is initially input into the register 114(a) thereby.
The input/output controller 56 then sends additional image processing data to multiplexer 92(b) by signals on bus 110 and directs multiplexer 92(b) to output either signals on bus 116 or signals on bus 110 to memory 90(b) by use of control signals on bus 112. This output data from the multiplexer 92(b) is then output upon bus 96. The data stored within the memory 90(b) is then output to register 114(c) by signals on bus 118 and is further input into the multiplexer 92(c). The input/output controller 56 also sends control inputs to the multiplexer 92(c) by signals on bus 110 and, as before, directs the multiplexer 92(c), by signals on bus 112, to output either signals on bus 110 or signals on bus 118 therefrom and which ultimately appear on the bus 98.
Signal data upon bus 98 is input into memory 90(c) where it is subsequently output to register 114(d) by signals on bus 120 and to multiplexer 92(d) upon the same bus 120. The input/output controller 56 then transmits additional control data to multiplexer 92(d) by signals on bus 112 and this control data will cause multiplexer 92(d) to output either signals on bus 120 or signals on bus 110 to the memory 90(d). The output data associated with the multiplexer 92(d) is placed upon bus 100.
Subsequently, memorY 90(d) outputs the received data upon bus 122 to register 114(e). Thus, in the aforementioned manner, either the video input data originally received upon bus 82 or image processing data which appears upon bus 110 is serially shifted through the memory units 90(a-d) and is subsequently stored within the shift register window assembly 52 (FIG. 2), which is comprised of elements 114(a-e) of FIG. 3. This shifting is done into shift register window assembly 52 in order to allow the video or control data on busses 84 and 82 respectively to be accessed and used by subprocessors 58, 60, 62, and 64.
The address generator and read/write controller assembly 102 is used, in the aforementioned operation, to allow data to be written to memories 90(a-d) by sending a typical enabling signal on bus 104 thereto. Also, controller address generator and read/write controller assembly allows data to be written therefrom in response to a signal on bus 106.
Address generator and read/write controller assembly 102 further defines which addresses, of memories 90(a-d), the received data will be placed within by the use of usual counter mechanisms. This address definition is also sent to memories 90(a-e) by bus 104. The end of scan input signal 108, on bus 82, causes the address generator and read/write controller assembly 102 to note a complete line of scanned data has been received and, in one embodiment, is used by assembly 102 to resynchronize and reset its address counters in order to begin generating addresses for the next line of image data pixels associated with image signals on bus 82.
3. Input/Output Controller
Referring now to FIG. 4 there are shown further details of the input/output controller 56 of FIG. 2 as containing a normalization pointer 130 used for reading data from or writing data to specific locations within storage RAM 50, a write enable controller 132, a comparator 136, parameter data registers 138, data registers 140 and 142, video registers 144, selector control assembly 146, and bypass multiplexer 148.
Specifically, the data registers 140 are coupled to the parameter data registers 138 and to the data registers 142 by signals on bus 150 while receiving input/output data from a previously mentioned external control apparatus by signals on bus 84. Data registers 140 are also coupled to video registers 144 by signals on bus 152, while video registers 144 are coupled to the input video data represented by signals on bus 82.
The selector control assembly 146 is coupled to the normalization pointer 130 by signals on bus 154 and is further coupled to the parameter data registers 138, to the write enable controller 132, and to data registers 142 by signals on bus 156, while additionally being coupled to data registers 142 by signals on bus 158. Additionally, selector control assembly 146 generates a bypass enable signal upon bus 160 which is subsequently sent to the bypass multiplexer 148 which allows data to be sent through image processor 24 without being acted upon by any of the preprocessors 58, 60, 62, or 64 of FIG. 2. (The use of bypass multiplexer 148 will be explained in a later section of this description.)
Additionally, the selector control assembly 146 is coupled to signals on bus 84 which comprises input/output write signal 162, input/output enablement signal 164, input/output select signal 166, function select signal 168, and input/output acknowledge signal 170. Additionally, comparator 136 is coupled to signals on bus 104 (FIG. 3) which carry address information from the controller assembly 102 and is coupled to the pointer 130 by bus 172, and is further coupled to assembly 146, registers 144, and to controller 132 by bus 174.
In operation, the video data represented by signals on bus 82 is input into the registers 144 and is stored temporarily therein, and parameter data associated with the normalization preprocessor 58 (FIG. 2) is input to data registers 140 by signals on bus 84. The output of data registers 140 is coupled by bus 150 to the parameter data registers 138 and represents parameters associated with the normalization preprocessor block 58 of FIG. 2. The parameter data registers 138 then place these parameters upon bus 110, as mentioned earlier. The parameters associated with signals on bus 110 are output to the individual memories 90(a-d) (FIG. 3) (by means of bus enabling signals 112 to multiplexers 92(a-d) but are not written thereto until a signal on bus 104, generated by the write enable controller 132, is transmitted to the memories 90(a-d). This will occur only if controller 56 issues a signal on bus 106 to assembly 102. That is, the write enable controller 132 must receive a signal upon buses 156 and 174 which will enable the controller 132 to transmit the appropriate write enabling signal on the bus 106.
The signal on bus 174 indicates that an address output, which is placed upon bus 104 from the address generator and read/write controller assembly 102 (FIG. 3), is equal to the contents of pointer 130. The signal on bus 156 indicates that the normalization function has been selected by a signal 168 and that one of the registers associated with the plurality of parameter data registers 138 has been selected by a signal 166. If all these conditions are true, then the signal on bus 106 emanates from write enable controller 132 to the assembly 102, which directs the assembly 102 to allow, by signals on bus 104, parameter data register outputs on bus 110 to be placed in memories 90(a-d) in the manner previously described.
The contents of video registers 144 are input into data registers 140 by bus 152 and are latched into registers 140 only when a signal on bus 174 is activated by comparator 136. This video data may be output via bus 84 for viewing by users of the image processor 24. Output signals on bus 72 also contain the select signal 168 on bus 158 which is used to select one the subprocessor blocks 58, 60, 62, or 64 of FIG. 2 and also transmit signals on bus 112 to multiplexers 92(a-d) in response to signals 166 and 168.
Specifically, as to the input signals 162, 164, 166, 168, and 170 of bus 84, the signal 166 directs the data on bus 84 to a specific entity 50, 52, 54, 58, 60, 62, and 64 (FIG. 2) within image processor 24 while signal 162 determines the direction of data (i.e. input or output) relative to the input/output controller 56. Signal 164 enables assembly 146 to begin an input/output operation, and signal 170 is sent by assembly 146 to acknowledge receipt of data upon bus 84.
The assembly 146, in one embodiment, comprises a sequential state machine which is enabled by the activation of signal 164. Next assembly 146 examines the state of signals 168, 166 and 162 to determine which preprocessor 54-64, which register in the selected preprocessor 54-64, and which direction the data is directed respectively. The selection and direction are made over bus 156 to register 142. After selection, the data is input or output from bus 84 by means of data registers 140. Completion of the cycle is indicated by the activation of signal 170. If the normalization function is selected by signals 168 then the acknowledgment can be held off until comparator 136 has indicated an address match on bus 174.
The controller 132, in one embodiment, also comprises a sequential state machine which is enabled by a signal on bus 174 and then examines signals on bus 156 and then places a unique output which directs assembly 102, by signals on bus 106 to continuously perform read/write cycles. If the normalization preprocess is selected, by signal 168, assembly 102 is directed to only read or write at the address set by pointer 130.
4. Normalization
The purpose of the normalization preprocessor is to correct image defects associated with camera system 11. Referring now to FIG. 5 there is shown a block diagram of further details of normalization preprocessor block 58 of FIG. 2, including adders 200 and 202, subtractor 204, AND gates 206 and 208, delay unit 210, unsigned multiplier 212, and remapper 214. Also shown is bypass multiplexer 148 which is used to pass data through image processor 24 without traversing the normalization preprocessor block 58.
Signals on lines 216, 218, 220, and 222 are used in conjunction with the logic entities 200, 202, 204, 206, 208, 210, 212, and 214 in order to achieve a test gain and a test bias which generates a repeatable pattern of data. Specifically, the gain compensation and the bias compensation values, present on busses 222 and 218 are calculated in a software routine by the user of the pipeline such that when the two signals on busses 218 and 222 are combined with signals on busses 216 and 220 the aforementioned known repeatable pattern emerges on busses 224 and 226.
AND gate 206 is coupled to a signal on bus 228, which represents a test mode enablement, and to a signal on bus 218. AND gate 208 is also coupled to the signal on bus 228 and to the signal on bus 222. The output of the AND gate 206 is input into the adder 200, along with a signal on bus 216. The adder 202 is coupled, at its inputs, to an output of AND gate 208 and to the signal on bus 220. Adders 200 and 202 produce outputs on buses 224 and 226, respectively, which are, in turn, coupled to subtractor 204 and to unsigned multiplier 212, respectively. The output of subtractor 204 is coupled to an input of multiplier 212 on bus 232.
The subtractor 204 has a first input thereof coupled to the video input signals on bus 82. The output of adder 202 is coupled to the unsigned multiplier 212 which produces an output signal on bus 234 for transmission to remapper 214. Remapper 214 then produces, in a manner to be described below, an output on bus 236 which is sent to bypass multiplexer 148.
Additionally, a signal on bus 238 representing the presence of a document is also coupled to the delay assembly 210 which produces an output upon bus 240 for transmission to bypass multiplexer 148. Further, the delay assembly 210 is coupled to an end-of-scan signal on bus 108 and the bypass multiplexer is additionally coupled to the video input signal on bus 82. Bus 108 is also coupled to multiplexer 148.
Finally, the input/output controller is coupled to bypass multiplexer 148 via bus 242 which carries an enablement signal to select which of the input signals to multiplexer 148 will be passed to the multiplexer output at bus 244 (either delayed output on bus 240 and output on bus 236 or non-delayed output on buses 238 and 82, and 108.
Specifically, the gain and bias (and associated compensation) tables required to perform the normalization function are input into input/output controller by bus 84. The input/output controller routes this table data of four tables to the storage RAM 50 by bus 70 (FIG. 2). Each table is loaded in a separate storage RAM 90(a-d) (FIG. 3).
Following loading of the tables, values of the tables are sequentially output to the shift register window assembly and this output is synchronized with the video data on bus 82. The synchronization of the storage RAM 50 is effectuated by the end of scan signal on bus 108. That is, a signal on bus 108 identifies the last pixel in a video scan and causes the address generator and read/write controller assembly to reset to a predetermined initial address.
The outputs of the shift register window assembly (i.e., bias storage signal 216, bias compensation storage signal 218, gain storage signal 220, and gain compensation storage signal 222) are output on bus 70 to control assembly input/output controller where they can be read by a user of image processor 24.
Entities 200, 202, 206 and 208 were placed within preprocessor block 58 in order to allow testing of the block while providing for identical outputs. The testing methodology generally requires the use of gain and bias compensation signals which, when combined with the typical gain and bias signals, cause the test gain and test bias signals to be generated, which are predetermined to be the same for all of the preprocessor blocks 58, regardless of what channel of data they are operating upon (i.e., in situations where multiple channels of data are processed, in parallel, by a plurality of blocks 58). Because the gain and bias values will be different for each channel, the user must calculate the gain and bias compensation values by taking the difference between the test gain and bias values the user requires, and the actual gain and bias values.
In test mode operation, the signals on the bus 228 enable both the AND gates 206 and 208 and allow the value of signals on the bus 218 and signals on bus 222 to be respectively output therefrom. Thusly, the adder 200 adds the signal on the bus 218 to the signal on bus 216 and produces this added signal onto bus 224. The adder 202 then adds the bus 220 to the bus 222 and produces this output signal upon the bus 226. The subtractor 204 then subtracts the signal on the bus 224 from each of the pixel values appearing upon signal on the bus 82 and produces an output to the unsigned multiplier 212. The unsigned multiplier 212 then multiplies the outputs of adders 202 and subtractors 204 thereby producing an output signal on the bus 234 to the remapper 214 which converts the seven bit value of incoming data into six bit values of gray-scale video and in one embodiment comprise truly a lookup table. The remapper is used in order to have the data represent the true actual accuracy associated therewith.
In normal operating mode, signals on bus 228 force the outputs of gate 206 and 208 to zero allowing bias and gain values from busses 216 and 220 to pass unaltered through adders 200 and 202 respectively.
Multiplexer 148 allows a user of image processor 24 to bypass subprocessor block 58 as the need arises. In one embodiment, this entity 148 is provided in order to allow test data to pass through block 58 unaltered.
5. Background Suppression
The purpose of background suppression is to eliminate unwanted scenic or patterned background information while retaining printed and written information. Referring now to FIG. 6 there is shown a flowchart 300 which represents the generalized process involved in the background suppression sequence associated with subprocessor 60 of FIG. 2. Many of these general operations associated with flowchart 300 have, in the preferred embodiment of this invention, been implemented as a pipelined process in hardware, in order to increase the speed associated with subprocessor 60. Essentially, the background suppression function begins with an initial step 301 followed by the step 302 which requires the obtaining of a desired video image. This image is usually placed upon the bus 82 and is input into the shift register window assembly 52 in the manner previously specified. Next, step 304 requires the initialization of a dynamic/fixed threshold memory which is used to determine if the threshold will be dynamic or fixed for each of the individual pixels within the obtained image and is used to store a fixed threshold (which may be updated--to be explained later) therein (i.e. a gray-scale background reference).
The next step 306 requires the extraction (from each of the image pixels within the window assembly 52) of data (to be later explained). The next step 308, is associated with the initialization of a variable "P" used for explanatory purposes onlY, while the next step, 310 requires the obtainment and updating of a gradient histogram for each of the pixels of the obtained image associated with the variable "P".
Step 312 requires the incrementing of the variable "P" which represents an index to each pixel in the acquired image and is followed by step 314 which requires image processor 24 to determine if a scan of the acquired image line has ended. If a scan line has indeed ended, then step 314 is followed by step 316 which requires the computation of a new gradient threshold associated with the portion of the acquired image which has been inspected. If a scan line has not ended, then step 314 is followed by step 318 which requires a determination, if all the pixels of the image have operated upon. If all the pixels have not been operated upon, then step 318 is followed by step 310. If the determination in step 318 is that all the pixels of the image have been operated upon, then step 318 is followed by step 320 which reinitializes the previously defined variable "P". A gradient threshold, therefore, has been generated for each column or vertical scan line of the image at this point.
Step 320 is followed by step 322 which requires the checking for fixed or dynamic thresholding. Step 322 is followed by step 324 which requires calculation and selection of the pixel threshold. Step 324 is followed by step 326 which requires a thresholding and remapping of the pixel, and step 326 is followed by step 328 which requires the updating of the background gray-level reference associated therewith.
Step 330 follows step 328 and requires the storage in the dynamic/fixed threshold memory of the updated background gray-level reference, and step 332 follows step 330 which requires image processor 24 to update the previously defined variable "P". Step 334 follows step 332 and requires image processor 24 to determine if all of the pixels have been operated upon. If all the pixels have not been operated upon, then step 334 is followed by step 322. However, if all the pixels of the obtained image have been operated upon, then the initial state 301 is re-entered.
In order to fully understand the utilization of the following steps by the background suppression subprocessor 60 of FIG. 2, it is now necessary to turn to FIG. 7 which shows a typical pixel packing associated with the shift register window assembly 52 of FIGS. 2 and 3. That is, shift register window assembly 52 is seen to have columns 438, 440, 442, 444, and 446 and rows 448, 450, 452, 454, and 456. Each intersection of a column 438, 440, 442, 444, or 446 with an associated row 448, 450, 452, 454, or 456 yields a unique pixel value associated with the acquired image which was represented by signals on bus 82 (FIG. 2). For example, the pixels associated with column 442 are designated as "P 31 ", "P 32 ", "P 33 ", "P 34 ", and "P 35 ".
Turning now to FIG. 8, there is shown a more detailed block diagram of the background suppression subprocessor 60 of FIG. 2. Subprocessor 60 includes an arithmetic and control assembly 460, a histogram counter controller 462, a plurality of histogram counters 464, a stroke edge detector 466, a thresholding enabler 468, a threshold selector 470, a remapper 472, and a background gray-level updater 474.
The background suppression arithmetic/control assembly 460 is coupled to shift register window assembly 52 by signals on bus 478 and is coupled to the histogram counter controller 462 and to the plurality of histogram counters 464 by bus 480. Control assembly 460 additionally is coupled to signals 482, 484, and 486 which respectively represent a background reference update factor, a change in peak percentage, and an exit stroke gradient threshold value (all of which will be herein explained). These signals initially appear on bus 84 and are programmably input from a user of image processor 24 of FIG. 2 to the controller 56.
Additionally, the control assembly 460 is coupled to the stroke detector 466 by bus 488 and to the threshold selector 470, the remapper 472, and to the background gray-level reference updater 474 by bus 490. Enabler 468 is coupled to the detector 466 by bus 492, to updater 474 by bus 494, and to the threshold selector 470 by bus 496. The remapper 472 is coupled to the selector 470 by bus 498 and to the updater 474 by bus 500.
In operation, the histogram counter controller 462 and histogram counters 464 are used to create a histogram of gradient magnitudes associated with the acquired image in order to dynamically process the image knowing frequently occurring gradient magnitudes that exist therein. The histogram is updated with each new pixel 458 in the shift register window assembly 52, in practice. This tailoring of gradients, in a dynamic fashion, is seen to increase the usefulness of the background suppression operation. That is, the background patterns with fairly high contrast could interfere with a typical background suppression algorithm. The gradient histogram allows the image processor 24 to distinguish between infrequently occurring high contrast printing and more frequently occurring low contrast background patterns, and allows these more frequently occurring patterns to be suppressed.
The control assembly 460 is used to control the histogram counter controller 462 and counters 464, the stroke edge detector 466, the selector 470, and the updater 474 while calculating a plurality of values associated with the imaging process. The dynamic/fixed threshold memory is contained, in this embodiment, in assembly 460 and is used to determine if a particular pixel 458 within the acquired image will have a dynamic or fixed thresholding associated therewith while the thresholding enabler 468 enables either the dynamic or the fixed thresholding.
The stroke edge detector 466 signals enabler 468, by bus 492, when a contrast change has occurred which is caused by the detection of the leading and trailing edges of printed or written strokes upon the image. The threshold selector 470 then computes the dynamic threshold, if it has been previously selected, or allows fixed thresholding to occur. The remapper 472 readjusts the gray-level associated with the threshold and pixel 458 in question, based on the threshold selector 470 and the updater 474 then updates the gray-level or fixed thresholding reference. As previously alluded to, it has been determined that the dynamic thresholding has yielded empirically better results than the results associated with the fixed thresholding due to the fact that the dynamic thresholding may be modified for different pixel values rather than having one single thresholding value against which all the pixels are represented.
Referring now to FIG. 9, there are shown further details of the background suppression arithmetic control assembly 400 and controller and counters 462 and 464 respectively (FIG. 8). Assembly 460 is seen to contain a background suppression arithmetic unit 502 coupled by bus 504 to a comparator 506 and further coupled by the bus 508 to a divisor unit 510. Additionally, the divisor unit 510 is coupled to a comparator 512 by bus 514 and is coupled to the counter controller 462 by the same bus 514. The dynamic/fixed threshold memory 518 is coupled to unit 502 by busses 520 and 522.
The dynamic/fixed threshold memory 518 contains two pieces of data for each pixel position in a channel of data 82 (FIG. 2). The two pieces of data are a dynamic threshold flag bit (signal on bus 520) and a background gray level reference (signal on bus 522).
The flag bit, on bus 520, is "set" to indicate that at the pixel location in a scan, dynamic thresholding should be used to separate character strokes from background. The value of this background gray level reference is re-evaluated for every scan line of the channel (hereinafter explained). If the flag bit is cleared, then a fixed gray level reference threshold is used to separate strokes from background data.
The comparators 506 and 512 output signals on the buses 524 and 526 which are input into an AND gate 528. The output of AND gate 528 is coupled by bus 530 to counter selector controller 462. The counter selector 462 outputs signals on the bus 532 which are input into the histogram counters 464. The histogram counters 464 place an output signal on bus 534 which is coupled to the background suppression arithmetic/control unit 502.
In operation, the background suppression arithmetic unit 502 is used to generate a plurality of quantities associated with each of the pixels within the shift register window assembly 52. These values include a current horizontal gradient, a current vertical gradient, a current gradient magnitude, previous horizontal gradient, previous vertical gradient, previous gradient magnitude, and an average local gray value. All of these aforementioned values are associated with a single pixel 458 shown in FIG. 7.
The following computational examples are with reference to pixel "P 33 " which is placed within column 442 and row 452 of shift register window assembly 52, as shown in FIG. 7. The current horizontal gradient for pixel "P 33 " is defined to equal the gray-scale value associated with pixel "P 33 " minus the current gray-scale value associated with pixel "P 43 ". The current vertical gradient associated with pixel "P 33 " is defined to be the current gray-scale value associated with pixel "P 34 " minus the current gray-scale value associated with pixel "P 32 ". The current gradient magnitude is defined to be the absolute value of the current horizontal gradient plus the absolute value of the current vertical gradient. The previous horizontal gradient associated with pixel "P 33 " is defined to be the gray-scale value associated with pixel "P 13 " minus the gray-scale value associated with pixel "P 33 ". The previous vertical gradient is defined to be the gray-scale value associated with pixel "P 24 " minus the gray-scale value associated with pixel "P 22 ". The previous gradient magnitude is defined to be the absolute value of the previous horizontal gradient plus the absolute value of the previous vertical gradient. The average local gray value associated with pixel "P 33 " is defined to be a summation of gray-scale values associated with pixels "P 22 ", "P 23 ", "P 24 ", "P 32 ", "P 33 ", "P 34 ", "P 42 ", "P 43 ", "P 44 ", plus two times the summation of the gray-scale values of pixels "P 11 ", "P 13 ", "P 15 ", "P 31 ", "P 35 ", "P 51 ", "P 53 ", "P 55 ". This summation is then divided by twenty-five to yield the aforementioned average local gray value.
After these quantities have been computed, the horizontal gradient is input to the comparator 506 of FIG. 9 by signals on the bu 504. A value of zero is also input into the comparator 506 along the bus 536. The comparator 506 then compares the value of zero which is defined by the bus 536 with the horizontal gradient placed upon the bus 504 and, if the value of the horizontal gradient, as previously defined, is greater than zero, then comparator 506 places a logical high value onto the bus 524. Each pixel 458 has six bits of data associated therewith at this point, in one embodiment.
The comparator 512 has an input coupled to the bus 514 which is also coupled to the divisor 510. The diVisor 510 divides the current gradient magnitude, on bus 508, by three and outputs the signal onto bus 514. The comparator 512 also has an input coupled to the bus 538 which is defined to be eight and compares the value of eight to the value upon bus 514. If the value of bus 514 is greater than eight, then the signal on the bus 526 is defined to be logically low. If the value upon bus 514 is less than eight, then the signal on bus 526 is defined to be logically high. The AND gate 528 then outputs a signal on the bus 530 which is logically high, if the horizontal gradient associated with the pixel in question is greater than zero, but having a current gradient magnitude being less than twenty-five. Should these conditions be satisfied, then the signal on the bus 530 is output from the AND gate 528 to the counter controller 462 and which enables the counter controller 462 such that one of the plurality of histogram counters 464 is activated.
The counter that is activated is defined by the signal on bus 532. That is, each of the counters within the plurality of histogram counters 464 is uniquely addressed by signals on bus 532. Thus, a histogram of values associated with each of the pixels in the assigned image is built such that the most frequently occurring gradients that exist within an image may be defined. Each of the counters within the plurality of counters 464 are addressed by the output of divisor 510. Therefore, the background suppression steps 301-314 of the flowchart of FIG. 6 have now generally been explained relative to the background suppression associated with subprocessor 60. In order to detail the general computation of a new gradient threshold associated with step 316 of FlG. 6, it is necessary now to refer to FIG. 10.
Specifically flowchart 550 of FIG. 10 begins with an initial step of 552 which is followed by step 554 which requires subprocessor 60 of FIG. 2 (i.e. entity 462 therein) to define a histogram peak. That is, controller 462 examines all of the counters within the plurality of histogram counters 464 to determine which one has the highest value. The counter within entity 464 with the highest value determines the peak. Step 556 follows step 554 and requires the subprocessor 60 to compute a cutoff value. This cutoff value is defined to be the value of the counter (within counters 464 having the highest value) multiplied by the signal 484 (FIG. 8) which may be programmed by the user of processor 24.
Signal 484, in the preferred embodiment of this invention represents a change in the gradient peak and in the preferred embodiment of this invention is typically 25%. This value was empirically derived and found to give adequate separations between background gradients represented by the peak of the histogram counters 464 and printed character stroke gradients represented by those gradients exceeding the cutoff value.
Next, step 558 follows step 556 and requires subprocessor 60 (i.e., controller 462) to search for the first histogram counter having contents less than or equal to the new cutoff value. Step 560 then follows step 558 and requires subprocessor 60 to compute a gradient threshold select, which is substantially equal to the following:
(address of histogram counter having highest value×3)+1
Step 560 is then followed by step 562 which defines the end of flowchart 550.
Referring now to FIG. 11 there is shown more detail of the stroke edge detector 466 of FIG. 8 as containing subtractors 600(a-c), lookup tables (LUT) 602(a-c) comparators 604a-c), subtractor 606, lookup table 608, comparator 610, and OR gate 612. Specifically, the background suppression arithmetic control unit 502 is coupled to subtractors 600(a-c) by buses 614 and 616 while also being coupled to lookup tables 602(a-c) by signals on the same bus 616. Subtractors 600(a-c) are coupled to the lookup tables 602(a-c) by bus 618, while lookup tables 602(a-c) are coupled to comparators 604(a-c) by buses 620 and 622.
In operation, the stroke edge detector 466 is used to determine the change in local contrast associated with every pixel 458 within the acquired image on bus 82. The change in local contrast is computed both in terms of coming into a handwritten or printed stroke and exiting a handwritten or printed stroke within the same pixel. The operation of the stroke edge detector 466 will now be explained in terms of a single pixel, that of pixel "P 33 " of FIG. 7, but it should be apparent to one of ordinary skill in the art that each of the pixels associated with window shift register window assembly, and illustrated in FIG. 6, may be processed in a substantially similar manner.
Unit 502 (see FIG. 9) obtains the gray-scale values associated with pixels "P 23 ", "P 13 ", and "P 33 " from the shift register window assembly 52 by signals on bus 478 (FIG. 8). These gray-scale values are then placed upon bus 614 and input into subtractors 600(a-c). Subtractor 600(a) subtracts the gray-scale value of pixel "P 33 " from that of pixel "P 23 " and outputs the difference on bus 618 to lookup table 602(a). Subtractor 600(b) subtracts the gray-scale value of pixel "P 33 " from that of pixel "P 13 " and outputs the subtracted value on bus 618 to lookup table 602(b). Subtractor 600(c) subtracts pixel "P 33 " from the background reference threshold, which has been fixed and stored within the unit 502, and outputs the subtracted value to the lookup table 602(c) by bus 618.
Additionally, unit 502, by signals on bus 616, outputs the gray-scale value of pixel "P 23 " to lookup table 602(a), the gray-scale value of pixel "P 13 " to lookup table 602(b), and the background gray-scale reference value to lookup table 602(c).
Signals on bus 618 are then used as addresses to access a local contrast value which has already been stored and which is assigned to a given change in pixel level value. Upon receipt of signals on bus 616, tables 602(a-c) output this change in local contrast to comparators 604(a-c) by signals on bus 620. Additionally, comparators 604(a-c) also are coupled by bus 622 to lookup tables 602(a-c), and tables 602(a-c) output thereto a stored (empirically formulated) contrast threshold which may be modified by a user of image processor 24 which, in the preferred embodiment of this invention, is 35.
Comparators 604(a-c) then compare the change in local contrast which is calculated by lookup tables 602(a-c) with the contrast threshold (i.e., 35) and determine if the changes in local contrast associated with these lookup tables 602(a-c) is greater than this threshold. If any of these changes in local contrast are indeed greater than the threshold, then OR gate 612 outputs a logical one onto bus 624.
The subtractor 606 is used in cooperation with lookup table 608 and comparator 610 to determine the change in local contrast associated with exiting from a stroke within the image in question. Specifically, assembly 502 inputs the gray-scale value associated with pixels "P 33 " and "P 13 " to the subtractor 606 by bus 626. Assembly 502 also inputs to lookup table 608 the background gray-scale reference value associated therewith along the same bus 626. Subtractor 606 then subtracts the gray-scale value associated with the pixel "P 13 " from the gray-scale associated with the pixel "P 33 " and outputs the subtracted value to the table 608 by signals on bus 628.
Lookup table 608 then provides the change in local contrast based upon the background reference gray-scale associated with signals on the bus 626 and the subtracted signal on the bus 628 and inputs this, by bus 629, to comparator 610. This calculation is defined as: [(P 33 -P 13 )/(Background Reference gray-scale)] *100.
The comparator 610 then compares the output value associated with the change in local contrast for the exiting stroke associated with the active pixel 458 against an empirically derived threshold contained in table 608. In the preferred embodiment of this invention it is 25. If, indeed, this threshold has been exceeded, comparator 610 produces a logical one on bus 630 indicating change in local contrast in the exiting direction associated with the local pixel 458 from a printed or written document stroke.
Referring now to FIG. 12, there is shown details of the threshold enabler 468 of FIG. 8 as containing a NOT gate 650, an AND gate 652, comparators 654, 656, and 658, a latch 660, OR gate 662, AND gates 664, 666, and 668, comparators 670 and 672, and an AND gate 674.
Specifically, AND gate 652 is coupled to the latch 660 by bus 676, while the NOT gate 650 is coupled to the latch 660 and to a first input of AND gate 664 by bus 678.
The output of OR gate 662 is coupled to a second input of AND gate 664 by bus 680. A first input of OR gate 662, is coupled to the output of AND gate 666 by signals on bus 682. A second input of OR gate 662 is coupled to an output of comparator 654 by signals on bus 684, and a third input of OR gate 662 is coupled to bus 630. AND gate 666 has a first input coupled to an output of AND gate 668 via bus 686 and a second input coupled to an output of AND gate 674 by bus 688. AND gate 652 has a first input coupled to bus 624 and a second input coupled to the dynamic thresholding signal on bus 520 which emanates from the dynamic threshold memory 518 of FIG. 9.
Comparator 654 has a first input coupled to the gray-scale value of the active pixel (i.e. pixel "P 33 ") obtained from the window shift register assembly 52 by bus 478 and a second input coupled to the background gray-scale reference signal 690 which is stored in the dynamic/fixed threshold memory 518 of FIG. 9 (and which will be explained later). Comparator 656 has a first input coupled to the current gradient magnitude via bus 492 from assembly 460 (FIG. 8) and a second input coupled to signal 486 which is a gradient threshold associated with an exit stroke of the active pixel (i.e., pixel "P 33 ") and which is empirically defined by the user of image processor 24 and in the preferred embodiment of this invention, this exit stroke gradient threshold comprises a value of seven out of a possible range of 0 to 127.
Comparator 658 has a first input coupled to the gradient threshold associated with the exit stroke (i.e., signal 486) and a second input coupled via bus 492 to the previous magnitude gradient associated with the background suppression arithmetic control assembly 460 (FIG. 8). The outputs of comparator 656 and 658 are respectively placed on bus 659 and 661 to gate 668. Comparator 670 has a first input coupled by bus 492 and 488 to the current horizontal gradient and a second input coupled to bus 692 which carries a logically zero signal. The comparator 672 likewise has a first input coupled, to the logically zero signal on bus 692 and a second input coupled to the previous horizontal gradient on bus 492. The outputs of comparators 670 and 672 are input to AND gate 674 by signals on bus 694.
In operation, the dynamic threshold flag signal on bus 520 is inverted by gate 650, and this inverted signal is then sent to the input of latch 660. Additionally, the AND gate 652 will cause the signal on bus 678, from invertor 650, to be latched by latch 660 when the conditions at the input of gate 652 produce a signal on the bus 676 which is logically high. Thus, the AND gate 652 cooperates with the latch 660 in producing a disabling signal, on bus 688, for the dynamic threshold select whenever the dynamic threshold flag signal on bus 520 is logically high and entry into a printed stroke is detected by signal on bus 624 going to a logically high state. In other words, dynamic thresholding is disabled if it has been previously enabled and a printed stroke, of the image, is being processed requiring no dynamic thresholding.
The signal on the bus 696 will comprise an enablement signal for the dynamic thresholding as long as any one of the signals on the buses 630, 684, or 682 are logically high and the enablement flag signal on bus 520 is low. That is, since the AND gate 664 logically combines signals on the bus 678 and 680, these signals must be both logically high in order for the signal on bus 696 to be the same. Therefore, the signal on the bus 520 must be logically low in order for the signal on the bus 678 be logically high. Additionally, in order for the signal on the bus 680 to be logically high, one of the signals on the buses 630, 684, and 682 must be logically high due to the operation of the OR gate 662.
The signal on the bus 630 will be logically high if the aforementioned output of the comparator 610 (FIG. 11) is logically high. The signal on the bus 684 will be logically high if the gray-scale value associated with the pixel in question (i.e. "P 33 ") is higher than the background gray-scale reference value associated with signal 690. The signal on the bus 682 will be logically high if the signals on the buses 686 and 687 are both logically high. Therefore, in order for the signal on the bus 686 to be logically high, the output of both comparators 656 and 658 must be logically high at the same time. This will occur if the current gradient threshold associated with the pixel in question is greater than the exit stroke gradient threshold and if the previous gradient threshold is greater than the exit stroke gradient threshold as well.
Signals on the bus 688 will be logically high if the output of the comparators 670 and 672 are logically high. This will occur only if the horizontal gradient is negative and the previous horizontal gradient is negative as well. Should the signals on the buses 686, and 688 all be logically high, then the signal on the bus 682 will be logically high and will cause the dynamic thresholding to be enabled via a logically high signal on the bus 696.
Referring now to FIG. 13, there are shown details of the threshold selector 470 of FIG. 8 as containing a comparator 700, a lookup table 702, and a multiplexer 704. Specifically, the comparator 700 is coupled to signals on bus 490 (FlG. 8) which carry the current gradient magnitude and the calculated gradient threshold. Additionally, the lookup table 702 is also coupled to a signal on the bus 490 corresponding to the average local gray value associated with the pixel in question.
The comparator 700 places its output signals on bus 706 to lookup table 702 which produces an output signal on bus 708 to the multiplexer 704. Multiplexer 704 has its input coupled to the signals on the bus 490 and receives an input associated with the background gray-scale reference value signal. The value of the dynamic threshold select signal carried by bus 496 is coupled to a select port of multiplexer 704. Multiplexer 704 produces an output upon bus 710.
In operation, comparator 700 compares the values of the current gradient magnitude to the computed threshold gradient, and if the current gradient magnitude is greater than or equal to the computed threshold gradient, comparator 700 produces a logical one onto bus 706. If the computed threshold gradient is greater than the current gradient magnitude, then the comparator 700 will produce a logical zero upon the bus 706. The lookup table 702 will then use the signals on bus 706 and the average local gray value associated with the pixel in question to produce a dynamic threshold associated with the pixel. The contents of the lookup table 702 are experimentally derived and associate a threshold value for every average local gray value of the pixel to be thresholded. In the preferred embodiment of this invention the dynamic threshold is approximately 102% of the average local gray value if the signal on bus 706 is a logical "one" and approximately 96% if it as logical "zero" in order to move the threshold up in an area having a relatively high contrast.
This dynamic threshold is output to the multiplexer 704 by signals on bus 708. The dynamic threshold select signal on buses 688 and 696 which are coupled to the bus 496 then selects either a background gray-scale reference value or an output of the lookup table 702 to be output from the multiplexer via bus 710 as the background suppression threshold to be used with the pixel in question ("P 3 " of FIG. 7).
Referring now to FIG. 14, there are shown further details of the remapper 472 of FIG. 8 as containing a remapped lookup table 714 having a first input coupled to the threshold present upon bus 710 and a second input coupled to the gray-scale value of the pixel in question which is present upon bus 490. The remapped lookup table 714 then compares the threshold value present upon the bus 710 with the gray-scale value of the pixel 490 and produces an output pixel value which is four bits long on bus 716.
Look up table 714 is used, in the preferred embodiment of this invention, to threshold each pixel 458 "P 33 " upon bus 490. This thresholding is used to decide whether to retain the pixel's current gray-scale value or turn it to white and simultaneously remap the pixel from a gray-scale range of 0 to 63 to a gray-scale range of 0 to 15.
Table 714 is created such that there is a separate remapping curve for each possible threshold associated with signals on line 710. Each curve has the following property:
(a) an input pixel gray value greater than the pixel threshold is given an output gray-scale value of 15 (white);
(b) an input pixel gray value less than twenty five percent of the threshold on bus 710 is given an output gray-scale value of zero (black); and
(c) an input pixel gray value between the above two levels is given an output gray-scale value between 0 and 15.
This remapping is done to facilitate later ease of compression and scaling, and provides increased character contrast.
Referring now to FIG. 15, there is shown further details of the background gray-level updater 474 FIG. 8 a containing a comparator 720, an AND gate 722, a subtractor 724, a latch 726, a divisor 728, and an adder 730. Specifically, comparator 720 has a first input coupled to the computed threshold value signal on bus 710 and a second input coupled to the gray-scale associated with the pixel "P 33 " by signals on bus 490. Additionally, the subtractor 724 has a first input coupled to the gray-scale value of the pixel "P 33 " by signals on bus 490 and a second input coupled to the background gray-scale reference value, currently used, by signals on bus 490.
The dynamic threshold flag signal on bus 520 (which is coupled to bus 490) is also coupled to AND gate 722 at a first input thereof. An output of comparator 720 is coupled by bus 732 to a second input of AND gate 722, and an output of AND gate 722 is coupled to the control latch 726 by bus 734. An output of subtractor 724 is coupled to divisor 728 by bus 736 and an output of divisor 728 is coupled to a first input of adder 730 by signals on bus 738. An output of adder 730 is coupled to the latch 726 by signals on bus 740. Additionally, the adder 730 has a second input coupled to the background reference gray-scale value associated with signals on the 490, and the divisor 728 has a second input coupled to the background gray-scale reference update factor on bus 490. The background reference gray-scale update factor (signal 482) is empirically determined and loadable to image processor 24 through input/output controller 56. The new background reference factor is output from latch 726 and placed on bus 742.
In the preferred embodiment of this invention, the background reference update factor is determinative of how much of the difference between the current reference value (on bus 490) and the pixel 458 (i.e., "P 33 ") will be added to the current reference value to form a new reference value. It has been determined that a continued updating of the reference value yields more accurate results. The preferred embodiment of this invention uses a value of 4 for the background reference update factor.
In operation, the background reference gray-scale value will be updated by the cooperation of the comparator 720, subtractor 724, divisor 728, and adder 730. This background reference gray-scale updated value will be output if a signal on bus 734 enables this to occur. Specifically, the subtractor 724 will subtract the background gray-scale reference value from the gray-scale value of the pixel 458 (e.g., pixel "P 33 ") and output the value upon the bus 736 to the divisor 728. The divisor 728 will divide the subtracted value by the background reference gray-scale value update factor which appears upon bus 490 and outputs this divided value via bus 738 to the adder 730. The adder 730 will then add the updated value to the current, existing gray-scale reference value (i.e., signal 482) and outputs the updated value upon the bus 740 to the input of latch 726. The data will not be accepted by latch 726 until signal on bus 734 is logically high. That is, in order for the latch 726 to input the updated gray-scale value therefrom, the signal upon the bus 490 and the signal upon the bus 732 must both be logically high. This, in turn, requires comparator 720 to determine that the gray-scale pixel value associated with the active pixel 458 (i.e., "P 33 ") appearing on bus 490 must be greater than the computed threshold value on bus 710. Additionally the dynamic thresholding signal on buses 490 and 520 must also be logically high. If these two aforementioned conditions are met, then the signal upon bus 734 is logically high and allows the latch 726 to output the updated gray-scale reference value, which is present upon the bus 742, therefrom.
6. Scaling
Referring now to FIG. 16, the scaling subprocessor block 64, which is used to modify the resolution of the image (i.e. by changing its dimension), contains a scan-line counter 772 and a scaling processor 774. The counter 772 is coupled to an end-of-scan signal on bus 108 (FIG. 3) and generates a single count for eVery "end-of-scan" pulse that appears on bus 108, thereby producing (on bus 776) a running identification of the columns associated with the acquired image. Bus 776 is coupled to an input of scaling processor 774. Additionally, the scaling processor 774 is coupled to row count signals on bus 104 (FIG. 3) and to bus 76. Processor 774 uses the row counts, on bus 104, and column counts, on bus 776 to correctly place the position of each of the pixels within the acquired image. The scaling processor 774 uses the column count and row count associated with signals on busses 776 and 104, respectively, to produce a scaled output.
Referring now to FIG. 17, there is shown a flowchart 800 which details the operation of the scaling processor 774. The initial step 802, of flowchart 800, is followed by step 804 which requires the scaling processor 774 to acquire the row and column counts of buses 776 and 104 respectively. Step 806 follows step 804 and requires the scaling processor 774 to select pixels of data from the RAM and shift window register assembly 50, 52, by bus 76, wherein these pixels are selected based upon the row and column counts on the buses 776 and 104 respectively.
Step 808 follows step 806 in which the scaling processor 774 processes the acquired pixels in a scaling usual manner and then outputs the processed data onto bus 809 (FIG. 16) to an output multiplexer 148. Step 808 is followed by step 804. In the preferred embodiment of this invention, the scaled output value associated with step 808 is a typical median scaled value of the selected pixels. This is proven to retain edge features better than standard averaging techniques. That is, three columns (i.e. 440, 442, and 444) of pixels and three rows (i.e. 450, 452, and 454) are processed by processor 774 at any instant of time. Processor 774 then discards the center pixel 458 and defines four quadrants as being defined by pixels "P 42 ", "P 32 ", and "P 43 "; "P 22 ", "P 32 ", and "P 23 "; "P 23 ", "P 24 ", and "P 34 "; and "P 43 ", "P 44 ", and "P 34 " respectively. Each quadrant is then assigned a single gray-scale value defined as the median of the gray-scale value of the pixels within each quadrant. Processor 774 then outputs one gray-scale value per quadrant at a time. This median scaling technique has proven to yield substantially sharper images then many prior scaling techniques.
7. Height Detection
Referring now to FIG. 18, there is shown more details of the document height detection subprocessor block 54 of FIG. 2 as containing a comparator 820, a 5×1 bit shift register 822, an AND gate 824, a comparator 826, an AND gate 828, a pulse generator 830, registers 832, 834, 836, and 838, a comparator 840, a NOT gate 842, and an AND gate 844.
A first input of comparator 820 is coupled to video input data on bus 82 and a second input thereof is coupled to input/output controller 56 by bus 846 which carries signals representing a gray-scale background reference. The reference, in the preferred embodiment of this invention has a value of 14. Its purpose is to distinguish between track background and current image data. The comparator 820 compares the video input (on a pixel by pixel basis) to that of the background reference present on bus 846 in order to determine if the pixel is of a document or background type. If the video input signal on bus 82 is greater than or equal to the background reference signal on bus 846, then the comparator 820 issues a logical one upon bus 848 to the 5×1 bit shift register 822. When the 5×1 bit shift register 822 contains five consecutive values of one therein, a signal on bus 850 to the AND gate 828 is transmitted. A document-present signal (emanating from a camera assembly 11 FIG. 1) is placed on bus 852 and is coupled to a second input of AND gate 828. The trailing edge of the signal upon bus 852 is also input into pulse generator 830 which causes a single pulse to emanate therefrom on bus 854 which is coupled to registers 832, 834, 836, and 838.
The output of AND gate 828 is represented by signals on bus 856 which is coupled to a first input of AND gates 824 and 844. A second input of AND gate 824 is coupled to an output of comparator 826 by signals on bus 858. The comparator 826 has inputs coupled thereto which are represented by signals on bus 104 (FIG. 3) and an output of the register 832 which is represented by signals on the bus 860.
In operation, when five consecutive bits are loaded into shift register 822 and the document-present signal upon bus 852 indicates a document is present, then AND gate 828 issues a logically high command on bus 856 to the AND gates 824 and 844. The AND gate 824 then will issue a signal on bus 862 as a load command to the register 832 in order to have the register 832 load the signals on bus 104 which is coupled thereto.
The load command will issue only if the comparator 826 determines that the contents of the bus 104 are greater than or equal to the contents of the output of the signal on the bus 860, meaning that the document video image was found at a higher position than has previously been determined. This load command on the bus 862 will then cause register 832 to place the current address (on bus 104) therein. The pulse signals on bus 854 will cause the contained value on bus 860 to be transferred to register 836 and cause register 832 to clear. The register 836 will then load the value associated with the signals on bus 860 due to the command associated with the pulse on bus 854 and output this value on bus 864 as an indication of the height of the document 16. When the acquired image is captured by a camera assembly 11 which scans from the top of the document to the bottom thereof, another technique must be used to determine the document height.
To determine the document height of the document 16, when the image acquisition system scans from the top to the bottom thereof, it is first necessary to couple the address, on bus 104, to invertor 842 whose output is coupled to an input of the register 834 via bus 866. This value is not loaded into register 866 until AND gate 844 issues a logically high command on bus 868 thereto. This logically high command will be issued if the input on bus 856 associated with the AND gate 824 is logically high, indicating an occurrence of five consecutive instances of logical ones in shift register 832 and if the output associated with the comparator 840 is logically high as well.
Specifically, comparator 840 compares the output of register 834 on bus 870 with the value of the output of invertor 842 on bus 866. That is, if this inverted value on bus 866 is greater than or equal to the current address value of the register 834, then signal on bus 841 is set to a logical one enabling register 834 to download data.
The pulse signals on bus 854, coupled to registers 834 and 838 allow register 834 to send its output data on bus 870 to the register 838 and cause the register 838 to load the data sent thereto. Register 834 is then cleared to zero. Subsequently, the register 838 outputs the data upon bus 872.
8. Spot/Void Filtering
The spot/void subprocessor 62 is used to fill in voids.
Referring now to FIG. 19, there is shown further details of the spot/void filtering subprocessor 62 as containing an averager 750, a comparator 752, and a look up table 754.
Averager 750 has an input coupled to the storage RAM 50 and window shift register window assembly 52 by signals on bus 76. Averager 750 has an output coupled to the bypass multiplexer 148 by signals on bus 756. The comparator 752 has first and second inputs coupled to input/output controller 56 by signals on buses 758 and an input coupled to the video on bus 82 respectively. An output of comparator 752 is coupled to the storage RAM and shift register window assembly by signals on bus 760.
In operation, the spot/void filtering subprocessor block 62 is used to eliminate substantially all isolated white and black spots, voids, and protrusions from the acquired image. Initially, video image data is input via bus 82 to the RAM and shift register window assembly 50, 52 and to an input of comparator 752. Comparator 752 then determines if each of the pixels associated with the acquired image is above a certain threshold defined by signals on bus 758. This threshold is loaded through control unit input/output controller 56 and is empirically derived. In the preferred embodiment of the invention its value is 14.
This comparison then produces a binary image from the acquired gray-scale image. This binary image is sent to RAM and shift register window assembly 50, 52 by bus 760. This binary bit patterned image is then output via bus 762 to a lookup table 754, which generates a signal on bus 764 to the bypass multiplexer 148. Additionally, the gray-scale image is sent via bus 76 to the averager 750 which produces an average value for each of the pixels 458 relative to the four pixels "P 32 ", "P 34 ", "P 34 ", and "P 43 " surrounding it, and passes this average by bus 756 to the bypass multiplexer 148. Also, the bypass multiplexer 148 has a white value entered into it by signals on bus 766 and a black value associated with signals on bus 768. The active pixel 458 (i.e., "P 33 " of FIG. 7) is also input into multiplexer 148 by bus 76.
The lookup table 754, generates output signals on bus 764 which are used to select which of the input signals (i.e., signals on buses 756, 766, 768, or 76) that are input to multiplexer 148 and are placed on bus 770. The signal on bus 770 represents a new pixel value associated with the pixel 458 being processed and lookup table 754 selects the output of multiplexer 148 depending upon the bit pattern of the image containing the active pixel 458. If the active pixel 458 represents a spot then white (signal on line 766) is selected otherwise one of signals on lines 768, 76, or 756 are selected based upon the empirically derived table.
9. Pipeline Configuration
Referring now to FIG. 20, there is shown a processing pipeline 800 plurality of substantially similar image processors 24(a-d) arranged in a pipelined configuration. Each of the image processors 24(a), 24(b), 24(c), and 24(d) comprise separate application specific integrated circuits and contain all of the subprocessors 58, 60, 62, and 64 shown in FIG. 2. Each processor 24(a), 24(b), 24(c), and 24(d) performs one of the functions associated with subprocessors 58, 60, 62, and 64. This function is chosen by function select signal 168 (FIG. 4) and which may be activated by an external jumpering arrangement. Input video data on bus 82 enters processor 24 which, in one embodiment, performs a normalization operation thereon. This normalized processed video data is then sent to bus 802 by bypass multiplexer 148 therein and then to processor 24(b) which performs background suppression thereon.
Processor 24(b) then outputs the background suppressed data to processor 24(c) by use of its multiplexer 148 and bus 804. Processor 24(c) receives the processed data, on bus 804, and performs spot/void processing thereon. Processor 24(c) then outputs this processed data on bus 806 to processor 24(d) which performs a scaling function thereon and outputs the scaled data on bus 808 as processed data output. Therefore, the use of processors 24(a-d), in the pipelined configuration 800, allows for greating processing efficiency.
It is to be understood that the invention is not to be limited to the exact construction or method illustrated and described above, but that various changes and modifications may be made without departing from the spirit and scope of the invention as set forth in the subjoined claims that follow. | Apparatus for detecting a dimension of a generally rectangular document in a system where the document is carried over a track to a station where the document is scanned by a sensor to create a digital image thereof. Pixel vales along a scan line which includes a portion of the track as well as the document are analyzed and provide an indication of the size of the document. | 6 |
TECHNICAL FIELD
[0001] The present invention relates reducing emissions from engines.
BACKGROUND
[0002] Transport of goods may require the use of engines, which may emit pollution such as hydrocarbons, oxides (CO, CO2, NOx), particulate matter, and the like. In some cases, reducing an emission of one pollutant may increase emission of another pollutant. Minimizing an integrated impact of pollution may require the optimization of emission of a large number of different pollutants.
SUMMARY OF THE INVENTION
[0003] This paper incorporates by reference U.S. patent application Ser. Nos. 12/183,917 (now U.S. Pat. No. 7,981,375), 13/171,489, 12/824,070, and 12/756,987. Various aspects provide for reducing pollution emitted during transportation. A combination of reduced CO2 emission and reduced criteria pollutant emission may result from an aftertreatment system and/or operation methods that combine to reduce integrated emission.
[0004] A tractor may include an engine and an aftertreatment system coupled to the engine. The aftertreatment system may treat the exhaust stream from the engine. Treatment may include reducing a concentration of one or more contaminants in the exhaust stream. The tractor may include a fairing, which may be shaped to improve a flow of air past the tractor, and more particularly past at least a portion of the aftertreatment system. The fairing may contain or otherwise be shaped to modify the airflow around at least a portion of the aftertreatment system in a manner that reduces air resistance.
[0005] In some cases, the fairing and portion of the aftertreatment system contained by the fairing are disposed above a cab of the tractor. For some tractors (e.g., a class 8 truck), a fairing and aftertreatment system may be sized and shaped to improve air flow past a trailer (e.g., an intermodal container trailer) configured to be towed by the tractor. The fairing may reduce fuel consumption of the engine, as compared to a similar tractor without the fairing, by at least 0.5%, or even 1% at a speed of 100 km/hr. The fairing and may reduce fuel consumption by at least 3% at a speed of 120 km/hr as compared to a similarly configured tractor without the fairing. Some embodiments may reduce fuel consumption by over 2% at 75 mph.
[0006] The aftertreatment system may include at least one of a DOC, DPF, SCR, SNCR, LNT, ammonia slip, and other reactors. In some cases, a reactor volume (e.g., a substrate volume) may be greater than 2, 3, 5, 7, 10, 15 or even 20 times a displacement of the engine. In some embodiments, an aftertreatment having reactor volume greater than 50 liters, 100 liters, 200 liters, or even 300 liters may be disposed above a cab of a tractor behind a fairing configured to improve air flow past the aftertreatment system.
[0007] Some aftertreatment systems (e.g., disposed above a cab) may be removably connected in a manner that provides for changing out a reactor from above (e.g., with a crane, lift, and the like). In some cases, an aftertreatment system may be disposed above a deck of a boat, and may include an exhaust tube having a valve (e.g., a flap) configured to seal an interior of the aftertreatment reactor during capsize. A large, sealed aftertreatment, disposed above the deck, may provide for “self righting” of a capsized boat.
[0008] An aftertreatment may include one or more portions, including first, second, third, fourth, or even fifth portions. In some cases, an aftertreatment system includes a DOC, DPF, SCR and ammonia slip reactor. Some portions may be disposed within a body of the tractor. A DPF may have a substrate volume greater than three, five, or even 10 times the engine displacement. An SCR may have a substrate volume greater than three, five, or even 10 times the engine displacement. An aftertreatment system may include a muffler.
[0009] A fairing may include a vent, which may be operable to allow air to pass through the fairing an interact with the aftertreatment system. In some operation, a reactor temperature is determined (e.g., measured), and the reactor is cooled by opening a valve in the fairing to allow air to pass through and cool the reactor. In one example, overtemperature conditions during regeneration of a DPF may be mitigated by opening one or more vents in a fairing containing the DPF.
[0010] In some cases, a fairing and aftertreatment system may be sized and shaped to match a locomotive, which may have an engine displacement of over 1000 liters. An aftertreatment system may be disposed on a roof of a construction tractor (e.g., a backhoe, bulldozer, and the like).
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 illustrates an exemplary embodiment.
[0012] FIG. 2 illustrates an exemplary embodiment.
[0013] FIGS. 3A-3C illustrate various views of a select embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Various embodiments provide for combining an aftertreatment system and an aerodynamic fairing, which may enable the location of an aftertreatment system (e.g., a large aftertreatment system) in a wide range of places on a tractor. FIG. 1 illustrates an exemplary embodiment. Tractor 100 may include a truck, a train, a boat, a car, and/or another motive device configured to move a load (e.g., goods, people). In some embodiments, tractor 100 may be coupled with a trailer (e.g., trailer 102 ) to form a tractor-trailer. In some embodiments, tractor 100 may include an integral bed and/or compartment (not shown) configured to carry a load. Tractor 100 may include a heavy duty normal control truck.
[0015] Tractor 100 may include a variety of structural components (chassis, suspension, panels, fenders, bumpers, compartments, and the like), described herein as a body 110 . Body 110 may house an engine 120 , which may be a direct injection engine, an indirect injection engine, a compression induced ignition engine, a spark ignited engine, a diesel engine, a gasoline engine, an alcohol engine, a turbine, and the like. Engine 120 may be configured to move tractor 100 (e.g., by transmitting power to turn wheels 104 ). Engine 120 may be coupled (e.g., with one or more tubes 130 ) to aftertreatment 140 . Aftertreatment 140 may comprise a system configured to reduce a concentration of one or more contaminants in an exhaust stream from engine 120 . Exemplary contaminants include criteria pollutants such as particulate matter (PM), NOx, CO, hydrocarbons, climate forcing contaminants (e.g., CO2), and the like.
[0016] At least a portion of aftertreatment 140 may be shielded by, contained in, or otherwise “made aerodynamic” by fairing 150 . Fairing 150 may be shaped to improve the aerodynamics of tractor 100 (e.g., reduce the aerodynamic drag associated with a flow of air past tractor 100 and/or trailer 102 ). Fairing 150 may be shaped to guide air around (e.g., at least the upstream face of) aftertreatment 140 . Fairing 150 may substantially contain at least a portion of aftertreatment 140 , and in some cases may be integrated with aftertreatment 140 . In some embodiments, a first portion of aftertreatment 140 (e.g., a DOC) is external to fairing 150 (e.g., adjacent to engine 120 ), and a second portion of aftertreatment 140 (e.g., a DPF) is contained within fairing 150 . Exhaust gases may exit aftertreatment system 140 via exhaust 160 , which may be integrated with fairing 150 .
[0017] In some embodiments, a portion of aftertreatment 140 is disposed substantially within body 110 (e.g., close coupled to engine 120 ). In some embodiments, a portion of aftertreatment 140 is disposed external to body 140 (e.g., attached to a chassis or frame member). A first portion may be disposed substantially within body 110 , a second portion may be disposed outside body 110 , and a third portion may be disposed behind fairing 150 .
[0018] Aftertreatment system 140 may include one or more reactors, such as a Diesel Oxidation Catalyst reactor, a NOx trap reactor (e.g., a Lean NOx Trap), a selective catalytic reduction (SCR) reactor, a particulate filter (e.g., a diesel particulate filter, DPF), an ammonia slip reactor, and/or a selective non-catalytic reduction (SNCR) reactor. In some cases, a reactor volume may be associated with a volume of a substrate within a reactor. In some cases, a reactor volume may be associated with a volume of a “canned” reactor (e.g., a substrate contained within a sealed container having an inlet and outlet through which exhaust passes. A reactor volume may be more than twice as large as a displacement volume of an engine 120 associated with tractor 100 . In some cases, reactor volume is at least three times, five times, or even ten times larger than the engine displacement. An aftertreatment system may have a volume (e.g., a reactor volume) greater than 40 gallons, 55 gallons, 100 gallons, or even 200 gallons. In some cases, a DPF reactor has a size greater than five times the engine displacement. In some cases, an SCR reactor has a size greater than three times the engine displacement. An exemplary reactor sized for a 10 liter engine may have a volume of at least 30 liters, including at least 50 liters, or even at least 100 liters.
[0019] In some cases, an aftertreatment 140 may include a DOC and DPF combined as a single unit (e.g., a DOC upstream of a DPF), which may be contained within fairing 150 . An aftertreatment 140 contained by fairing 150 may include an SCR reactor, and may also include an ammonia slip reactor. A first portion of aftertreatment 140 may include a DOC close to engine 120 and a second portion of aftertreatment 140 a DPF reactor and SCR reactor within fairing 150 . A first portion of aftertreatment 140 may include a DOC close to engine 120 , a second portion of aftertreatment 140 may include a DPF after the DOC and before fairing 150 (e.g., behind a cab of tractor 100 ) and a third portion may include an SCR reactor contained by fairing 150 . The position of various reactors (e.g., DOC, DPF, SCR) in the gas flow direction may be changed as desired. In some cases, a DOC, DPF and SCR are contained within fairing 150 .
[0020] For some tractors 100 , fairing 150 and at least a portion of aftertreatment system 140 may be disposed over body 110 (e.g., over the cab of tractor 100 ). A shape and height of the fairing 150 may be matched to an expected height of trailer 102 , e.g., in a manner that reduces aerodynamic drag as compared to a tractor not having the fairing. In an exemplary case, a fairing 150 (e.g., for a US class 8 truck) may be somewhat wedge shaped (possibly with smoothed corners and/or convex or concave surfaces) and have a front edge disposed just above a windshield height, rising to a back edge having a height close to that of a trailer to be coupled to the truck, which may create a large “leeward” volume within which aftertreatment 140 may be disposed. An “over the cab” aftertreatment 140 may have a volume that is larger than that of prior aftertreatment systems, whose dimensions may be constrained by space and geometry (e.g., under-chassis size constraints). By sheltering a large aftertreatment 140 behind fairing 150 , the benefits of a large aftertreatment (e.g., high soot storage capacity, high ash storage capacity, high surface area) may be achieved without reducing aerodynamic efficiency and/or being constrained by typical “on-chassis” installation locations. In some cases, an ash storage capacity of a DPF reactor associated with aftertreatment 140 may provide for greater than 100,000 miles of operation, greater than 500,000 miles of operation, or even greater than 1E6 miles of operation.
[0021] In some cases, a fuel consumption of tractor 100 having fairing 150 and contained aftertreatment system 140 may be reduced by more than 0.5%, 1%, 3%, or even 5% (e.g., at 100 km/hr) as compared to a tractor not having fairing 150 . In some embodiments, the contained portion of aftertreatment 140 may be removably attached to exhaust tubes 130 . In some cases, aftertreatment 140 and fairing 150 are connected, disposed above the cab of tractor 100 , and may be removed by hoisting from above. In certain cases, at least one exhaust tube 130 may be removably coupled to aftertreatment 140 in a manner that provides for de-ashing a substrate associated with aftertreatment 140 (e.g., an aftertreatment 140 having a particulate filter). A coupling 132 may provide fluidic communication with exhaust 160 via at least a portion of aftertreatment 140 . In some cases, a de-ashing apparatus may attach to exhaust 160 and coupling 132 to de-ash or otherwise regenerate at least a portion of aftertreatment 140 . In some embodiments, an aftertreatment 140 may be located above a cab (e.g., of a tractor, bulldozer, backhoe, and the like) of a low speed or even stationary device. An “above cab” location may provide for removing an aftertreatment 140 to an area that does not block the view of an operator.
[0022] FIG. 2 illustrates an exemplary embodiment. Tractor 200 may include body 210 , which may be configured as a “cab over engine” and/or forward control truck. Tractor 200 may be removably attachable to a trailer 202 . In some embodiments, tractor 200 may be connected to trailer 202 as an integrated unit (e.g., as a box truck). In some embodiments, a fairing may contain a compressor (e.g., an air conditioner compressor).
[0023] FIGS. 3A-3C illustrate various views of a select embodiment. FIG. 3A illustrates a first side view of a fairing 300 and integrated aftertreatment system 310 . FIG. 3B illustrates a rear view, and shows an exemplary configuration for exhausts 160 . FIG. 3C illustrates a front view, and shows an optional vent 320 . In some embodiments, one or more vents 320 may be disposed in a fairing (e.g., fairing 300 ). A vent 320 may be adjustable (e.g., to vary from closed to open) to allow a desired amount of air to flow through fairing 300 . In some embodiments, cold operation (e.g., while aftertreatment system 310 is cold) may include operating vent 320 in a closed position, and hot operation may include operating vent 320 in an open position. In some implementations, vent 320 may be opened during a period of time during which aftertreatment system 310 (e.g., having a filled particulate filter) is regenerated to burn of accumulated particulate matter). In some cases, vent 320 may be in communication with one or more powertrain control components (e.g., an engine control unit, ECU), and may be operated by the ECU to vary air flow through fairing 300 in concert with the operation of other engine controls. Vent 320 may include a plurality of vents (e.g., a first vent 320 on a front side of fairing 300 and a second vent 322 on a back side of fairing 300 ). One or both of the vents may be adjustable. An aftertreatment 140 may include a heat exchanger (e.g., for cooled exhaust gas recirculation, EGR). An heat exchanger may be disposed with vent 320 in a manner that allows air flow through vent 320 to control an amount of air flowing through the heat exchanger. Certain embodiments may include sensors (e.g., to sense temperature, contaminant concentration, soot loading, pressure, engine conditions, position, and the like) and/or actuators (e.g., to open/close valves). Some embodiments may include a processor, memory, and a computer readable storage medium having embodied thereon a program executable by the processor to perform a method.
[0024] The above description is illustrative and not restrictive. Many variations of the invention will become apparent to those of skill in the art upon review of this disclosure. The scope of the invention should, therefore, be determined not with reference to the above description, but instead should be determined with reference to the appended claims along with their full scope of equivalents. | Aspects provide for an engine and an aftertreatment system coupled to the engine and configured to treat an exhaust stream from the engine. The engine may be incorporated into a mobile piece of equipment (e.g., a truck). A fairing may be shaped to improve air flow during motion by reducing air resistance created by the aftertreatment system. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/145,143, filed Jun. 3, 2005 (Attorney Docket No. NVDA/P001581). The subject matter of this related application is hereby incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] Embodiments of the present invention generally relate to the field of semiconductor manufacturing, and more specifically to a system and method for improving the yield of integrated circuits containing memory.
[0004] 2. Description of the Related Art
[0005] The successful manufacture of integrated circuits depends on maximizing the yield, which is the number of tested good parts that are derived from each wafer. The greater the yield, the lower the overall cost of the product. The die area of the integrated circuit has a direct correlation to the yield. As die area increases, fewer dies can be fit on each wafer. As is well-known, larger die areas are more prone to manufacturing defects as well.
[0006] Typically, complex integrated circuits are comprised of a plurality of functional units providing set functionality and performance levels. For example, there may be shader, texture and arithmetic units within a graphics processing unit all working together to provide graphics functionality. After the integrated circuit is fabricated, the device undergoes a series of tests where each functional unit is tested to ensure that the integrated circuit is fully functional. If any functional unit fails a test, the entire integrated circuit is classified as inoperable and is discarded.
[0007] In an effort to increase yield, some designers add one or more redundant functional units to the design. If a failed functional unit is found, the failed unit is disabled and is replaced with one of the redundant functional units. For example, in a design that requires three Random Access Memory (RAM) arrays, a fourth RAM array may be added as a spare to be used when one of the three required RAM arrays fails. The problem with this approach is that the redundant functional units consume significant die area. If the redundant unit is not required, then the die area occupied by the redundant functional unit is wasted, and the yield is increased at the cost of die area usage.
[0008] As the foregoing illustrates, what is needed in the art is a way to increase yield without significantly increasing die area.
SUMMARY OF THE INVENTION
[0009] One embodiment of the present invention is a computing device configured to use only regions of a memory element that do not include memory failures. The computing device includes a processor and a memory element that has been tested for memory failures. The memory element has a first region and a second region, and a first memory state indicator indicates whether the first region includes a memory failure, and a second memory state indicator indicates whether the second region includes a memory failure. In another embodiment, the computing device also includes a software driver configured to read the first memory state indicator and the second memory state indicator and determine whether to use the first region based on a setting of the first memory state indicator and whether to use the second region based on a setting of the second memory state indicator.
[0010] One advantage of the disclosed computing device is that integrated circuits containing memory that would have been discarded for containing memory failures may now be used in the computing device. This approach also does not significantly impact the die area associated with the integrated circuits.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings 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.
[0012] FIG. 1 is a flow chart of method steps for testing an integrated circuit containing memory, according to one embodiment of the invention;
[0013] FIG. 2 is a flow chart of method steps for implementing an integrated circuit containing memory tested with the method of FIG. 1 , according to one embodiment of the invention;
[0014] FIG. 3 is a conceptual diagram of a memory inside an integrated circuit, according to one embodiment of the invention; and
[0015] FIG. 4 is a conceptual diagram of a computer system that may be configured to implement one or more aspects of the present invention.
DETAILED DESCRIPTION
[0016] FIG. 1 is a flow chart of method steps for testing an integrated circuit containing memory, according to one embodiment of the invention. Persons skilled in the art will understand that any system configured to perform the method steps in any order is within the scope of this invention.
[0017] As shown in FIG. 1 , the method for testing an integrated circuit begins in step 102 , where the memory to be tested is divided into regions. In the preferred embodiment, the memory is divided into two regions determined by the memory addresses; the lower addresses of memory are in the first memory region and the upper addresses of memory are in the second memory region. In step 104 , the first memory region is tested using Memory Built-In Self-Test (MBIST).
[0018] As is well-known, MBIST is a quick and efficient means of testing and finding failures within a memory region. Typically, MBIST is implemented with state machines that are co-located on the die with the memory, and moreover, these state machines are configured to test an entire memory region. In the preferred embodiment, the MBIST state machines are aware of the divided memory regions so that each memory region may be tested independently.
[0019] In step 106 , the results of the MBIST are examined. If there are no memory failures, then in step 110 , a first fuse is made to indicate that no memory failures are present in the first memory region. As is also well-known, fuses are used in integrated circuits to provide a low cost and low area method of non-volatile storage. In alternative embodiments, other means of non-volatile storage may be used to indicate the state of the different memory regions, such as Programmable Read Only Memory, (PROM), Erasable Programmable Read Only Memory, (EPROM), Electrically Erasable Programmable Read Only Memory (EEPROM) or the like. If one or more memory failures are detected in step 106 , the method proceeds to step 108 , where the first fuse is made to indicate that memory failures are present in the first memory region. In step 112 , the second region of memory is tested using MBIST, and, in step 114 , the results of the test are examined. If there are no memory failures in the second region, then in step 118 , a second fuse is made to indicate that no memory failures are present in the second region and the method terminates. If one or more memory failures are detected in step 114 , then in step 116 , the second fuse is made to indicate that memory failures are present in the second region. After step 116 , the method terminates.
[0020] FIG. 2 is a flow chart of method steps for implementing an integrated circuit containing memory tested with the method of FIG. 1 , according to one embodiment of the invention; Persons skilled in the art will understand that any system configured to perform the method steps in any order is within the scope of this invention.
[0021] As shown in FIG. 2 , the method for using the tested integrated circuit begins with step 202 , where a software driver reads the first fuse that was set during testing to determine if the first region of memory contains any failures. The software driver may include, without limitation, any software program or software routine that uses the memory within the integrated circuit. In step 204 , the software driver determines whether the first fuse indicates that there are memory failures in the first memory region. If the first fuse indicates that there are no memory failures, then in step 206 , the software driver uses the memory in the first region. If the first fuse indicates that there are one or more memory failures in the first memory region, then in step 208 , the software driver does not use the memory in the first region. The method then proceeds to step 210 where the software driver reads the second fuse. In step 212 , the software driver determines whether the second fuse indicates that there are memory failures in the second memory region. If the second fuse indicates that there are no failures in the second memory region, then in step 214 , the software driver uses the memory in the second region, and the method then terminates. If the second fuse indicates that there are one or more memory failures in the second memory region, then in step 216 , the driver does not use the memory in the second region, and the method terminates.
[0022] As the description of FIG. 2 indicates, the software driver is configured to use only the regions of memory that are free of memory failures. For example, in practice, if an integrated circuit were tested and found to posses no regions of memory that are free from failures, then that integrated circuit likely would be discarded. If, however, the part were nonetheless shipped, a software driver following the method of FIG. 2 would read fuses indicating that failures existed in all memory regions and, therefore, would not use any of the memory regions in the integrated circuit. Thus, through the use of the methods of FIGS. 1 and 2 , integrated circuits with memory failures may be reclaimed instead of being discarded. The ability to reclaim and use integrated circuits that otherwise would have been discarded increases yield. Another advantage is that the approach described in FIGS. 1 and 2 does not significantly impact the die area associated with the integrated circuits.
[0023] Persons skilled in the art will understand that the foregoing methods may be used with any type of memory where the relevant system using that memory maintains its operational effectiveness when only part of or none of the memory is useable. Cache memory, random access memory (RAM) and Z-cull RAM are some examples of such memory elements.
[0024] FIG. 3 is a conceptual diagram of a memory 300 inside an integrated circuit, according to one embodiment of the invention. As shown, the memory 300 is divided by memory addresses into a first memory region 320 and a second memory region 330 . The lower memory addresses are grouped into the first memory region 320 , and the upper memory addresses are grouped into the second memory region 330 . In alternative embodiments of the invention, the memory may be divided into more than two regions. In fact, in theory, there is no upper limit on the number of regions into which the memory may be divided. Among other things, dividing a memory into a greater number of regions provides more resolution on the location of any memory failures and potentially enables the use of a larger portion of the overall memory. In yet other embodiments, the memory may be divided by nibbles or other data bit groupings. As is well-known, a byte (bits 7 through bit 0 ) is comprised of two nibbles, a high nibble (bit 7 through bit 4 ) and a low nibble (bit 3 through bit 0 ). By dividing the memory by data groups instead of address groups, the failures in the memory may be better characterized for different applications.
[0025] FIG. 4 is a conceptual diagram of a computer system 400 that may be configured to implement one or more aspects of the present invention. Computer system 400 may be a desktop computer, server, laptop computer, palm-sized computer, personal digital assistant, tablet computer, game console, cellular telephone, computer-based simulator or any other type of similar computing device. As shown, computer system 400 may include, without limitation, a host computer 410 , host memory 415 , host processor 420 , system interface 425 , programmable graphics processor 430 , local memory 435 , programmable graphics processor interface 440 and fuses 445 .
[0026] The computer system 400 uses host memory 415 to store such programs such as the software driver, described in conjunction with FIG. 2 , and data used by the host processor 420 . The host processor 420 is connected to the system interface 425 . The system interface 425 allows the host processor 420 to communicate to the sub-systems within the computer system 400 such as the programmable graphics processor 430 . The system interface 425 is also connected to the programmable graphics processor interface 440 . Local memory 435 and the fuses 445 are connected to the programmable graphics processor interface 440 .
[0027] 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. | A system and method for increasing the yield of integrated circuits containing memory partitions the memory into regions and then independently tests each region to determine which, if any, of the memory regions contain one or more memory failures. The test results are stored for later retrieval. Prior to using the memory, software retrieves the test results and uses only the memory sections that contain no memory failures. A consequence of this approach is that integrated circuits containing memory that would have been discarded for containing memory failures now may be used. This approach also does not significantly impact die area. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates generally to a hermetic scroll-type compressor and, more particularly, to such a compressor having fixed and orbiting scroll members, wherein a compliance mechanism acts to bias the fixed and orbiting scroll members toward one another for proper mating and sealing therebetween.
A typical scroll compressor comprises two facing scroll members, each having an involute wrap, wherein the respective wraps interfit to define a plurality of closed compression pockets. When one of the scroll members is orbited relative to the other, the pockets decrease in volume as they travel between a radially outer suction port and a radially inner discharge port, thereby conveying and compressing the refrigerant fluid.
It is generally believed that the scroll-type compressor could potentially offer quiet, efficient, and low-maintenance operation in a variety of refrigeration system applications. However, several design problems persist that have prevented the scroll compressor from achieving wide market acceptance and commercial success. For instance, during compressor operation, the pressure of compressed refrigerant at the interface between the scroll members tends to force the scroll members axially apart. Axial separation of the scroll members causes the closed pockets to leak at the interface between the wrap tips of one scroll member and the face surface of the opposite scroll member. Such leakage causes reduced compressor operating efficiency and, in extreme cases, can result in an inability of the compressor to operate.
Leakage between compression pockets of a scroll compressor may also occur at those locations where the wrap walls sealingly contact each other to define the moving compression pockets. Specifically, the pressure of the compressed refrigerant in the compression pockets, together with manufacturing tolerances of the component parts, may cause slight radial separation of the scroll members and result in the aforementioned leakage.
Efforts to counteract the separating forces applied to the scroll members during compressor operation, and thereby minimize the aforementioned leakages, have resulted in the development of several prior art compliance schemes. With respect to axial compliance mechanisms, the scroll members may be preloaded axially toward each other with a force sufficient to resist the dynamic separating force. However, this approach results in high initial frictional forces between the scroll members and/or bearings when the compressor is at rest, thereby causing difficulty during compressor startup. Another prior art approach involves assuring close manufacturing tolerances for component parts and having the separating force borne by a thrust bearing. This approach not only requires an expensive thrust bearing, but also involves high manufacturing costs in maintaining close machining tolerances.
In a compressor having a pressurized, or "high side", housing, discharge pressure may be used on the back side of the fixed or orbiting scroll member to create a force to oppose the separating force. In such an arrangement, it is difficult to control the magnitude of the resulting force and excessive friction and power losses may result. One solution has been to use a combination of gaseous refrigerant at suction pressure and gaseous refrigerant at discharge pressure, and expose them to respective areas on the backside of an axially movable fixed or orbiting scroll member. In such compressor designs, various seal means have been utilized to separate the respective gaseous pressure regions and to compensate for axial movement of the scroll member.
In another type of axial compliance mechanism, an intermediate pressure chamber is provided behind the orbiting scroll member, whereby the intermediate pressure creates an upward force to oppose the separating force. Such a design recognizes the fact that only suction pressure behind the orbiting scroll member is insufficient to oppose the separating force, while discharge pressure behind the orbiting scroll member results in too great an upward force and may cause rapid wear of the scroll wraps and faces. However, establishing an intermediate pressure between suction pressure and discharge pressure requires that an intentional leak be introduced between an intermediate pressure pocket and a discharge pressure region. Such a leak results in less efficient operating conditions for the compressor.
The present invention is directed to overcoming the aforementioned problems associated with scroll-type compressors, wherein it is desired to provide axial forces on the mating scroll members to facilitate sealing and prevent leakage.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages of the above-described prior art scroll-type compressors by providing an improved axial compliance mechanism to resist the tendency of the scroll members to axially separate during compressor operation, wherein the fixed and orbiting scroll members are both axially movable and are biased toward one another by exposure of their respective back surfaces to a combination of discharge pressure and suction pressure.
Generally, the invention provides an axially floating scroll assembly for use as the fluid displacement apparatus in a scroll-type compressor. More specifically, the floating scroll assembly includes a fixed scroll assembly and an orbiting scroll assembly. The fixed scroll assembly includes a scroll plate having a back surface and a front surface from which an involute wrap downwardly extends. A separate scroll frame includes an attaching surface. The back surface of the fixed scroll plate is coupled to the attaching surface of the frame so as to permit axial movement of the fixed scroll plate and frame relative one another. A chamber is defined intermediate the scroll plate and the frame, for causing axial separation of the scroll plate and frame relative one another in response to pressurized fluid being introduced into the chamber.
The orbiting scroll assembly includes an orbiting scroll plate having a hind surface and a face surface from which an involute wrap upwardly extends. A separate drive plate includes a mounting surface and a hub surface. The hind surface of the orbiting scroll plate is coupled to the mounting surface of the drive plate so as to permit axial movement of the orbiting scroll plate and drive plate relative one another. A substantially sealed chamber is defined intermediate the orbiting scroll plate and the drive plate, for causing axial separation of the scroll plate and drive plate relative one another in response to pressurized oil being introduced into the chamber.
One advantage of the scroll compressor of the present invention is the provision of a compliance mechanism that is capable of operating in the presence of, and compensating for, axial space resulting from axial movement of the fixed and orbiting scroll members toward one another. Specifically, axial movement of both scroll members permits the axial space to be taken up by the respective seals of both scroll members, thereby lowering the cost to manufacture the compressor by permitting larger machining tolerances for the component parts and stack-up tolerances during assembly.
Another advantage of the scroll compressor of the present invention, according to one form thereof, is that of a floating fixed and orbiting scroll member pair having balanced axial loading, thereby decreasing loading on compressor frame members.
A further advantage of the scroll compressor of the present invention is the provision of a simple, reliable, inexpensive, and easily manufactured compliance mechanism for producing a substantial force on the fixed scroll plate and orbiting scroll plate toward each other.
The invention, in one form thereof, provides a floating scroll assembly for use as the displacement apparatus in a scroll-type compressor. The floating scroll assembly includes a fixed scroll member assembly and an orbiting scroll member assembly.
The fixed scroll member assembly includes a fixed scroll plate with an involute wrap attached thereon, and a fixed scroll frame with an attaching surface. Spaced along the back surface of the fixed scroll plate is a mechanism to couple the scroll plate and frame. Specifically, there is at least one axial bore in the back surface of the scroll plate, and a corresponding axial bore in the attaching surface of the scroll frame. Each one of the axial bores in the scroll plate is axially aligned with a respective one of the axial bores in the scroll frame. A connecting pin is received within each respective bore in the scroll plate and a corresponding respective bore in the scroll frame.
The orbiting scroll member assembly includes an orbiting scroll plate with an involute wrap attached thereon, and a drive plate with a mounting surface and hub surface. Spaced along the hind surface of the scroll plate is a mechanism to couple the orbiting scroll plate and drive plate. Specifically, there is a plurality of axial bores in the hind surface of the orbiting scroll plate, and a corresponding plurality of axial bores in the mounting surface of the drive plate. Each one of the plurality of axial bores in the scroll plate is axially aligned with a respective one of the plurality of axial bores in the drive plate. A plurality of connecting pins are each received within a respective bore in the scroll plate and a corresponding respective bore in the drive plate.
In accord with one aspect of the invention, a mechanism for sealing between the fixed scroll plate and frame is provided. Specifically, the sealing mechanism includes an annular seal groove on the back surface of the fixed scroll plate and an annular seal element unattachedly retained therein. This seal element permits fluid at compressor discharge pressure to substantially fill the space between the fixed scroll plate and fixed scroll frame. Consequently, the fixed scroll plate and fixed frame are forced axially apart, permitting axial compliance of the fixed scroll plate with the orbiting scroll member assembly.
According to a further aspect of the invention, a mechanism for sealing between the orbiting scroll plate and the drive plate is provided. Specifically, the sealing mechanism includes an annular seal groove on the hind surface of the orbiting scroll plate and an annular seal element unattachedly retained therein. This seal element permits oil at compressor discharge pressure to substantially fill the space between the orbiting scroll plate and drive plate. Consequently, the orbiting scroll plate and drive plate are forced axially apart, permitting axial compliance of the orbiting scroll plate with the fixed scroll member assembly.
According to another aspect of the invention, the respective areas sealed off by the annular seal on the orbiting scroll plate and the annular seal on the fixed scroll plate are substantially the same. This ensures that substantially the same pressure is placed on each scroll plate, thereby axially balancing the net axial force on the floating scroll assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal sectional view of a compressor of the type to which the present invention pertains;
FIG. 2 is an enlarged fragmentary sectional view of the compressor of FIG. 1, particularly showing the floating scroll assembly of the present invention;
FIG. 3 is an enlarged transverse sectional view of the compressor of FIG. 1, taken along the line 3--3 in FIG. 2 and viewed in the direction of the arrows, particularly showing the back surface of the fixed scroll plate and the surrounded frame member;
FIG. 4 is an enlarged transverse sectional view of the orbiting scroll member assembly of the compressor of FIG. 1, taken along the line 4--4 in FIG. 2 and viewed in the direction of the arrows, particularly showing the hind side of the orbiting scroll plate;
FIG. 5 is an enlarged fragmentary sectional view of the annular seal element of the fixed scroll member assembly of the compressor of FIG. 1, shown in a non-actuated state;
FIG. 6 is an enlarged fragmentary sectional view of the annular seal element of the orbiting scroll member assembly of the compressor of FIG. 1, shown in a non-actuated state;
FIG. 7 is an enlarged fragmentary sectional view of the annular seal element of the fixed scroll member assembly of the compressor of FIG. 1, shown in an actuated state; and
FIG. 8 is an enlarged fragmentary sectional view of the annular seal element of the orbiting scroll member assembly of the compressor of FIG. 1, shown in an actuated state.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, there is shown a compressor 10 having a housing generally designated at 12. The housing has a top cover plate 14, a central portion 16, and a bottom portion 18, wherein central portion 16 and bottom portion 18 may alternatively comprise a unitary shell member. The three housing portions are hermetically secured together as by welding or brazing. A mounting flange 20 is welded to bottom portion 18 for mounting the compressor in a vertically upright position.
Located within hermetically sealed housing 12 is an electric motor generally designated at 22, having a stator 24 and a rotor 26. Stator 24 is provided with windings 28. Rotor 26 has a central aperture 30 provided therein into which is secured a crankshaft 32 by an interference fit. A terminal cluster 34 is provided in central portion 16 of housing 12 for connecting motor 22 to a source of electric power.
Compressor 10 also includes an oil sump 36 generally located in bottom portion 18. A centrifugal oil pickup tube 38 is press fit into a counterbore 40 in the lower end of crankshaft 32. Oil pickup tube 38 is of conventional construction and includes a vertical paddle (not shown) enclosed therein. An oil inlet end 42 of pickup tube 38 extend downwardly into the open end of a cylindrical oil cup 44, which provides a quiet zone from which high quality, non-agitated oil is drawn.
A floating scroll compressor mechanism 46 is enclosed within housing 12, and generally comprises a fixed scroll member assembly 48 and an orbiting scroll member assembly 50, which are capable of moving axially relative a main bearing frame member 52. Orbiting scroll assembly 50 is prevented from rotating about its own axis by means of a conventional Oldham ring assembly, comprising an Oldham ring 54, and orthogonally arranged Oldham key pairs associated with orbiting scroll assembly 50 and frame member 52, respectively. The floating scroll pair of fixed scroll assembly 48 and orbiting scroll assembly 50, in accordance with the present invention, will be more fully described hereinafter.
Referring to FIGS. 2 and 4, orbiting scroll assembly 50 comprises a generally flat orbiting scroll plate 60, including a face surface 62 having an involute wrap 64 thereon, and a hind surface 66. Hind surface 66 includes an annular seal groove 68 within which an annular seal element 70 is partially disposed. The orbiting scroll assembly also includes a drive plate 72 having a top mounting surface 74 and a bottom hub surface 76.
Hind surface 66 of scroll plate 60 has a plurality, and preferably a pair, of axial holes 78, while mounting surface 74 of drive plate 72 has a corresponding number of axial holes 80. Orbiting scroll plate 60 and drive plate 72 are coupled together by a plurality of connecting pins 82 received within respective axial holes 78 and 80.
The connecting pins 82 are slidingly received in either orbiting scroll plate 60 or drive plate 72, to allow axial movement of orbiting scroll plate 60 relative to drive plate 72. In the disclosed embodiment of the invention, a pair of connecting pins 82 have one of their ends press fit into a corresponding pair of axial holes 80 at diametrically opposed locations on drive plate 72. The other ends of the pins 82 extend upwardly from mounting surface 72 and are slidingly received into a corresponding pair of axial holes 78.
A lubrication system for compressor 10 provides lubricating oil from oil sump 36 to floating scroll mechanism 46, crankshaft 32, and crank mechanism 84. Specifically, an oil passageway 86 is provided in crankshaft 32, which communicates with tube 38 and extends upwardly through crankshaft 32 to an opening 88 on the top of an eccentric crankpin 90 at the top of crankshaft 32. Oil passageway 86 permits oil to fill a chamber 92 formed by annular seal 70, hind surface 66, and mounting surface 74. A radial oil passage 94 delivers oil from oil passage 86 to the bearing portion of main frame 52. An annular seal 96 is operably disposed between main bearing frame member 52 and orbiting scroll assembly 50, thereby sealing between a radially inner discharge pressure and a radially outer suction pressure.
Referring to FIGS. 2 and 3, fixed scroll assembly 48 comprises a generally flat scroll plate 98, including a front surface 100 having an involute wrap 102 thereon, and a back surface 104. Back surface 104 includes an annular seal groove 108 within which an annular seal element 110 is partially disposed. Back surface 104 also includes at least one, and preferably a pair, of axial holes 106, as well as a port 105 through which compressed fluid is discharged from the compression pockets.
Fixed scroll assembly 48 also includes a fixed scroll frame 112 having an attaching surface 114 and an outside surface 116. Attaching surface 114 includes axial holes 118 corresponding to axial holes 106 of back surface 104. Fixed scroll frame 112 also has an opening 120 to allow pressurized fluid to flow into housing 12 from discharge port 105 of fixed scroll plate 105. Fixed scroll plate 98 and fixed scroll frame 112 are coupled together by connecting pins 122 received within respective axial holes 106 and 118.
The connecting pins 122 are slidingly received in either the scroll plate 98 or scroll frame 112, to allow axial movement of scroll plate 98 relative to scroll frame 112. In the disclosed embodiments of the invention, a pair of connecting pins 122 have one of their ends press fit into a corresponding pair of axial holes 118 at diametrically opposed locations on scroll frame 112. The other ends of the pins extend downwardly from attaching surface 114 and are slidingly received into a corresponding pair of axial holes 106. Connecting pins 122 prevent rotation of the scroll plate 98 relative scroll frame 112, as well as permit axial movement relative thereto. Scroll frame 112 is aligned with main bearing frame member 52 by a number of aligning pins 124, and is attached to main bearing frame member 52 and top cover plate 14 by a plurality of bolts 126.
Floating scroll mechanism 46 is assembled such that orbiting scroll wrap 64 interfits with the fixed scroll wrap 102 to permit compression of refrigerant when orbiting scroll assembly 50 is orbited relative to fixed scroll assembly 48. Moreover, the floating scroll pair is capable of moving axially, inasmuch as the respective scroll plates of each scroll assembly is designed to move axially from its respective mounting or attaching surface.
Radial compliance in the floating scroll mechanism 46, in accordance with the embodiment of FIG. 2, is achieved through the use of an eccentric crank mechanism 84 situated on the top of crankshaft 32. Crank mechanism 84 comprises a conventional swing-link mechanism including a cylindrical roller 128 and eccentric crankpin 90, whereby roller 128 is eccentrically journalled about eccentric crankpin 90. As previously described, drive plate 72 of orbiting scroll assembly 50 includes a hub surface 76 that defines a cylindrical well 130 into which roller 128 is received. This arrangement allows the orbiting scroll assembly 50 to be moved into radial compliance with the fixed scroll member 48.
The axial compliance mechanism of compressor 10, in accordance with the floating scroll assembly of the present invention, will now be further described with reference to FIGS. 3-8. Generally, respective circular central portions of back surface 104 of fixed scroll plate 98 and hind surface 66 of orbiting scroll plate 60 are exposed to discharge pressure, thereby providing a substantially constant force distribution forcing the fixed and orbiting scroll plates toward one another. More specifically, a first annular seal mechanism 132 cooperates between back surface 104 and adjacent scroll frame 112 in order to sealingly separate between a radially inner portion 134 and a radially outer portion 136 of back surface 104, which are exposed to discharge pressure and suction pressure, respectively. A second annular seal mechanism 138 cooperates between hind surface 66 and adjacent mounting surface 74 in order to sealingly separate between a radially inner portion 140 and a radially outer portion 142 of hind surface 66, which are exposed to discharge pressure and suction pressure, respectively.
In accordance with the disclosed embodiment, seal mechanism 132 comprises an annular elastomeric seal element 110 unattachedly received within seal groove 108. In the preferred embodiment, the radial thickness of seal element 110 is less than the radial width of seal groove 108, as best shown in FIGS. 5 and 7. Referring to FIG. 5, annular seal groove 108 includes a radially inner wall 144, a radially outer wall 146, and a bottom wall 148 extending therebetween. Annular seal element 110 is generally rectangular and includes a radially inner surface 150, a radially outer surface 152, a top surface 154, and a bottom surface 156. In its unactuated condition shown in FIG. 5, seal element 110 has a diameter less than the diameter of outer wall 146, whereby outer surface 152 is slightly spaced from outer wall 146. Also, top surface 154 is initially spaced from attaching surface 114 due to the influence of gravitational force on fixed scroll plate 98.
Likewise, seal mechanism 138 comprises an annular elastomeric seal element 70 unattachedly received within seal groove 68. Annular seal groove 68 on orbiting scroll plate 60 encircles approximately the same area as annular seal groove 108 on fixed scroll plate 98, thereby ensuring balanced axial force on the floating scroll assembly, as previously described. Referring to FIGS. 6 and 8, the radial thickness of seal element 70 is less than the radial width of seal groove 68, as shown in FIGS. 6 and 8. Referring to FIG. 6, annular seal groove 68 includes a radially inner wall 158, a radially outer wall 160, and a bottom wall 162 extending therebetween. Annular seal element 70 is generally rectangular and includes a radially inner surface 164, a radially outer surface 166, a top surface 168, and a bottom surface 170. In its unactuated condition shown in FIG. 6, seal element 70 has a diameter less than the diameter of outer wall 160, whereby outer surface 166 is slightly spaced from outer wall 160. Also, seal element 70 initially supports the combined weight of fixed scroll plate 98 and orbiting scroll plate 60, being acted upon by gravity.
Axial compliance of floating scroll assembly 46 is initiated as refrigerant fluid is compressed and discharged through port 105 and opening 120, whereupon it enters and causes pressurization of the interior of housing 12. Initially, the floating scroll pair will begin moving axially upwardly, away from the thrust surface of frame member 52. At the same time, orbiting scroll plate 60 and fixed scroll plate 98 will experience a separating force urging them toward drive plate 72 and fixed scroll frame 112, respectively.
The compressed refrigerant exiting through port 105 and opening 120 enters a chamber 145 formed by attaching surface 114, back surface 104, and seal element 110, as shown in FIGS. 2 and 7. The introduction of pressurized refrigerant causes seal element 110 to expand radially outwardly and fixed scroll plate 98 to move axially downwardly away from frame 112, guided by connecting pins 122. As a result of the axial movement of fixed scroll plate 98, increased space is created between back surface 104 and frame 112. Seal element 110 moves telescopingly upwardly toward frame 112 under the influence of a venturi effect created by the initial fluid flow between top surface 154 and frame 112. Consequently, refrigerant at discharge pressure occupies the space between bottom wall 148 and bottom surface 156. From the foregoing, it will be appreciated that refrigerant at discharge pressure acting on bottom surface 156 and inner surface 150 of seal element 110 creates a force distribution on the seal element 110 that urges it axially upwardly toward attaching surface 114 and radially outwardly toward outer wall 146 to seal thereagainst.
During compressor operation, oil pickup tube 38 draws lubricating oil at discharge pressure from oil sump 36 and causes oil to move upwardly through oil passageway 86. Referring to FIG. 2, oil pumped through opening 88 fills a substantially sealed chamber 92 defined by hind surface 66 of scroll plate 60, mounting surface 74 of drive plate 72, seal element 70 disposed therebetween, and the top surface of crank mechanism 84 within well 130.
The presence of oil at discharge pressure within chamber 92 causes orbiting scroll plate 60 to move axially away from drive plate 72, guided by connecting pins 82. The oil occupies the volume shown radially inwardly of seal element 70 in FIG. 8, thereby causing seal element 70 to expand radially outwardly and orbiting scroll plate 60 to move further axially upwardly away from drive plate 72, as shown in FIG. 8. As a result of the axial movement of orbiting scroll plate 60, increased space is created between hind surface 66 and drive plate 72. Seal element 70 moves telescopingly downward toward drive plate 72 under the influence of gravity and/or a venturi effect created by the initial fluid flow between bottom surface 170 and drive plate 72. Consequently, oil at discharge pressure occupies the space between bottom wall 162 and top surface 168. From the foregoing, it will be appreciated that oil at discharge pressure acting on top surface 168 and inner surface 164 of seal element 70 creates a force distribution on the seal element 70 that urges it axially downwardly toward mounting surface 74 and radially outwardly toward outer wall 160 to seal thereagainst.
The provision of a stationary surface against which the seal elements 70, and 110 slidingly seal exhibits several noteworthy advantages. For instance, relative movement between the seal elements and sealing surfaces is minimized, thereby reducing frictional forces and increasing seal life. Additionally, leakage past the seal is more effectively controlled. It should also be noted that in the seal configurations described herein, leakage is minimized by the absence of seal mounting apparatus and complex multi-piece seal configurations.
The annular seal elements disclosed herein is preferably composed of a Teflon material. More specifically, a glass-filled Teflon, or a mixture of Teflon, Carbon, and Ryton is preferred in order to provide the seal element with the necessary rigidity to resist extruding into clearances due to pressure differentials. Furthermore, the surfaces against which the Teflon seal contacts are preferably cast iron. While the seal grooves have been shown as being in a particular one of two adjacent surfaces, it is contemplated that the seal groove could alternatively be formed in the other surface.
It is believed that the provision of a floating scroll set, wherein fixed and orbiting scroll plate members are axially movable with respect to a fixed frame and an orbiting drive plate, permits easier compensation for the axial space created by compliance movement and machining and assembly tolerances. Furthermore, it is contemplated that by providing clearance between the connecting pins and the axial holes in the scroll plates into which they are received, a slight tilting of the floating scroll pair may be accomplished, thereby helping to maintain sealing despite overturning moments imparted on the orbiting scroll assembly by the drive configuration.
It will be appreciated that the foregoing description of various embodiments of the invention is presented by way of illustration only and not by way of any limitation, and that various alternatives and modifications may be made to the illustrated embodiment without departing from the spirit and scope of the invention. | A floating scroll assembly of a hermetic scroll-type compressor including, a fixed scroll frame, a fixed scroll plate, connecting pins coupling the plate and frame together in a manner permitting axial separation, an orbiting scroll plate, a drive plate, connecting pins coupling the orbiting plate and drive plate together in a manner permitting axial separation, and seals unattachedly retained intermediate the scroll frame and fixed scroll plate and intermediate the drive plate and orbiting scroll plate by grooves in the scroll plates. The fixed and orbiting scroll assemblies are forced axially toward one another by exposure of their back surfaces to a combination of refrigerant at suction pressure and refrigerant and oil at discharge pressure. The seals extend out of the grooves to slidingly seal upon compressor operation. Regions on the scroll plates exposed to discharge pressure are substantially the same size. | 5 |
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
This invention relates to machines for harvesting cotton and, in particular, to a novel structure for pulling the mature cotton plant from the stalk or burr.
More particularly, this invention relates to a machine for harvesting cotton which includes a novel paired disk picking mechanism mounted for rotation about a central shaft in which the individual disks of the disk pair are separated to allow a portion of the cotton plant to pass therebetween and which are brought to a closed position to squeeze or pull the mature cotton from the stalk of the plant.
The most widely used mechanical harvesting machine for cotton is the spindle picker in which the mature cotton is collected on a plurality of pins positioned around the rotating spindle arms. Although other machines, characterized as strippers, are used to harvest cotton, such machines gather too much extraneous portions of the cotton plant to obtain the high quality harvest the cotton mills demand. The spindle picker has undergone only minor improvements in design since its widespread introduction in the late 1940's, and although the picking efficiency is very satisfactory, the large mass of individual components in every row unit or header of this type of cotton harvesting machine is disadvantageous for several reasons.
The large amount of components consequently demands a large amount of time for daily maintenance, such as for lubrication, and seasonal attention to replace worn parts which comprise a large portion of the operation cost of the spindle picker. The weight of the individual headers which contain all the picking machinery is another serious disadvantage since the number of headers that can be mounted on a harvesting machine is severely limited. Only by removing some of the component parts to reduce weight and thereby sacrifice picking efficiency can this disadvantage be somewhat overcome.
Accordingly, a need exists for a cotton harvesting machine which eliminates the problems associated with the conventionally used spindle picking machines. Thus, in accordance with the present invention, such problems are eliminated by utilizing a novel method of picking the mature cotton from the stalk in which less machinery is required, thereby reducing daily and seasonal servicing of the cotton harvesting machine and reducing the respective labor and machinery cost. Another advantage of the novel picking device of the present invention is the drastically reduced weight per header, allowing more headers to be mounted on each harvesting machine and thereby allowing a single machine to cover more acreage at greater speed than present machines, cutting both labor and fuel costs.
DISCLOSURE STATEMENT
Cotton harvesting machines, such as the spindle picker, have existed as far back as the turn of the 20th century. As described above, such machines include an endless carrier with rapidly rotating spindles. As the machine travels along the rows of cotton, the spindles enter the plants and gather the cotton, the spindles then being doffed and the cotton collected in suitable receivers. Examples of patented spindle picker cotton harvesting machines include U.S. Pat. No. 1,208,591, issued Dec. 12, 1916, to Lovejoy, and U.S. Pat. No. 2,143,901, issued Jan. 17, 1939, to Rust et al. U.S. Pat. No. 1,213,529, issued Jan. 23, 1917, to Neil, also discloses a cotton picker in which a rotating roller picks the mature cotton from the plant. U.S. Pat. No. 3,164,942, issued Jan. 12, 1965, to Middlesworth et al, discloses a fruit harvester having gathering fingers or spindles in which the fingers are adapted to be advanced into a tree and pursuant to rotation of the spindles to auger into the tree and then be withdrawn to strip the fruit off the plant. The fingers are shaped in the form of helical convolutions and each group of four spindles are arranged so that the crest of adjacent helically shaped spindles always oppose each other. No mention is made in the patent to Middlesworth et al of using the harvesting machine to pick cotton. The novel paired disk picking mechanism of the present invention is not taught by any of the above references and is considered to be an improved substitute for the spindle picking cotton harvesters.
SUMMARY OF THE INVENTION
Briefly, the cotton harvesting machine of the present invention utilizes a novel mechanism for separating the mature cotton from the cotton stalk or burr. The novel separating mechanism comprises a plurality of paired disks mounted for rotation about a central shaft, the harvesting machine including two or more columns of paired disks per header. Each opposed column of paired disks rotate in opposite directions so that the perimeters of each disk move in the same direction as the cotton plants pass through the picking area of the harvesting machine. Each disk of a disk pair is provided with a resilient opposing pad and is mounted so that opposed disks of a disk pair separate as the cotton plants are passing through the picking area and close to pinch the mature cotton between the opposed resilient pads, pulling the mature cotton from the stalk as the opposed disks rotate in the closed position. The opening and closing movement of the opposed paired disks is effected by a pair of opposed cams mounted in a stationary position around each central shaft. A separate cam follower attached for rotation about the central shaft and to one of the paired disks follows a specifically structured cam track placed on the cams to move each disk in position during rotation of the shaft.
During the picking operation, the cotton plant enters the picking area of the header as the harvesting machine travels through the rows of cotton. At this point, the opposed disks of each of the paired disks are in the open position so that the plant limbs are funneled between the pads of the opposed open disks. As the harvesting machine moves forward along the rows of cotton plants, the cotton plant in the picking area moves toward the back of the header at which point rotation of the central shaft causes the cam follower to close the opposed disks, squeezing the mature cotton with sufficient pressure to pull the cotton from the burr as movement of the cotton harvester and rotation of the central shaft continues. The pressure that the opposed pads exert on the cotton plant can be varied to meet changing field conditions by an adjustment device which various the relative position between opposed cams. After the cotton has been pulled from the burr, the disks continue to rotate to an appropriate place adjacent a vacuum area in the header whereupon the cam tracks for the opposed paired disks are such that the cam followers cause the opposed disks to open and through centrifugal force throw the cotton from between the opposed disks to a vacuum area which pulls the cotton into a storage area situated on the cotton harvesting machine.
Each row of paired disks are in the form of a circle about the central shaft, each row containing a plurality of upper and lower disks in which each disk is attached to the central shaft and is associated with its own cam follower positioned within the cam track. Each rotating column of paired disks in the header hold several rows of paired disks vertically spaced along the central shaft, the number of rows varying depending upon height requirements.
An object of the present invention is to provide a cotton harvesting machine which will eliminate the problems associated with conventional spindle pickers.
Another object of the invention is to provide a cotton harvesting machine which includes a novel mechanism to pull the mature cotton from the stalk or burr.
Another object of the present invention is to provide a novel picking mechanism which will require less daily and seasonal maintenance than cotton spindle pickers.
Still another object of the invention is to provide a novel picking mechanism which will drastically reduce the weight of a header placed on a cotton harvesting machine over conventional spindle pickers, allowing more headers to be mounted on each harvesting machine.
Still yet another object of the invention is to provide a cotton harvesting machine which includes a picking mechanism which is adjustable to meet varying field conditions.
These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view illustrating a cotton harvesting machine including the novel rotating paired disk picking mechanism of the present invention.
FIG. 2 is a top plan view illustrating the arrangement of components within the header of the cotton harvesting machine of FIG. 1.
FIG. 3 is an enlarged fragmentary elevational view illustrating two of the novel disk pairs of the present invention in which one pair is in the fully open position and the other in the fully closed position.
FIGS. 4A and 4B are fragmentary elevational views of the adjusting mechanism for altering the relative position between opposed cams, the dashed line illustrating phantom positions of the adjustment arms, the adjustment being indicated by the arrows.
FIG. 5 is an elevational view of the cam adjustment mechanism without the hand adjustable nut threaded onto the adjustment shaft.
FIG. 6 is a transverse sectional view of the cam adjustment device taken generally along the line 6--6 of FIG. 4B.
FIG. 7 is a transverse sectional view of the cam adjustment device taken generally along the line 7--7 of FIG. 5.
FIG. 8 is an exploded perspective view illustrating the disk support collar which supports the paired disks for rotation about the central shaft.
FIG. 9 is a transverse sectional view illustrating the cam follower and spring attachment to the individual disks.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2, cotton harvesting machine 10 includes an operator's station 12 including seat 14, storage area 16 for storing the picked cotton harvest, header 18, vacuum conduit 20 for directing the picked cotton into storage area 16, guards 21 and 22 which assist in directing the cotton plants into the picking area of header 18 and the novel picking mechanism 24 placed inside header 18 and operated by gear drive train 26 which is rotated from a power source (not shown) in cotton harvesting machine 10.
Picking mechanism 24 comprises three rows of paired disks, rows 28, 29 and 30 mounted and spaced vertically along a central rotating shaft 32 which is driven by gear train 26. The rows of paired disks form a single column about each rotating shaft 32 and 42. Each row of paired disks forms a circle surrounding the central shaft in which the individual disks forming the row are separately mounted to respective central shafts 32 and 42. In FIG. 2, it can be seen that each row is formed from eight disk pairs in which each disk is pie-shaped or triangular, such as disk 34. The side edges of each disk being contiguous with the adjacent disk, such as shown by disks 36, 38 and 40. The number of rows of paired disks in each column can be varied depending upon height requirements. Likewise, the number of each picking disk column per header can be varied and can include one, two columns, such as the picking disk columns disposed about central shafts 32 and 42 in FIG. 2, and even three or more disk columns per header.
As opposed to the spindle picking mechanism of conventionally used cotton harvesting machines, in which rotating spindles gather mature cotton from the plant, picking mechanism 24 of the present invention utilizes the opening and closing of each paired disk to funnel the cotton plant between the open paired disks and for gripping the mature cotton from the cotton plant as the paired disks close during movement towards the rear of the header.
FIG. 3 illustrates the structure utilized to move the paired disks into the open and closed position. Two rows of paired disks are shown, 44 and 46, only two of the disk pairs being shown per row, though it is to be understood that as many as eight disk pairs can exist per row to form a complete circle about the central shaft. Row 44 includes paired disks 48 and 50 in the closed and open positions, respectively. Paired disk 48 is formed from disks 52 and 54 while paired disk 50 is formed from disks 56 and 58. Each disk is provided with a rubber pad 60 which is fastened to the opposed faces of each disk pair. The use of pliable rubber allows pads 60 to grip and conform to a certain extent to the irregularities of the cotton plant, thus providing for increased picking efficiency. A pair of cams, 62 and 64, having contained therein cam tracks 66 and 68, respectively, are associated with the upper or lower disks of the disk pairs which form the paired disk row. Accordingly, cam 62 and cam track 66 guide upper disks 52 and 56 during rotation of shaft 70 by means of individual cam followers 72 and 74, respectively, while lower disks 54 and 58 are moved into the open and closed positions by respective cam followers 76 and 78 travelling in cam track 68 of cam 64. The movement of each disk pair will be explained with respect to disk pair 48. The movement of cam follower 72 in respective cam track 66, is transferred to disk 52 through spring loaded cam support 80, pivotally mounted to the upper face of disk 52 opposite the face containing rubber pad 60. Cam support 80 can be mounted to disk 52 by any conventional pivot means, such as a pivot pin 82, passing through a lug 84 secured to the upper face of disk 52. In a like manner, disk 54 is associated with cam follower 76. Cams 62 and 64 are mounted to central shaft 70 in a nonrotatable position, while disks 52 and 54 are mounted for rotation to shaft 70 via support collars 86 and 88, respectively, so that as central shaft 70 rotates, each individual cam follower moves in the respective cam track about the perimeter of the cam and through the respective cam supports moves each disk in a circle about the axis of rotation of central shaft 70. The cam tracks are structured in the respective cams so that during each rotation of the cam follower within the cam track, each paired disk is in the fully opened and fully closed positions only once. As can be seen in FIG. 3, paired disks 52 and 54 are in the fully closed positions, since cam followers 72 and 76 are positioned in respective cam tracks 66 and 68 at a location where the distance between the cam tracks is the smallest with respect to the remaining distances between the cam tracks along the perimeter thereof. Similarly, disks 56 and 58 are in the open position as their respective cam followers 74 and 78 are at a position along the perimeter of the respective cam tracks which comprises the greatest distance between the respective cam tracks. This position represents the fully opened position of the disk row.
Each upper and lower disk in the paired disk row is supported for rotation with central shaft 70 by respective upper and lower support collars, such as upper support collar 86 which supports disk segments 52 and 56 and lower support collar 88 which supports disks 54 and 58. Each individual disk is pivotally mounted to the respective support collar in any conventional manner, such as by a pivot pin 90 passing through lug 92 attached to the respective disk. To prevent the individual cam followers from binding in the cam track during rotation, each cam support 80 is maintained in a vertical position by means of a parallel linkage 94 pivotally mounted to each support collar. In FIG. 3, linkage 94 can be seen pivotally mounted to respective support collars 86 and 88 by means of pivots 96 and 98, respectively, and to the cam supports by means of pivots 100, each of which are preferably pins movable within a lug attached to the support collars.
FIG. 8 illustrates a support collar 102 equivalent to support collars 86 and 88 shown in FIG. 3. Support collar 102 is in the form of a hollow cylinder containing a hollow space 104 which enables the support collar to slip over the central rotating shaft. A roll pin placed through aperture 106 formed through the body of the support collar maintains the support collar firmly secured to the central shaft. Placed around the perimeter of disk support collar 102 are a plurality of elongated vertical grooves 108 placed along the full length of the support collar cylinder. Placed within each groove 108 is a hinge bar 110 fastened to support collar 102 by means of screw 112 through aperture 114 contained in hinge bar 110. Apertures 116 and 118 placed through hinge bar 110 are utilized for pivotally supporting either linkages 94 or one of the disks depending upon whether the support collar is used for mounting the upper or lower disk of the disk pair.
FIG. 9 illustrates cam support 80 for converting the movement of the individual cam followers in the cam tracks into the open and close movements of the attached disks. Cam support 80 includes a pair of interfitting cylinders 120 and 122 interconnected by means of a rigid spring 124 attached to cylinder 122 by means of hook 126 and to cylinder 120 by means of hook 128. Cylinder 122 contains a lug 130 which supports the cam follower indicated by reference numeral 132 for movement within cam track 134 of cam 136. Lug 138 attached to the bottom surface of cylinder 120 holds the pivot pin for pivotally mounting cam support 80 to the individual disk. Spring 124 allows some relative movement between interfitting cylinders 120 and 122 so that the individual picking disks can conform to the different types of materials passing between the paired disks. Pivot mechanism 100 for pivotally mounting cam support 80 to linkage 94 is fastened to the exterior of cylinder 120 by any conventional means, such as by welding, a strong adhesive, etc.
Referring back to FIG. 3, it is seen that attached to cam 64 of paired disk row 44 and cam 140 of paired disk row 46 is a yoke assembly 141 comprising a pair of pivotal linkages 142 and 144, attached to cams 64 and 140, respectively, the linkages being mounted to a connecting rod 146 at pivot point 143. By movement of connecting rod 146 to the right, cams 64 and 140 move closer together and consequently move the individual cams in respective paired disk rows a farther distance apart. Likewise, moving connecting rod 146 to the left moves the cam members of individual paired disk rows closer together. This vertical adjustment of the cams is an accessory which is used to position the cams at varying distances from the disks and which varies the amounts of spring pressure applied to the disk segments via spring 124 in cam support 80. Thus, the amount of squeezing or pulling action by the closed paired disks can be adjusted to meet varying field conditions. Connecting rod 146 and attached pivot arms 142 and 144 are part of a cam adjustment 148 illustrated in FIGS. 4 through 7. Cam adjustment 148 comprises a tube 150 enclosing a threaded shaft 152 containing threads 154. A hand adjustable nut 156 moves threaded shaft 152 relative to the surrounding tube 150. Yoke assembly 158 is pivotally fastened to connecting rod 146 at pivot point 147 and includes arm 160 fastened to shaft 152 and arm 162 fastened to outer tube 150. Arms 160 and 162 are pivotally mounted to support arms 164 and 166, respectively, each arm 164 and 166 being mounted at pivot point 147 to connecting rod 146. Referring to FIG. 4A, as threaded shaft 152 is moved further into tube 150 by means of nut 156, arms 160 and 164 are moved closer to arms 162 and 166 causing a scissoring action whereby connecting arm 146 is moved toward the cams causing attached linkages 142 and 144 to scissor outwardly from pivot point 143 bringing the pair of cams in each row of paired disks closer together, FIG. 3. Likewise, pulling shaft 152 out of 150 causes yoke assembly 158 to spread further apart as shown in FIG. 4B causing connecting rod 146 to pull away from the attached cams causing the individual cams in each paired disk row to separate. FIGS. 5-7 show that arms 160 and 162 can be attached to shaft 152 and tube 150, respectively, by means of lugs 167 screwed or welded thereto.
Referring again to FIGS. 1 and 2, header 18 is shown containing two columns of paired disk rows. Each column comprises three rows of paired disks equivalent to the structure set forth in FIG. 3 and includes a cam adjustment 168 equivalent to that shown in FIGS. 4A and 4B. Header 18 also includes vacuum areas 170 and 172 which communicate with vacuum conduit 20 to direct the pulled cotton into storage area 16. Plant dividers 174 and 176 funnel the cotton plant limbs between the paired disks rotating about respective shafts 32 and 42. Vacuum areas 170 and 172 are bounded by shields 178 and 180, respectively, the ends of each shield protruding between the open disks to prevent the picked cotton from being carried back into the picking area. Shields 182 and 184 positioned at the back of the header are used as buffers to ease the cotton limbs back into the picking area.
Operation of a cotton harvesting machine manufactured in accordance with the teachings of the present invention will be described with respect to FIGS. 1 and 2 which illustrate cotton harvesting machine 10 containing picking mechanism 24. Picking mechanism 24 comprises a pair of columns picking disks, each column containing three rows of paired disks, rows 28, 29 and 30 each constructed in an equivalent manner to the picking mechanism illustrated in FIG. 3. As cotton harvesting machine 10 moves forward, the cotton plants are funneled into the space between the columns with the aid of guards 21 and 22 and plant dividers 174 and 176. Rotation of central shafts 32 and 42 by a drive mechanism (not shown) in cotton harvesting machine 10 also rotates the individual paired disks which are opened and closed by movement of the cam followers in the cam tracks as described above. Area A, as shown in FIG. 2, is the picking area where the rubber pads on the paired disks are closed completely applying pressure to the plant limbs to pull the mature cotton from the burrs as shafts 32 and 42 continue rotation. Area B is a transitional area in which the cotton is released from between the closed pads as the paired disks start to separate due to the diverging direction of the respective cam tracks. The paired disk segments go from a fully closed to a fully opened position at the end of area B adjacent vacuum areas 170 and 172, the cotton being thrown by centrifugal force into the vacuum area. In area C, the paired disk segments are fully open. Area D is the other transitional area whereby the disks go from the fully open position to the closed position as the plant limbs come between the pads to complete the cycle. During movement of harvesting machine 10 through the rows of cotton plants, a constant vacuum is being applied to pull the pulled cotton from the vacuum area into storage area 16.
The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention. | A cotton harvesting machine which utilizes a novel structure for pulling the mature cotton plant from the burr includes a plurality of paired rotating disks mounted on a drive shaft for rotation in the same relative direction as the movement of the cotton plant through the picking area of the machine, each disk pair being moved into an open position whereby the cotton plant is funnelled between the open disk pair and a closed position whereby the disk pair grips the mature cotton and pulls it from the burr. The opening and closing movement of each disk pair is provided by a pair of cams and associated cam followers, one for each disk in the pair, each cam being mounted in a stationary position around the rotating drive shaft, the cam followers being fastened to each disk and following a path of movement along a cam track during the rotation of the shaft. The cam tracks associated with each pair of cams converge and diverge around the shaft causing the closing and opening position of the disk pair as the cam followers move in the track. An adjusting mechanism can be provided to change the relative positions between opposing disks by relative movement of the associated pair of cams. | 0 |
BACKGROUND
The invention relates to a liquid crystal display (LCD) substrate, and more particularly, to a LCD substrate having spacers with steps and a fabrication method thereof using a photolithographic process.
Liquid crystal displays (LCDs) typically comprise a pair of opposing substrates and a liquid crystal layer interposed therebetween. And a plurality of photo spacers is defined the distance between the opposing substrates. (i.e., cell gap). In order to extend the category of the LCD application, the cell gap of the LCD shall be shrunk and cell gap uniformity control will be a key issue in manufacturing. An uneven cell gap may cause luminance variation over a line or a region of the LCD panel, hereinafter referred to as mura defects.
Mura defects are related to the density of photo spacers or contact areas of the substrate with photo spacers. When external force temporarily applied, such as finger wiping, the photo spacers are deformed, causing photo spacer deviation. However, as the density of the photo spacer is large, the friction force increases. The spacer deviation cannot recover even if force removed, thereby causing a wipe mura defect.
If the density of the spacers decreases to ameliorate the wipe mura defect, other problems will occur. For example, when normal force is exerted on the substrate, the spacer deforms. When the density of the photo spacer is reduced, however, the support provided thereby is insufficient to withstand the force such that deformation cannot recover even if the force is removed, resulting in a push mura defect.
U.S. Patent. No. 2002/0075443, the entity of which is fully incorporated by reference herein, Shimizu et al. disclose two different height column-shaped spacers to solve the aforementioned problems.
Two different height column-shaped spacers are formed on the color filter substrate. One spacer contacts the TFT substrate, while the other does not. FIG. 1 is a cross section illustrating two different height column-shaped spacers on the color filter substrate. A TFT substrate 100 A comprises signal lines 103 and 104 , an insulating layer 150 , a passivation layer 108 , and an alignment layer 111 thereon. A color filter substrate 100 B comprises a substrate 205 , a black matrix (BM) 203 , a passivation layer 204 , spacers 1 b and 1 c , and an alignment layer 208 . A liquid crystal layer 900 is interposed between the TFT substrate 100 A and the color filter substrate 100 B.
Spacer 1 b disposed on the signal line 104 contacts the TFT substrate 100 A, thereby creating a specific gap between the TFT substrate 100 A and the color filter substrate 100 B. The spacer 1 c is not disposed on the signal line 104 and often kept a small distance away from the TFT substrate 100 A. When a normal force is applied on the LCD substrate, the spacer 1 b can be elastically deformed while the spacer 1 c can contact the TFT substrate 100 A. The entire density of the spacer increases such that more load can be sustained, thereby preventing push mura defects.
FIG. 2 is a cross section illustrating another embodiment of two different height column-shaped spacers according to U.S. Patent. No. 2002/0075443. Only a portion of the color filter substrate 100 B is shown for the sake of simplicity. Numeral 205 denotes a substrate, 202 denotes a color filter, 203 denotes a black matrix (BM), 204 denotes a passivation layer, and 311 denotes a base pattern. The spacer 1 b is disposed on the base pattern 311 . Similarly, the spacer 1 b contacts the TFT substrate (not shown), while the spacer 1 c is kept a small distance from the TFT substrate. When a normal force is applied on the LCD substrate, the spacer 1 b can be elastically deformed while the spacer 1 c can contact the TFT substrate. The entire density of the spacer increases such that more load can be sustained, thereby preventing push mura defects.
Shimizu et al. also disclose a spacer with a step on top of the spacers capable of preventing push mura defects. A spacer with a step is formed on the color filter substrate. The step on the spacer partially contacts the TFT substrate. FIGS. 3 a - 3 c schematically depict procedures for manufacturing the spacer with a step. Referring FIG. 3 a , a black matrix 203 and a color filter 202 are sequentially formed on the substrate 205 . A passivation layer 204 is formed on the substrate 205 covering the black matrix 203 and the color filter 202 . A photoresist layer 410 is formed on the passivation layer 204 .
Referring to FIG. 3 b , the photoresist layer is lithographically exposed using a half-tone mask 510 . The center region 413 is exposed to a higher dosage than the peripheral region 411 , thus forming a spacer 420 with a step comprising a protrusion 425 and a recess 426 , as shown in FIG. 3 c.
FIGS. 4 a - 4 c schematically depict other procedures for manufacturing the spacer with a step using dual exposure steps. Referring FIG. 4 a , a black matrix 203 and a color filter 202 are sequentially formed on the substrate 205 . A passivation layer 204 is formed on the substrate 205 covering the black matrix 203 and the color filter 202 . A photoresist layer 410 is formed on the passivation layer 204 . A portion 415 of the photoresist layer 410 is exposed using a mask 510 .
Referring to FIG. 4 b , the photoresist layer 410 is then exposed using a second mask 510 b with a smaller exposed region such that a portion 417 of the photoresist layer 410 is shielded. The region 415 is exposed to a higher dosage than the region 417 , thus forming a spacer 420 with a step comprising a protrusion 425 and a recess 426 , as shown in FIG. 4 c.
According to the spacers with a step as disclosed in both FIGS. 3 a - 3 c and FIGS. 4 a - 4 c , the protrusion 425 contacts the TFT substrate, while the recess 426 does not. When a normal force is applied on the LCD substrate, the protrusion 425 can be elastically deformed while the recess 426 can contact the TFT substrate. The entire density of the spacer increases such that more load can be sustained, thereby preventing push mura defects.
The conventional methods of forming spacers with a step require half-tone exposure or dual exposure steps, thereby creating technical hurdles, process complexity, and cost barriers.
SUMMARY
Embodiments of the invention substantially overcome the disadvantages associated with the related art and achieve other advantages not realized by the related art.
Embodiments of the invention provide a LCD substrate comprising a structure having a first step. A spacer with a second step can be formed on the first step. Consequently, only one photo mask step is required to form a spacer with a step and is simpler than the conventional half-tone masking method.
One aspect of the invention is directed to a LCD substrate comprising a substrate, a spacer definition layer formed on the substrate comprising a first step, and a spacer formed along a profile of the first step adjacent to the first step, thereby forming a second step on the photo spacer. It is noted that the spacer definition layer comprises a light shield array or a color filter.
Another aspect of the invention is directed to a method for fabricating a LCD substrate comprising forming a spacer definition layer on a substrate having a first step, forming a spacer layer on the spacer definition layer, thereby forming a second step along a profile of the first step on the spacer layer, and defining the spacer layer into a spacer by a lithographic development step remaining from the second step.
In accordance with a first embodiment of the invention, a LCD substrate comprises a substrate, a light shield array formed on the substrate comprising a first opening and a second opening, thereby the first opening defines an active region and the second opening defines a first step, a color filter formed on the active region of the substrate, and a spacer formed along a profile of the first step adjacent to the first step, thereby forming a second step on the photo spacer.
The fabrication method for the LCD substrate in accordance with the first embodiment comprises forming a light shield array on a substrate comprising a first opening and a second opening, thereby the first opening defines an active region and the second opening defines a first step, forming a color filter in the active region, forming a spacer layer on the light shield array, thereby forming a second step along a profile of the first step, and defining the spacer layer into a spacer with the forgoing second step by a lithographic process.
In accordance with a second embodiment of the invention, a LCD substrate comprises a substrate, a light shield array formed on the substrate comprising a first opening defining an active region, a color filter formed in the active region of the substrate having an edge defining a first step, and a spacer formed along a profile of the first step adjacent to the first step, thereby forming a second step on the spacer.
The fabrication method for the LCD substrate in accordance with the second embodiment comprises forming a light shield array on a substrate comprising a first opening defining an active region, forming a color filter in the active region of the substrate having an edge defining a first step, forming a pacer layer on the color filter, thereby forming a second step along a profile of the first step, and defining the spacer layer into a spacer by a lithographic development step remaining from the second step.
In accordance with a third embodiment of the invention, a LCD substrate comprises a substrate, a light shield array formed on the substrate comprising a first opening defining an active region, a color filter formed in the active region and non-active region of the substrate, wherein the color filter comprises a third opening defining a first step in the non-active region, and a spacer formed along a profile of the first step adjacent to the first step, thereby forming a second step on the spacer.
The fabrication method for the LCD substrate in accordance with the third embodiment comprises forming a light shield array on a substrate comprising a first opening defining an active region, forming a color filter in the active region of the substrate, wherein the color filter comprises a third opening defining a first step in the non-active region, forming a spacer layer on the color filter, thereby forming a second step along a profile of the first step, and defining the spacer layer into a spacer with the forgoing second step by a lithographic process.
In accordance with a fourth embodiment of the invention, a LCD substrate comprises a substrate, a light shield array formed on the substrate comprising a first opening defining an active region, a color filter formed in the active region and non-active region of the substrate, and a first spacer and second spacer, wherein the first spacer is formed in the region without color filter, and the second spacer is formed in the non-active region with color filter, wherein a height difference is between the first spacer and the second spacer.
Embodiments of the invention additionally provide a liquid crystal display comprising a first substrate, a second substrate, a liquid crystal layer interposed between the first substrate and the second substrate, wherein a spacer definition layer formed on the first or the second substrate having a first step, a plurality of spacers formed along a profile of the first step adjacent to the first step, thereby forming a second step on the spacer.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments of the invention can be more fully understood by reading the subsequent detailed description in conjunction with the examples and references made to the accompanying drawings, wherein:
FIG. 1 is a cross section illustrating two different height column-shaped spacers on the color filter substrate;
FIG. 2 shows a cross section illustrating another embodiment of two different height column-shaped spacers according to the related art;
FIGS. 3 a - 3 c schematically illustrate procedures for manufacturing a spacer with a step;
FIGS. 4 a - 4 c schematically illustrate other procedures for manufacturing a spacer with a step using dual exposure steps to form the spacer;
FIG. 5 is a cross section illustrating a LCD substrate according to one aspect of the invention;
FIG. 6 is a cross section illustrating a LCD substrate according to another aspect of the invention;
FIG. 7 a is a top view illustrating a LCD substrate of the first embodiment of the invention;
FIG. 7 b is a cross section taken along line 7 b - 7 b of FIG. 7 a;
FIG. 8 a is a partial top view of FIG. 7 b illustrating an arrangement of the light shield array and spacer within the region A;
FIGS. 8 b and 8 c are partial top views illustrating an alternative illustrative embodiment of the invention;
FIG. 9 a is a top view illustrating a LCD substrate in which the spacer definition layer is a color filter layer in accordance with a second illustrative embodiment of the invention;
FIG. 9 b is a cross section taken along line 9 b - 9 b in FIG. 9 a;
FIG. 10 a is a top view illustrating a LCD substrate in which the spacer definition layer is a color filter layer in accordance with a third illustrative embodiment of the invention;
FIG. 10 b is a cross section taken along line 10 b - 10 b in FIG. 10 a;
FIG. 11 a is a top view illustrating a LCD substrate in accordance with a fourth illustrative embodiment of the invention;
FIG. 11 b is a cross section taken along line 11 b - 11 b in FIG. 11 a ; and
FIGS. 12 a - 12 c are cross sections illustrating parts of a liquid crystal display in which the spacer definition layer comprises a capacitor, a TFT, or a metal line of illustrative embodiments of the invention.
DETAILED DESCRIPTION
Reference will now be made in detail to embodiments of the invention, examples of which are illustrated in the accompanying drawings.
FIG. 5 is a cross section illustrating a LCD substrate according to one aspect of the invention. The LCD substrate comprises a substrate 12 , a spacer definition layer 14 formed on the substrate 12 , a photo spacer PS formed on the spacer definition layer 14 . The spacer definition layer 14 comprises an opening with a first step S 1 along the opening. The photo spacer PS is formed along the profile of the first step S 1 on the spacer definition layer 14 adjacent to the first step S 1 , thereby forming a second step S 2 on the photo spacer PS.
FIG. 6 is a cross section illustrating a LCD substrate according to another aspect of the invention. The LCD substrate comprises a substrate 12 , a spacer definition layer 16 formed on the substrate 12 , a photo spacer PS formed on the spacer definition layer 16 . The edge of the spacer definition layer 16 comprises a first step S 1 . The photo spacer PS is formed along the profile of the first step S 1 on the spacer definition layer 16 adjacent to the first step S 1 , thereby forming a second step S 2 on the photo spacer PS.
Accordingly, the spacer definition layer can be a light shield array or a color filter. The spacer definition layer also can be conductive line, such as M 1 , M 2 , and the likes, semiconductor, insulator layer or passivation. Further, the spacer definition layer can be a stacked structure of above-mentioned layers. Excepted, the substrate can be color filter substrate or TFT array substrate.
First Embodiment
FIG. 7 a is a partial top view illustrating a LCD substrate of a first illustrative embodiment of the invention, wherein the spacer definition layer is a light shield array. FIG. 7 b is a cross section taken along line 7 b - 7 b of FIG. 7 a . In FIG. 7 b , a liquid crystal display comprises a color filter substrate 1 , a TFT array substrate 2 , and a liquid crystal layer 50 interposed between the color filter substrate 1 and the TFT array substrate 2 .
Referring to FIGS. 7 a and 7 b , the color filter substrate 1 comprises a first glass substrate 10 , a light shield array 30 , a plurality of color filters CF, a passivation layer 40 , and a photo spacer PS. A fabrication method of the color filter substrate 1 comprises forming a light shield array 30 on the first glass substrate 10 , wherein the light shield array comprises a first opening 31 and a second opening 32 . The first opening 31 defines an active region AR. The second opening 32 defines a first step S 1 . The second opening, as shown in FIGS. 7 a and 7 b , is a slit. Sequentially, a plurality of color filters CF are formed on the active region AR of the first glass substrate 10 . The color filters CF comprise strip-type red R, green G, and blue B color layers. Next, a passivation layer 40 is formed on the color filters CF and the light shield layer 30 along the profile of the color filters CF and the light shield layer 30 .
A photo spacer layer (not shown) is formed on the passivation layer 40 such that the photo spacer layer creates a second step S 2 along the profile of the first step S 1 . The thickness of the photo spacer layer is approximately 2.5-5 μm. Afterward, an exposure using a mask and at least one development step are sequentially performed to remove a portion of the photo spacer layer creating a photo spacer PS with a second step S 2 . The second step S 2 comprises a protrusion 61 and a recess 62 . And the TFT array substrate 2 , depicted in FIG. 7 b , comprises a second glass substrate 20 , a metal line 22 , and an insulating layer 24 .
According to embodiments of the invention, the photo spacer PS with a second step S 2 is formed on the light shield array 30 utilizing the profile of a second opening 32 with a first step. To prevent light leakage, a metal line 22 , such as a signal line of a gate line or a data line, is formed on the TFT array substrate 2 corresponding to the second opening 32 of the light shield array 30 .
FIG. 8 a is a partial top view of FIG. 7 b illustrating an arrangement of the light shield array 30 and photo spacer PS within the region A. Referring to FIGS. 7 b and 8 a , after exposure and development, photo spacer PS is formed across the second opening 32 of the light shield array 30 , thereby forming two second steps S 2 on the photo spacer PS.
FIGS. 8 b and 8 c are partial top views illustrating an alternative embodiment of the invention. Referring to FIG. 8 b , light shield array 30 comprises a second opening 32 in the form of a slit. FIG. 8 b is different form FIG. 8 a in that the photo spacer PS is disposed adjacent to only one step S of the second opening 32 of the light shield array 30 instead of the other step S 1 , thereby forming a second step S 2 on the photo spacer PS.
Referring to FIG. 8 c , light shield array 30 comprises a second opening 32 in the form of a circular hole. After exposure and development, the photo spacer PS is formed covering the circular hole 34 of the light shield array 30 , thereby forming two circular second steps (not shown) on the photo spacer PS.
The feature of this embodiment of the invention is that the photo spacer PS is formed on a structure with a step, thereby substantially forming a step on the photo spacer PS. For example, according to the first illustrative embodiment, photo spacer PS is formed on the light shield array with a first step S 1 , thereby substantially forming a second step S 2 on the photo spacer PS along the first step S 1 of the light shield array 30 . Therefore, the invention requires only one photo mask step to from a photo spacer with a spacer and is simpler than the conventional half-tone masking step.
Accordingly, the height of the second step S 2 of the photo spacer PS, such as the distance between protrusion 61 and recess 62 as shown in FIG. 7 b , is preferably between approximately 0.05 and 0.3 μm. After assembling the color filter substrate 1 and the TFT array substrate 2 , the protrusion 61 of the photo spacer PS normally contact the array substrate 2 , while the recess 62 of the photo spacer PS does not contact the TFT array substrate 2 . When a normal force is applied on the substrate, the protrusion 61 can be elastically deformed while the recess 62 can contact the TFT substrate. The entire density of the spacer increases such that more load can be sustained, thereby preventing push mura defects.
When a black matrix resin is introduced to the light shield array 30 , the height of the first step S 1 of the second opening 32 is approximately between 1.2-1.5 μm, because the thickness of the black matrix resin is approximately between 1.2-1.5 μm. After the passivation layer 40 is formed, the height of the second step S 2 formed by the photo spacer layer is slightly less than that of the first step S 1 but still cannot reach the desired range of 0.05-0.3 μm. If the second step S 2 is too high, when a normal force applied, the recess 62 cannot contact the TFT substrate and the entire density of the spacer cannot effectively increase such that push mura defects cannot prevented. Accordingly, a step of reflow is performed to appropriately adjust the height of the second step S 2 prior to exposure and development, thereby reducing the height of the second step S 2 such as within the desired range of 0.05-0.3 μm.
Additionally, when chromium (Cr) is introduced, the height of the first step S 1 of the second opening 32 is approximately between 0.2-0.3 μm, because the thickness of the chromium layer is approximately between 0.2-0.3 μm. After the passivation layer 40 is formed, the height of the second step S 2 formed by the photo spacer layer can reach the desired range of 0.05-0.3 μm without requiring additional reflow. Reflow, however, can also be performed to adjust the height of the second step S 2 dependent on design requirements.
Second Embodiment
FIG. 9 a is a partial top view illustrating a LCD substrate in which the spacer definition layer is a color filter layer in accordance with a second illustrative embodiment of the invention. FIG. 9 b is a cross section taken along line 9 b - 9 b in FIG. 9 a . In FIG. 9 b , a liquid crystal display comprises a color filter substrate 1 , a TFT array substrate 2 , and a liquid crystal layer 50 interposed between the color filter substrate 1 and the TFT array substrate 2 .
Referring to FIGS. 9 a and 9 b , the color filter substrate 1 comprises a first glass substrate 10 , a light shield array 30 , a plurality of color filters CF, a passivation layer 40 , and a photo spacer PS. A fabrication method of the color filter substrate 1 comprises forming a light shield array 30 having a first opening 31 on the first glass substrate 10 , thereby defining an active region AR. A plurality of color filters CF are sequentially formed on the active region AR of the first glass substrate 10 . The color filters CF comprise strip-type red R, green G, and blue B color layers. Next, a passivation layer 40 is formed on the color filters CF and the light shield layer 30 and along the profile of the color filter CF and the light shield layer 30 .
A photo spacer layer (not shown) is formed on the passivation layer 40 such that the photo spacer layer creates a second step S 2 along the profile of the first step S 1 . Afterward, an exposure using a mask and at least one development step are sequentially performed to remove a portion of the photo spacer layer creating a photo spacer PS with a second step S 2 . The second step S 2 comprises a protrusion 63 and a recess 64 . And the TFT array substrate 2 , depicted in FIG. 9 b , comprises a second glass substrate 20 , a metal line 26 , and an insulating layer 24 .
In the second embodiment, the photo spacer PS is formed on the color filters CF with a first step S 1 , thereby forming a second step S 2 on the photo spacer PS along the first step S 1 of the color filters CF. Therefore, the invention requires only one lithographic process to form a photo spacer with a step.
Similarly, in the second embodiment, the height of the second step S 2 of the photo spacer PS, i.e., the distance between protrusion 63 and recess 64 , is preferably between approximately 0.05 and 0.3 μm. After assembling the color filter substrate 1 and the TFT array substrate 2 , the protrusion 63 of the photo spacer PS normally contacts the TFT array substrate 2 , while the recess 64 of the photo spacer PS does not contact the TFT array substrate 2 . When a normal force is applied on the LCD substrate, the protrusion 63 can be elastically deformed while the recess 64 can contact the TFT substrate. The entire density of the spacer increases such that more load can be sustained, thereby preventing push mura defects.
Moreover, if the height of the second step S 2 of photo spacer PS cannot reach the desired range simply using the profile of the first step S 1 of the color filters and passivation layer 40 , a step of reflow can be performed to appropriately adjust the height of the second step S 2 prior to exposure and development.
Third Embodiment
FIG. 10 a is a partial top view illustrating a LCD substrate in which the spacer definition layer is a color filter layer in accordance with a third illustrative embodiment of the invention. FIG. 10 b is a cross section taken along line 10 b - 10 b in FIG. 10 a . In FIG. 10 b , a liquid crystal display comprises a color filter substrate 1 , a TFT array substrate 2 , and a liquid crystal layer 50 interposed between the color filter substrate 1 and the TFT array substrate 2 .
Referring to FIGS. 10 a and 10 b , the color filter substrate 1 comprises a first glass substrate 10 , a light shield array 30 , a plurality of color filters CF, a passivation layer 40 , and a photo spacer PS. A fabrication method of the color filter substrate 1 comprises forming a light shield array 30 having a first opening 31 on the first glass substrate 10 , thereby defining an active region AR. Sequentially, a plurality of color filters CF are formed on the active region AR and non-active region NAR of the first glass substrate 10 . A third opening C 3 is formed within the color filters CF, thereby defining a first step S 1 . The color filters CF comprise strip-type red R, green G, and blue B color layers. Next, a passivation layer 40 is formed on the color filters CF and the light shield layer 30 and along the profile of the color filters CF and the light shield layer 30 .
A photo spacer layer (not shown) is formed on the passivation layer 40 such that the photo spacer layer creates a second step S 2 along the profile of the first step S 1 . Afterward, an exposure using a mask and at lease one development step are sequentially performed to remove a portion of the photo spacer layer creating a photo spacer PS with a second step S 2 . The second step S 2 comprises a circular protrusion 65 and recess 66 . And the TFT array substrate 2 , depicted in FIG. 10 b , comprises a second glass substrate 20 , a metal line 26 , and an insulating layer 24 .
In the third embodiment, the photo spacer PS is formed on the color filters CF with a first step S 1 , thereby forming a second step S 2 on the photo spacer PS along the first step S 1 of the color filters CF. Therefore, the invention requires only one lithographic process to form a photo spacer with a step.
Similarly, in the third embodiment, the height of the second step S 2 of the photo spacer PS, i.e., the distance between protrusion 65 and recess 66 as shown in FIG. 10 b , is preferably between approximately 0.05 and 0.3 μm. After assembling the color filter substrate 1 and the TFT array substrate 2 , the protrusion 65 of the photo spacer PS normally contact the array substrate 2 , while the recess 66 of the photo spacer PS does not contact the TFT array substrate 2 . When a normal force is applied on the substrate, the protrusion 65 can be elastically deformed while the recess 66 can contact the TFT substrate. The entire density of the spacer increases such that more load can be sustained, thereby preventing push mura defects.
Moreover, if the height of the second step S 2 of photo spacer PS cannot reach the desired range simply using the profile of the first step S 1 of the color filters and passivation layer 40 , a step of reflow can be performed to appropriately adjust the height of the second step S 2 prior to exposure and development.
Fourth Embodiment
FIG. 11 a is a partial top view illustrating a LCD substrate in accordance with a fourth illustrative embodiment of the invention. FIG. 11 b is a cross section taken along line 11 b - 11 b in FIG. 11 a . In FIG. 11 b , a liquid crystal display comprises a color filter substrate 1 , a TFT array substrate 2 , and a liquid crystal layer 50 interposed between the color filter substrate 1 and the TFT array substrate 2 .
Referring to FIGS. 11 a and 11 b , the color filter substrate 1 comprises a first glass substrate 10 , a light shield array 30 , a color filter CF, a passivation layer 40 , a first photo spacer PS 1 , and a second photo spacer PS 2 . Light shield array 30 having a first opening 31 is formed on the first glass substrate 10 , thereby defining an active region AR. Sequentially, a plurality of color filters CF are formed on the active region AR and non-active region NAR of the first glass substrate 10 . The color filters CF comprise strip-type red R, green G color, and blue B layers. Next, a passivation layer 40 is formed on the color filters CF and the light shield layer 30 along the profile of the color filters CF and the light shield layer 30 .
A photo spacer layer (not shown) is formed on the passivation layer 40 such that the photo spacer layer creates a second step S 2 along the profile of the first step S 1 . Afterward, an exposure using a mask and at least one development step are sequentially performed to remove a portion of the photo spacer layer creating a first photo spacer PS 1 and second photo spacer PS 2 . And the TFT array substrate 2 , depicted in FIG. 11 b , comprises a second glass substrate 20 , a metal line 26 , and an insulating layer 24 .
In the fourth illustrative embodiment, the first photo spacer PS 1 is formed in the region without color filters CF, and the second photo spacer is formed in the non-active region NAR with color filters CF. The distance difference H between the first photo spacer PS 1 and the second photo spacer PS 2 is preferably between approximately 0.05 and 0.3 μm. After assembling the color filter substrate 1 and the TFT array substrate 2 , the second photo spacer PS 2 normally contact the array substrate 2 , while the first photo spacer PS 1 does not contact the TFT array substrate 2 . When a normal force is applied on the substrate, the second photo spacer PS 2 can be elastically deformed while the first photo spacer PS 1 can contact the TFT substrate. The entire density of the spacer increases such that more load can be sustained, thereby preventing push mura defects.
Fifth Embodiment
FIG. 12 a is a cross section illustrating a part of a liquid crystal display in which the spacer definition layer is a capacitor in accordance with a fifth illustrative embodiment of the invention. In FIG. 12 a , a liquid crystal display comprises a color filter substrate 1 , a TFT array substrate 2 , and a liquid crystal layer 50 interposed between the color filter substrate 1 and the TFT array substrate 2 .
Referring to FIG. 12 a , the TFT array substrate 2 comprises a glass substrate 20 , a thin film transistor T, a capacitor C, a passivation layer 214 , and a photo spacer PS. The capacitor C comprises a first electrode 211 b , a dielectric layer 212 and a second electrode 213 , thereby defining a first step S 1 .
A photo spacer layer (not shown) is formed on the passivation layer 214 such that the photo spacer layer creates a second step S 2 along the profile of the first step S 1 . Afterward, an exposure using a mask and at least one development step are sequentially performed to remove a portion of the photo spacer layer creating a photo spacer PS with a second step S 2 .
In the fifth embodiment, the photo spacer PS is formed on the TFT array substrate 2 with a first step S 1 , thereby forming a second step S 2 on the photo spacer PS along the first step S 1 of the capacitor C. Therefore, the invention requires only one lithographic process to form a photo spacer with a step.
Similarly, in the fifth embodiment, the height of the second step S 2 of the photo spacer PS, i.e., the distance between protrusion 63 and recess 64 as shown in FIG. 12 a , is preferably between approximately 0.05 and 0.3 μm. After assembling the color filter substrate 1 and the TFT array substrate 2 , the protrusion 63 of the photo spacer PS normally contact the color filter substrate 1 , while the recess 64 of the photo spacer PS does not contact the color filter substrate 1 . When a normal force is applied on the substrate, the protrusion 63 can be elastically deformed while the recess 64 can contact the color filter substrate 1 . The entire density of the spacer increases such that more load can be sustained, thereby preventing push mura defects.
Sixth Embodiment
FIG. 12 b is a cross section illustrating a part of a liquid crystal display in which the spacer definition layer is a thin film transistor in accordance with a sixth illustrative embodiment of the invention. In FIG. 12 b , a liquid crystal display comprises a color filter substrate 1 , a TFT array substrate 2 , and a liquid crystal layer 50 interposed between the color filter substrate 1 and the TFT array substrate 2 .
Referring to FIG. 12 b , the TFT array substrate 2 comprises a glass substrate 20 , a thin film transistor T, a capacitor C, a passivation layer 214 , and a photo spacer PS. The thin film transistor T comprises a gate electrode 211 a , a dielectric layer 212 , a channel 213 , and a source/drain 215 a . An ohmic contact layer 215 b is disposed between the channel 213 , and the source/drain 215 a . The passivation layer 214 covers the thin film transistor T. The edge of the ohmic contact layer 215 b and the source/drain 215 a defines a first step S 1 .
A photo spacer layer (not shown) is formed on the passivation layer 214 such that the photo spacer layer creates a second step S 2 along the profile of the first step S 1 . Afterward, an exposure using a mask and at least one development step are sequentially performed to remove a portion of the photo spacer layer creating a photo spacer PS with a second step S 2 . The second step S 2 comprises a circular protrusion 65 and recess 66 .
In the sixth embodiment, the photo spacer PS is formed on the thin film transistor T with a first step S 1 , thereby forming a second step S 2 on the photo spacer PS along the first step S of the thin film transistor T. Therefore, the invention requires only one lithographic process to form a photo spacer with a step.
Similarly, in the fifth embodiment, the height of the second step S 2 of the photo spacer PS, i.e., the distance between protrusion 65 and recess 66 as shown in FIG. 12 b , is preferably between approximately 0.05 and 0.3 μm. After assembling the color filter substrate 1 and the TFT array substrate 2 , the protrusion 65 of the photo spacer PS normally contact the color filter substrate 1 , while the recess 66 of the photo spacer PS does not contact the color filter substrate 1 . When a normal force is applied on the substrate, the protrusion 65 can be elastically deformed while the recess 66 can contact the color filter substrate 1 . The entire density of the spacer increases such that more load can be sustained, thereby preventing push mura defects.
The spacer definition layer on the TFT array substrate is not limited to a capacitor C and a thin film transistor T. Other structures, such as metal lines 211 c , providing a first step S 1 can also act as the spacer definition layer, as shown in FIG. 12 c.
Furthermore, a LCD structure of color filter on array (COA) could be also introduced into the foregoing invention. Accordingly, the invention improves on the related art in that the photo spacer PS is formed on the spacer definition layer, such as light shield array, color filter, conductive line, semiconductor, passivation or insulator layer with a first step, thereby substantially forming a second step on the photo spacer along the first step. Therefore, only one photo mask step is required to from a photo spacer with a step and is simpler than the conventional half-tone masking step. After assembling the color filter substrate and the TFT array substrate, the protrusion of the photo spacer normally contacts the opposite substrate, while the recess of the photo spacer does not contact the surface of the opposite substrate. When a normal force is applied on the substrate, the protrusion can be elastically deformed while the recess can contact the opposite substrate. The entire density of the spacer increases such that more load can be sustained, thereby preventing push mura defects.
Additionally, the invention also provides two photo spacers. One photo spacer is formed in the region without spacer definition layer, and the other photo spacer is formed in the non-active region with spacer definition layer. A height difference is between the first photo spacer and the second photo spacer. After assembling the color filter substrate and the TFT array substrate, the second photo spacer normally contacts the opposite substrate, while the first photo spacer does not contact the surface of the opposite substrate. When a normal force is applied on the substrate, the second photo spacer can be elastically deformed while the first photo spacer can contact the opposite substrate. The entire density of the spacer increases such that more load can be sustained, thereby preventing push mura defects.
While the invention has been particularly shown and described with reference to preferred embodiments, it will be readily appreciated by those of ordinary skill in the art that various changes and modifications may be made without departing from the spirit and scope of the invention. It is intended that the claims be interpreted to cover the disclosed embodiment, those alternatives which have been discussed above, and all equivalents thereto. | A liquid crystal display (LCD) substrate and a fabrication method thereof are provided. The LCD substrate comprises a substrate, a spacer definition layer formed on the substrate comprising a first step, and a spacer formed along a profile of the first step of spacer definition layer and adjacent to the first step, thereby forming a second step on the spacer. The invention utilizes a single photolithographic process to form spacers with steps, thus, effectively lowering the probability of mura defects caused by gravity, contact, or an uneven cell gap. | 6 |
TECHNICAL FIELD
The present invention relates to foam sports boards for recreational use and, more particularly, to a laminated gliding board with improved bonding characteristics.
BACKGROUND ART
Body boards for riding waves and other recreational sports boards made of foam or other floatational material are known in the prior art. In general, such boards are composed of a number of polyethylene foam and polyethylene film layers that are laminated together by heating the layers and then immediately passing them through a pair of nip rollers. Another conventional process of lamination is to apply heat to the film layer with a heated nip roller on the film side and a normal nip roller on the foam side, where the heated nip roller may be a flat roller. In most cases the surface of the heated nip roller contains an engraved pattern of convex and concave area for better heat transfer. Both of these conventional heating processes cause adhesion by the localized collapse and bonding of the foam cells on the surface of the respective layers. The resulting laminate of the polyethylene foam and polyethylene film is then often heat laminated onto a standard foam core.
Because the standard foam core does not have a perfectly flat or planar surface, adhesive contact between the film and foam core is limited to the apexes of the cells on the surface of the foam core. Thus the point of contact is not uniform between the film and foam, but instead the film contacts the points of the outer surface of the core that protrude from the irregular cellular surface of the foam core.
Conventional film lamination method typically use micro-cellular high density foam sheets to improve the adhesion between the film and foam core. The micro-cellular foam sheet contains smaller peaks and valleys, with the peaks closer together. The surface area of contact between the sheet and foam is thereby increased. However, this kind of structure is still prone to delamination by mechanical contact forces and by the effect of heat and pressure when in use.
While it is known in the prior art that a thin layer of thermal plastic polyethylene film between a polyethylene foam sheet and a polyethylene film can be used to promote lamination, such thin layer of film is generally an unmodified low density polyethylene with limited efficacy.
Accordingly, there is need for adhesively bonded sports boards with improved bonding between layers of different polymeric material having different surface contouring and cellular structure.
DISCLOSURE OF THE INVENTION
With parenthetical reference to the corresponding parts, portions or surfaces of the disclosed embodiment, merely for the purposes of illustration and not by way of limitation, the present invention provides an improved sports board ( 15 ) comprising a polymer film layer ( 16 ) having an outer surface ( 18 ) and an inner surface ( 19 ), a polyethylene foam layer ( 23 ) having first ( 24 ) and second ( 25 ) outer surfaces, and an extruded adhesive resin layer ( 20 ) bonded to the inner surface of the film layer and the first surface of the foam layer. The adhesive resin may be selected from a group consisting of an ethylene and methyl acrylic copolymer and an anhydride-modified polyolefin, and the hydride-modified polyolefin may be selected from a group consisting of anhydride-modified ethylene vinyl acetate, adhydride-modified low-density polyethylene and anhydride-modified linear low-density polyethylene. The polyethylene foam layer may be selected from a group consisting of polyethylene, cross-linked polyethylene, and a copolymer of ethylene vinyl acetate and polyethylene polymeric material. The film layer may be non-opaque and may further comprise a graphic image ( 29 ) printed on the inner surface of the film layer. The board may further comprise a second non-opaque polymer film layer ( 31 ) having an outer surface ( 32 ) and an inner surface ( 33 ), and having a graphic image ( 46 ) imprinted on the inner surface of the second film layer, and the inner surface of the second film layer bonded to the outer surface ( 35 ) of the first film layer ( 34 ). The first film layer may have a thickness of between about 0.01 mm and about 0.15 mm and the second film layer may have a thickness of between about 0.02 mm and about 0.15 mm. The board may further comprise a polyethylene film layer ( 26 ) bonded to the second outer surface ( 25 ) of the foam layer. The board may further comprise a polyethylene foam core ( 62 ) having an upper outer surface ( 63 ) and a lower outer surface ( 64 ), the second outer surface ( 61 ) of the foam layer ( 60 ) bonded to the upper surface ( 63 ) of the foam core ( 62 ). The second outer surface and the upper surface may be heat bonded and the foam layer may have a thickness less than the thickness of the core layer. The board may further comprise a second polymer film layer ( 72 ) having an outer surface ( 74 ) and an inner surface ( 73 ), a second polyethylene foam layer ( 65 ) having first ( 68 ) and second ( 66 ) outer surfaces, a second extruded adhesive resin layer ( 69 ) bonded to the inner surface of the second film layer and the first surface of the second foam layer, and the second surface of the foam layer bonded to the lower outer surface ( 64 ) of the foam core. The board may further comprise a second polymer film layer ( 99 ) having an outer surface ( 101 ) and an inner surface ( 100 ), and a second extruded adhesive resin layer ( 95 ) bonded to the inner surface of the second film layer and the lower outer surface ( 94 ) of the foam core ( 92 ).
The present invention also provides an improved sports board comprising a polymer film layer having an outer surface and an inner surface, a non-polyethylene foam layer having first and second outer surfaces, and an extruded adhesive resin layer bonded to the inner surface of the film layer and the first surface of the foam layer. The non-polyethylene foam layer may comprise expanded polypropylene foam or expanded polystyrene foam.
The invention also provides an improved sports board ( 102 ) comprising a polyethylene foam layer ( 103 ) having an outer surface ( 104 ) and an inner surface ( 105 ), a non-polyethylene foam layer ( 110 ) having first ( 111 ) and second ( 112 ) outer surfaces, and an extruded adhesive resin layer ( 106 ) bonded to the inner surface of the polyethylene foam layer and the first outer surface of the non-polyethylene foam layer. The non-polyethylene foam layer may comprise expanded polypropylene foam or expanded polystyrene foam. The sports board may further comprise a second polyethylene foam layer ( 116 ) having an outer surface ( 119 ) and an inner surface ( 118 ), and a second extruded adhesive resin layer ( 113 ) bonded to the inner surface of the second polyethylene foam layer and the second outer surface ( 112 ) of the non-polyethylene foam layer ( 110 ). The board may further comprise a polyethylene film layer ( 120 ) having an inner surface ( 121 ) and an outer surface ( 122 ), the inner surface of the polyethylene film layer bonded to the outer surface of the second polyethylene foam layer.
Accordingly, the general object of the present invention is to provide an improved sports board in which different polyolefin materials may be used in the layers without a derogation in bonding strength.
Another object is to provide an improved sports board which permits the layers to be laminated together using more efficient and less expansive laminating methods.
Another object is to provide an improved sports board with improved bond strength and flexibility along the bond line between the laminates.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective and partial sectional view of a first embodiment of the sports board.
FIG. 2 is a partial vertical sectional view of the sports board shown in FIG. 1 .
FIG. 3 is a perspective and partial sectional view of a second embodiment of the sports floor.
FIG. 4 is a partial vertical sectional view of the sports board shown in FIG. 3 .
FIG. 5 is a perspective and partial sectional view of a third embodiment of the sports board.
FIG. 6 is a partial vertical sectional view of the sports board shown in FIG. 5 .
FIG. 7 is a perspective and partial sectional view of a fourth embodiment of the sports board.
FIG. 8 is a partial vertical sectional view of the sports board shown in FIG. 7 .
FIG. 9 is a perspective and partial sectional view of a fifth embodiment of the sports board.
FIG. 10 is a partial vertical sectional view of the sports board shown in FIG. 9 .
FIG. 11 is a schematic showing the process by which a film layer is bonded to a foam layer with an adhesive resin of the preferred embodiments.
FIGS. 12-13 are a schematic showing the process by which a first foam layer is laminated to a second foam layer with an adhesive resin of the preferred embodiments.
FIG. 14 is an enlarged sectional view of adhesive resin between two different layers.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
At the outset, it should be clearly understood that like reference numerals are intended to identify the same structural elements, portions or surfaces, consistently throughout the several drawing figures, as such elements, portions or surfaces may be further described or explained by the entire written specification, of which this detailed description is an integral part. Unless otherwise indicated, the drawings are intended to be read (e.g., cross-hatching, arrangement of parts, proportion, degree, etc.) together with the specification, and are to be considered a portion of the entire written description of this invention. As used in the following description, the terms “horizontal”, “vertical”, “left”, “right”, “up” and “down”, as well as adjectival and adverbial derivatives thereof (e.g., “horizontally”, “rightwardly”, “upwardly”, etc.), simply refer to the orientation of the illustrated structure as the particular drawing figure faces the reader. Similarly, the terms “inwardly” and “outwardly” generally refer to the orientation of a surface relative to its axis of elongation, or axis of rotation, as appropriate.
Referring now to the drawings and, more particularly, to FIG. 1 thereof, this invention provides an improved sports board, the first embodiment of which is generally indicated at 15 . As shown in FIGS. 1-2 , sports board 15 is comprised of four layers laminated together.
Top Layer 16 is a graphically-imprinted polymer film. The graphics on layer 16 are imprinted using any of several conventional processes for printing. An example of such a process is corona printing, in which an electrical discharge temporarily alters the surface molecules of the polyethylene film, allowing inks to adhere to the film. Layer 16 has a thickness of between 0.02 mm and 0.15 mm, and preferably a thickness of 0.07 mm. Layer 16 has a density in the range of 0.91 to 0.98 g/cm 3 , and preferably a density of 0.95 g/cm 3 .
In the preferred embodiment, layer 20 is an ethylene and methyl acrylic copolymer. Layer 20 has a thickness of between 0.02 and 0.15 mm, and preferably a thickness of 0.07 mm. Layer 20 has a density in the range of 0.90 to 0.98 g/cm 3 , and preferably a density of 0.95 g/cm 3 . The ethylene methyl acrylate copolymer EMAC provided by Eastman Chemical Company, of 100 North Eastman Road, Kingsport, Tenn. 37662, may be employed in the preferred embodiment. It is contemplated that alternative adhesive resins, such as anhydride-modified polyolefin, anhydride-modified ethylene vinyl acetate, anhydride-modified low-density polyethylene, and anhydride-modified linear low-density polyethylene, maybe employed. The Bynel® adhesive resin, provided by Dupont Packaging, of 1007 Market Street, Wilmington, Del. 19898, maybe employed in such an embodiment.
Layer 23 is closed-cell polyethylene foam, and acts as the core of board 15 . Core 23 may be beaded type, extruded type or cross-linked polyethylene foam. Core 23 has a thickness of between 0.5 and 2 inches and preferably a thickness of 1 inch. Core 23 has a density in the range of 1.6 to 4 lb/ft 3 , and preferably a density of 2.2 lb/ft 3 . It is contemplated that core 23 may be formed from two or more layers laminated together to provide the appropriate thickness.
Layer 26 is polyethylene film. Layer 26 has a thickness of between 0.2 and 1.5 mm, and preferably a thickness of 0.35 mm. Layer 26 has a density in the range of 0.91 to 0.98 g/cm 3 , and preferably a density of 0.95 g/cm 3 .
Board 15 is formed in a series of steps. First, layer 26 is heat laminated to the bottom surface 25 of layer 23 using a conventional heat lamination method. The resulting laminate 23 / 26 is then cut and configured to the desired shape. Next, layer 16 is imprinted with the desired graphics using a conventional imprinting procedure. As shown in FIG. 12 , layer 16 is then fed from a bottom roll 125 and hot resin 20 is extruded and with pressure applied to surface 19 of layer 16 to form a top laminate of layers 16 and 20 . This top laminate 16 / 20 is then turned over and, with the application of heat and pressure, is laminated to the upper surface 24 of the shaped core 23 , thereby forming the fully-laminated board 15 . Layers 16 and 20 are cut and configured to wrap-around and cover the sloped edge of core 23 and the straight edge of layer 26 to form a contoured side to board 15 .
As shown in FIG. 14 , the adhesive resin in this embodiment, as well as the following embodiments, fills in the gaps between the peaks and valleys of each of the opposed surfaces of the two adjacent layers to provide greater contact and better bonding. The extruded resin between two layers of different polymeric material having different surface contouring and cellular structure provides an improved lamination.
FIGS. 3-4 show a second embodiment 30 . In this embodiment, board 30 has five laminated layers rather than four. Layer 31 is of the same structure and composition as layer 16 in the first embodiment 15 . Layer 34 is polyethylene film. Layer 34 has a thickness of between 0.01 and 0.15 mm, and preferably a thickness of 0.07 mm. Layer 34 has a density in the range of 0.91 to 0.98 g/cm 3 , and preferably a density of 0.95 g/cm 3 . Layers 37 , 40 and 43 are of the same structure and composition as layers 20 , 23 and 26 , respectively, of the first embodiment 15 .
Sports board 30 is formed in a series of steps. First, layer 31 is imprinted with the desired graphics using a conventional imprinting procedure. Layer 34 is then laminated to surface 33 of layer 31 to form a laminate film layer 31 / 34 . As shown in FIG. 11 , laminate film layer 31 / 34 is then fed from a top roll 123 and layer 40 is fed from bottom roll 124 . As laminate layer 31 / 34 and layer 40 are fed from rolls 123 and 124 , respectively, resin 37 is extruded, using a conventional extrusion process, between surface 36 of layer 34 and surface 41 of layer 40 to form a laminated sheet of layers 31 , 34 , 37 and 40 . Layer 43 is then heat laminated to surface 42 of laminated sheet 31 / 34 / 37 / 40 using a conventional heat lamination method, thereby forming the fully-laminated sheet 30 . This laminated sheet is then cut and configured to the desired shape.
FIGS. 5-6 show a third embodiment 48 . In this embodiment, board 48 has eight laminated layers. Layers 49 , 52 and 55 are of the same structure and composition as Layers 31 , 34 and 37 , respectively, of the second embodiment 30 .
Layer 59 is polyethylene foam. Layer 59 has a thickness of between 1 and 5 mm, and preferably a thickness of 3 mm. Layer 59 has a density in the range of 4 to 8 lb/ft 3 , and preferably a density of 6 lb/ft 3 .
Layer 62 is polyethylene foam. Layer 62 has a thickness of between 0.5 inches and 2 inches, and preferably a thickness of 1 inch. Layer 62 has a density in the range of 1.6 to 4 lb/ft 3 , and preferably a density of 2.2 lb/ft 3 .
Layer 65 is of the same structure and composition as layer 59 .
Layer 69 is of the same structure and composition as layer 52 and layer 72 is of the same structure and composition as layer 49 .
Sports board 48 is formed in a series of steps. First, layer 49 is imprinted with the desired graphics using a conventional imprinting procedure. Layer 52 is then laminated to surface 51 of layer 49 to form a laminate film layer 49 / 52 . As shown in FIG. 11 , laminate film layer 49 / 52 is then fed from a top roll 123 and layer 59 is fed from bottom roll 124 . As laminate layer 49 / 52 and layer 59 are fed from rolls 123 and 124 , respectively, hot resin 55 is extruded, using a conventional extrusion process, between surface 54 of layer 52 and surface 60 of layer 59 to form a top laminate sheet of layers 49 , 52 , 55 , and 59 . Next, again with reference to FIG. 11 , film layer 72 is then fed from a top roll 123 and layer 65 is fed from bottom roll 124 . As layer 72 and layer 65 are fed from rolls 123 and 124 , respectively, hot resin 69 is extruded, using a conventional extrusion process, between surface 73 of layer 72 and surface 68 of layer 65 to form a bottom laminate sheet of layers 65 , 69 and 72 . These laminates are then cut and configured to the desired shape and size. Surface 61 of top laminate 59 / 55 / 52 / 49 is then heat-laminated to the top surface 63 of core 62 using a conventional heat laminating method, and surface 66 of bottom laminate 65 / 69 / 72 is then heat-laminated to the bottom surface 64 of core 62 using a conventional heat laminating method, thereby forming the fully-laminated board 48 .
As shown in FIG. 5 , polyethylene foam strips 75 and 76 are then heat laminated to cover the side edges of laminated layers 49 , 52 , 55 , 59 , 62 , 65 , 69 and 72 . Strips 75 and 76 have a thickness of between 2 and 6 mm, and preferably a thickness of 4.5 mm. Strips 75 and 76 have a density in the range of 4 to 8 lb/ft 3 , and preferably a density of 6 lb/ft 3 .
FIGS. 7-8 show a fourth embodiment 78 . In this embodiment, board 78 has seven laminated layers. Layers 79 , 82 , 85 , 89 and 92 are of the same structure and composition as layers 49 , 52 , 55 , 59 and 62 , respectively, and layers 95 and 99 are of the same structure and composition as layers 69 and 72 , respectively, of board 48 . However, sports board 78 does not include the foam backing layer 65 of board 48 . The versatility of the adhesive resin allows for the bonding between different foams as well as between different films and foams.
Sports board 78 is formed in a series of steps. First, layer 79 is imprinted with the desired graphics using a conventional imprinting procedure. Layer 82 is then laminated to surface 81 of layer 79 to form a laminate film layer 79 / 82 . As shown in FIG. 11 , laminate film layer 79 / 82 is then fed from a top roll 123 and core 92 is fed from bottom roll 124 . As laminate 79 / 82 and layer 89 are fed from rolls 123 and 124 , respectively, hot resin 85 is extruded, using a conventional extrusion process, between surface 84 of layer 82 and surface 90 of layer 89 to form a top laminate sheet of layers 79 , 82 , 85 and 89 . Next, with reference to FIG. 12 , film layer 99 is fed from a bottom roll 125 and hot resin 95 is extruded and with pressure applied to surface 100 of layer 99 to form a bottom laminate of layers 95 and 99 . This bottom laminate 95 / 99 is then turned over and, with the application of heat and pressure, is laminated to surface 94 of core 92 . The resulting laminate 92 / 95 / 99 is then cut and configured to the desired shape. Surface 91 of top laminate 79 / 82 / 85 / 89 is then heat-laminated to the top surface 93 of the shaped core 92 using a conventional heat laminating method, thereby forming the fully-laminated board 78 . Layers 79 , 82 , 85 and 89 are cut and configured to wrap-around and cover the sloped edge of layer 92 and the straight edges of layers 95 and 99 to form a contoured side to board 78 . This embodiment does not include the separate side strips 75 and 76 of the third embodiment 48 .
FIGS. 9-10 show a fifth embodiment 102 . In this embodiment, board 102 has six laminated layers.
Layer 103 is polyethylene foam. Layer 103 has a thickness of between 2 and 8 mm, and preferably a thickness of 4.5 mm. Layer 103 has a density in the range of 4 to 10 lb/ft 3 , and preferably a density of 7 lb/ft 3 .
Layer 106 is of the same structure and composition as layer 55 in the fourth embodiment.
Layer 110 is non-polyethylene foam. In the preferred embodiment, layer 110 is polystyrene foam. However, it is contemplated that other types of foam may be used, such as polypropylene foam. Layer 110 has a thickness of between 1 and 2.5 inches, and preferably a thickness of 2.125 inches. In the preferred embodiment, layer 110 is polystyrene foam and has a density in the range of 1.0 to 2.5 lb/ft 3 , and preferably a density of 1.5 lb/ft 3 . If polypropylene foam is used, layer 110 would have a density in the range of 1.5 to 3 lb/ft 3 , and preferably a density of 1.9 lb/ft 3 .
Layer 113 is of the same structure and composition as layer 106 .
Layer 116 is polyethylene foam. Layer 116 has a thickness of between 1 and 5 mm, and preferably a thickness of 3 mm. Layer 116 has a density in the range of 4 to 8 lb/ft 3 , and preferably a density of 6 lb/ft 3 .
Layer 120 is polyethylene film. Layer 120 has a thickness of between 0.2 and 1.5 mm, and preferably a thickness of 0.35 mm. Layer 120 has a density in the range of 0.91 to 0.98 g/cm 3 , and preferably a density of 0.95 g/cm 3 .
Sports board 102 is formed in a series of steps. First, polyethylene foam layer 116 is heat laminated to film layer 120 using conventional heat laminating methods. As shown in FIGS. 12 and 13 , laminate 116 / 120 is then unrolled from a bottom roll 125 and hot resin 113 is extruded and with pressure applied to surface 118 of layer 116 to form a bottom laminate of layers 113 , 116 and 120 . This bottom laminate 113 / 116 / 120 is then turned over and, with the application of heat and pressure, is laminated to the bottom surface 112 of a pre-formed core 110 , as shown in FIG. 13 . Next, again with reference to FIG. 12 , polyethylene foam layer 103 is unrolled from a bottom roll 125 and hot resin 106 is extruded and with pressure applied to surface 105 of layer 103 to form a top laminate of layers 103 and 106 . This top laminate 103 / 106 is then heat laminated to surface 111 of core layer 110 as shown in FIG. 13 , thereby forming the fully-laminated board 102 . The top laminate 103 / 106 is cut and configured to wrap-around and cover the inclined edges of core layer 110 . This embodiment also includes two separate side strips 123 and 124 of polyethylene foam which are applied with hot resin, using the same method as the application of resin 106 to layer 103 , and then heat laminated to cover the lower inclined side edges of core layer 110 . Side strips 123 and 124 have a thickness of between 1 and 5 mm, and preferably a thickness of 3 mm. Side strips 123 and 124 have a density in the range of 4 to 8 lb/ft 3 , and preferably a density of 6 lb/ft 3 .
The present invention contemplates that many changes and modifications may be made. Therefore, while the presently-preferred forms of the improved sports board have been shown and described, and several 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. | The invention is directed to a sports board ( 15 ). In the preferred embodiment, the sports board comprises a polymer film layer ( 16 ) having an outer surface ( 18 ) and an inner surface ( 19 ), a polyethylene foam layer ( 23 ) having first ( 24 ) and second ( 25 ) outer surfaces, and an extruded adhesive resin layer ( 20 ) bonded to the inner surface of the film layer and the first surface of the foam layer. The adhesive resin may be selected from a group consisting of an ethylene and methyl acrylic copolymer and an anhydride-modified polyolefin, and the hydride-modified polyolefin maybe selected from a group consisting of anhydride-modified ethylene vinyl acetate, adhydride-modified low-density polyethylene and anhydride-modified linear low-density polyethylene. In an alternate embodiment, the sports board ( 102 ) comprises a polyethylene foam layer ( 103 ) having an outer surface ( 104 ) and an inner surface ( 105 ), a non-polyethylene foam layer ( 110 ) having first ( 111 ) and second ( 112 ) outer surfaces, and an extruded adhesive resin layer ( 106 ) bonded to the inner surface of the polyethylene foam layer and the first outer surface of the non-polyethylene foam layer. The non-polyethylene foam layer may comprise expanded polypropylene foam or expanded polystyrene foam. | 1 |
BACKGROUND OF THE INVENTION
Technical Field
The present invention relates to the technical field of sewage treatment, more specifically to a method for advanced treatment of bio-treated coking wastewater.
Description of Related Art
Coking wastewater is generated in the high-temperature carbonization of raw coal, coal gas purification and refining process of chemical products. The constituents in coking wastewater vary greatly in accordance with the nature of raw coal, carbonization temperature and recovering modes of chemical byproducts. Coking wastewater usually contains ammonia nitrogen, cyanides, thiocyanides, phenols and other pollutants such as polycyclic aromatic hydrocarbons and heterocyclic compounds containing nitrogen, oxygen and sulfur. These persistent pollutants are very harmful to the ecological system, in addition, most of polycyclic and heterocyclic compounds are subject to constant transformation and are carcinogenic by nature. Therefore, treatment of coking wastewater is a tough challenge for all countries. At present, most coking plants discharge coking wastewater after such processes as de-phenol pretreatment and biological treatment, the biological oxygen demand (BOD) in the effluent treated in this way can reach the B-level of [Chinese National] Integrated Wastewater Discharge Standard (GB8978-1996), but the chromaticity and the chemical oxygen demand (COD) therein usually exceed the national standards. Though advanced oxidation processes and active carbon adsorption can effectively solve the above problems, they are limited in use due to high operating cost and small treatment capacity. Thus, seeking a simple, low-cost and effect-stable technology for the advanced treatment of coking wastewater becomes a primary yet challenging task.
In recent years, iron oxide and manganese oxide are widely used in removing heavy metals (Zn, Cd, Ni, Pb, etc.) and inorganic ion pollutants (arsenate, fluorinion, perchlorate, etc.) in solution, which have been reported in various literature and patents. Some organics in the wastewater can form coordinated complexes with hydrated ferric oxide and hydrated manganese oxide, which makes it possible to remove organic pollutants from coking wastewater by means of nano-composite adsorbents made of iron oxide or manganese oxide. However, up-to-standard discharge of coking wastewater that has been treated as such is still a technical difficulty.
BRIEF SUMMARY OF THE INVENTION
1. Technical Problems to be Solved
In order to solve the problem existing in prior arts, viz the concentration of pollutants contained in bio-treated coking wastewater exceeds the national discharge standard, the present invention provides a method for advanced treatment of bio-treated coking wastewater. It can effectively reduce COD and chromaticity in the effluent down to less than 70 mg/L and 20 times respectively with relatively low cost.
2. Technical Solutions
The technical solutions disclosed in the present invention are as follows:
A method for advanced treatment of bio-treated coking wastewater, comprising the following steps:
(A) Guide the effluent from the secondary sedimentation tank of a coking wastewater bio-treatment plant to a flocculation mixer, add in polymeric ferric sulfate (PFS) and polyacrylamide (PAM), and make the raw wastewater mix thoroughly with the flocculant. The PFS and PAM are added in the form of solution; the PFS solution has a mass concentration of 2-10%, the dosage is 5-25 L/m 3 ; the PAM solution has a mass concentration of 0.05-0.2%, and the dosage is 5-20 L/m 3 . The rotational speed of the stirrer in the flocculation mixer is 200-300 rpm, and the mixing time is 2-6 min.
(B) Guide the mixed solution obtained from step (A) into a flocculation reactor to generate a flocculation reaction, form large coagulated particles through such physical and chemical processes as double-layer compression, adsorption-charge neutralization and net retentation, and remove pollutants including colloidal particles and insoluble COD in the wastewater. The rotational speed of the stirrer in the flocculation reactor is 50-100 rpm, and the mixing time is 20-60 min.
(C) Guide the mixed solution obtained through the flocculation reaction in step (B) into a settling tank to separate the precipitated solids from the liquid. The settling time is 30-60 min.
(D) Filter the supernatant obtained in step (C), and guide the filtrate to pass through an adsorption column filled with nano-composites at a flow rate of 4-10 BV/h (BV represents the bed volume) such that the non-biodegradable organic pollutants and some of inorganic pollutants are effectively adsorbed by the nano-composites. Keep the treatment capacity at 500-1,000 BV each batch and the post-treatment COD and chromaticity in the effluent is less than 70 mg/L and 20 times respectively.
In the present invention, the matrix of the nano-composites is quaternized spherical polystyrene with nano-size pore structure, loaded with iron oxide or manganese oxide nano-particles. It can be either the composite NDA-HMO (produced by Jiangsu Yongtai Environmental Protection Scientific Co., Ltd.) loaded with manganese oxide nano-particles or the composite NDA-HFO (produced by Jiangsu Yongtai Environmental Protection Scientific Co., Ltd.) loaded with iron oxide nano-particles, wherein the composite NDA-HMO loaded with manganese oxide nano-particles is preferred.
(E) When the adsorption process reaches the breakthrough point (COD exceeding 70 mg/L or the chromaticity exceeding 20 times), the adsorption operation will be stopped, and a desorption process is initiated by using 2-10% sodium hydroxide solution as the desorption reagent at the flow rate of 0.5-2 BV/h at the temperature of 40-85° C.
(F) The high-concentrated desorption liquid obtained in step (E) is further condensed and then transferred out for incineration or production of coal water slurry, meanwhile the low-concentrated desorption liquid obtained in the same step is used to prepare sodium hydroxide solution for the desorption process of the next batch.
Common methods for advanced treatment of coking wastewater can only reduce COD to approximately 100 mg/L. They are also low in removal efficiency, poor in decolorization and small in treatment capacity. In contrast, the method disclosed in the present invention shows excellent efficiency in removing COD and color due to high selectivity, high adsorption efficiency and the Donnas membrane effect of nano-oxides adopted herein in removing monocyclic or polycyclic aromatic compounds, heterocyclic compounds containing nitrogen, oxygen or sulfur, and phenols as well as highly reductive inorganic compounds such as cyanides and thiocyanides.
3. Beneficial Effects
The present invention has the following beneficial effects: 1. After advanced treatment, the COD in the bio-treated coking wastewater can be decreased from 160 mg/L to below 70 mg/L, and the chromaticity from 80 times to below 20 times. The data meet the A-level standard of the Integrated Wastewater Discharge Standard (GB8978-1996); 2. Large treatment capacity; 500-1,000 BV bio-treated coking wastewater can be treated with satisfactory treatment effect; 3. The nano-composites can be employed for repeated use with stable removal efficiency due to its outstanding regenerative properties and high mechanical strength. In conclusion, the advantages of the present invention include simpler operation procedure and lower operating cost in contrast with prior arts, which consequently embodies not only significant environmental benefits but also promising market potential.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is further described with the following embodiments.
Embodiment 1
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 10 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 5% and 10 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.1% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 50 rpm for 60 min of reaction; guide the mixed solution into a settling tank for 30 min of settling.
Fill 5 mL (approximately 3.8 g) nano-composite NDA-HMO into a jacketed glass adsorption column (16×160 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 10±5° C.; the treatment capacity is kept at 4,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 61 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 5 mL sodium hydroxide solution with a mass concentration of 6%, 5 mL sodium hydroxide solution with a mass concentration of 1% and 20 mL tap water through the nano-composite adsorption bed at the flow rate of 5 mL/h at the temperature of 45±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 2
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 10% and 20 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.05% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 60 rpm for 50 min of reaction; guide the mixed solution into a settling tank for 40 min of settling.
Fill 10 mL (approximately 7.5 g) nano-composite NDA-HMO into a jacketed glass adsorption column (16×160 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 100 mL/h at the temperature of 25±5° C.; the treatment capacity is kept at 8,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 65 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 10 mL sodium hydroxide solution with a mass concentration of 6%, 10 mL sodium hydroxide solution with a mass concentration of 2% and 40 mL tap water through the nano-composite adsorption bed at the flow rate of 10 mL/h at the temperature of 55±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 3
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 12 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 4% and 6.5 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.15% into the flocculation mixer consecutively; mix the substances for 6 min with a stirrer at the speed of 200 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 70 rpm for 40 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 50 mL (approximately 37.5 g) nano-composite NDA-HMO into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 400 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 50,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 64 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 50 mL sodium hydroxide solution with a mass concentration of 8%, 50 mL sodium hydroxide solution with a mass concentration of 2% and 200 mL tap water through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 60±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 4
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 8 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 6% and 12 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.08% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 80 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 60 min of settling.
Fill 100 mL (approximately 75 g) nano-composite NDA-HMO into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 600 mL/h at the temperature of 15±5° C.; the treatment capacity is kept at 80,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 62 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 100 mL sodium hydroxide solution with a mass concentration of 10%, 100 mL sodium hydroxide solution with a mass concentration of 2% and 400 mL tap water through the nano-composite adsorption bed at the flow rate of 100 mL/h at the temperature of 70±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 5
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 6.5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 8% and 8 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.12% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 90 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 200 mL (approximately 150 g) nano-composite NDA-HMO into a jacketed glass adsorption column (64×320 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 1000 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 200,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 66 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 200 mL sodium hydroxide solution with a mass concentration of 8%, 200 mL sodium hydroxide solution with a mass concentration of 3% and 800 mL tap water through the nano-composite adsorption bed at the flow rate of 200 mL/h at the temperature of 75±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 6
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 25 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 2% and 5 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.2% into the flocculation mixer consecutively; mix the substances for 5 min with a stirrer at the speed of 200 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 100 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 60 min of settling.
Fill 500 mL (approximately 375 g) nano-composite NDA-HMO into a jacketed glass adsorption column (100×360 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 2000 mL/h at the temperature of 10±5° C.; the treatment capacity is kept at 400,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 59 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 500 mL sodium hydroxide solution with a mass concentration of 10%, 500 mL sodium hydroxide solution with a mass concentration of 3% and 2000 mL tap water through the nano-composite adsorption bed at the flow rate of 500 mL/h at the temperature of 80±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 7
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 10 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 5% and 10 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.1% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 50 rpm for 60 min of reaction; guide the mixed solution into a settling tank for 30 min of settling.
Fill 10 mL (approximately 7.5 g) nano-composite NDA-HMO into a jacketed glass adsorption column (16×160 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 100 mL/h at the temperature of 25±5° C.; the treatment capacity is kept at 8,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 65 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 10 mL sodium hydroxide solution with a mass concentration of 6%, 10 mL sodium hydroxide solution with a mass concentration of 2% and 40 mL tap water through the nano-composite adsorption bed at the flow rate of 10 mL/h at the temperature of 55±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 8
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 10% and 20 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.05% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 60 rpm for 50 min of reaction; guide the mixed solution into a settling tank for 40 min of settling.
Fill 50 mL (approximately 37.5 g) nano-composite NDA-HMO into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 400 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 50,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 64 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 50 mL sodium hydroxide solution with a mass concentration of 8%, 50 mL sodium hydroxide solution with a mass concentration of 2% and 200 mL tap water through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 55±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 9
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 12 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 4% and 6.5 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.15% into the flocculation mixer consecutively; mix the substances for 6 min with a stirrer at the speed of 200 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 70 rpm for 40 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 100 mL (approximately 75 g) nano-composite NDA-HFO into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 600 mL/h at the temperature of 15±5° C.; the treatment capacity is kept at 80,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 62 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 100 mL sodium hydroxide solution with a mass concentration of 10%, 100 mL sodium hydroxide solution with a mass concentration of 2% and 400 mL tap water through the nano-composite adsorption bed at the flow rate of 100 mL/h at the temperature of 70±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 10
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 8 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 6% and 12 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.08% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 80 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 60 min of settling.
Fill 200 mL (approximately 150 g) nano-composite NDA-HFO into a jacketed glass adsorption column (64×320 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 1000 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 200,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 66 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 200 mL sodium hydroxide solution with a mass concentration of 8%, 200 mL sodium hydroxide solution with a mass concentration of 3% and 800 mL tap water through the nano-composite adsorption bed at the flow rate of 200 mL/h at the temperature of 75±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 11
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 6.5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 8% and 8 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.12% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 90 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 500 mL (approximately 375 g) nano-composite NDA-HMO into a jacketed glass adsorption column (100×360 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 2000 mL/h at the temperature of 10±5° C.; the treatment capacity is kept at 400,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 59 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 500 mL sodium hydroxide solution with a mass concentration of 10%, 500 mL sodium hydroxide solution with a mass concentration of 3% and 2000 mL tap water through the nano-composite adsorption bed at the flow rate of 500 mL/h at the temperature of 80±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 12
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 10 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 5% and 10 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.1% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 50 rpm for 60 min of reaction; guide the mixed solution into a settling tank for 30 min of settling.
Fill 50 mL (approximately 37.5 g) nano-composite NDA-HFO into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 400 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 50,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 64 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 50 mL sodium hydroxide solution with a mass concentration of 8%, 50 mL sodium hydroxide solution with a mass concentration of 2% and 200 mL tap water through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 60±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 13
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 10% and 20 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.05% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 60 rpm for 50 min of reaction; guide the mixed solution into a settling tank for 40 min of settling.
Fill 100 mL (approximately 75 g) nano-composite NDA-HMO into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 600 mL/h at the temperature of 15±5° C.; the treatment capacity is kept at 80,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 62 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 100 mL sodium hydroxide solution with a mass concentration of 10%, 100 mL sodium hydroxide solution with a mass concentration of 2% and 400 mL tap water through the nano-composite adsorption bed at the flow rate of 100 mL/h at the temperature of 70±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 14
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 12 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 4% and 6.5 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.15% into the flocculation mixer consecutively; mix the substances for 6 min with a stirrer at the speed of 200 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 70 rpm for 40 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 200 mL (approximately 150 g) nano-composite NDA-HMO into a jacketed glass adsorption column (64×320 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 1000 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 200,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 66 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 200 mL sodium hydroxide solution with a mass concentration of 8%, 200 mL sodium hydroxide solution with a mass concentration of 3% and 800 mL tap water through the nano-composite adsorption bed at the flow rate of 200 mL/h at the temperature of 75±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 15
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 8 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 6% and 12 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.08% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 80 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 60 min of settling.
Fill 500 mL (approximately 375 g) nano-composite NDA-HFO into a jacketed glass adsorption column (100×360 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 2000 mL/h at the temperature of 10±5° C.; the treatment capacity is kept at 400,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 59 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 500 mL sodium hydroxide solution with a mass concentration of 10%, 500 mL sodium hydroxide solution with a mass concentration of 3% and 2000 mL tap water through the nano-composite adsorption bed at the flow rate of 500 mL/h at the temperature of 80±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 16
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 10 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 5% and 10 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.1% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 50 rpm for 60 min of reaction; guide the mixed solution into a settling tank for 30 min of settling.
Fill 100 mL (approximately 75 g) nano-composite NDA-HFO into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 600 mL/h at the temperature of 15±5° C.; the treatment capacity is kept at 80,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 62 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 100 mL sodium hydroxide solution with a mass concentration of 10%, 100 mL sodium hydroxide solution with a mass concentration of 2% and 400 mL tap water through the nano-composite adsorption bed at the flow rate of 100 mL/h at the temperature of 70±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 17
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 5% and 20 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.05% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 60 rpm for 50 min of reaction; guide the mixed solution into a settling tank for 40 min of settling.
Fill 200 mL (approximately 150 g) nano-composite NDA-HMO into a jacketed glass adsorption column (64×320 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 1000 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 200,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 66 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 200 mL sodium hydroxide solution with a mass concentration of 8%, 200 mL sodium hydroxide solution with a mass concentration of 3% and 800 mL tap water through the nano-composite adsorption bed at the flow rate of 200 mL/h at the temperature of 75±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 18
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 12 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 4% and 6.5 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.15% into the flocculation mixer consecutively; mix the substances for 6 min with a stirrer at the speed of 200 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 70 rpm for 40 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 500 mL (approximately 375 g) nano-composite NDA-HFO into a jacketed glass adsorption column (100×360 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 2000 mL/h at the temperature of 10±5° C.; the treatment capacity is kept at 400,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 59 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 500 mL sodium hydroxide solution with a mass concentration of 10%, 500 mL sodium hydroxide solution with a mass concentration of 3% and 2000 mL tap water through the nano-composite adsorption bed at the flow rate of 500 mL/h at the temperature of 80±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 19
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 10% and 20 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.05% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 60 rpm for 50 min of reaction; guide the mixed solution into a settling tank for 40 min of settling.
Fill 5 mL (approximately 3.8 g) nano-composite NDA-HMO into a jacketed glass adsorption column (16×160 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 10±5° C.; the treatment capacity is kept at 4,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 61 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 5 mL sodium hydroxide solution with a mass concentration of 6%, 5 mL sodium hydroxide solution with a mass concentration of 1% and 20 mL tap water through the nano-composite adsorption bed at the flow rate of 5 mL/h at the temperature of 45±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 20
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 6.5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 4% and 20 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.15% into the flocculation mixer consecutively; mix the substances for 6 min with a stirrer at the speed of 200 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 70 rpm for 40 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 10 mL (approximately 7.5 g) nano-composite NDA-HMO into a jacketed glass adsorption column (16×160 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 100 mL/h at the temperature of 25±5° C.; the treatment capacity is kept at 8,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 65 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 10 mL sodium hydroxide solution with a mass concentration of 6%, 10 mL sodium hydroxide solution with a mass concentration of 2% and 40 mL tap water through the nano-composite adsorption bed at the flow rate of 10 mL/h at the temperature of 55±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 21
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 8 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 6% and 12 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.08% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 80 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 60 min of settling.
Fill 50 mL (approximately 37.5 g) nano-composite NDA-HFO into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 400 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 50,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 64 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 50 mL sodium hydroxide solution with a mass concentration of 8%, 50 mL sodium hydroxide solution with a mass concentration of 2% and 200 mL tap water through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 60±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 22
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 6.5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 8% and 8 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.12% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 90 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 100 mL (approximately 75 g) nano-composite NDA-HMO into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 600 mL/h at the temperature of 15±5° C.; the treatment capacity is kept at 80,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 62 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 100 mL sodium hydroxide solution with a mass concentration of 10%, 100 mL sodium hydroxide solution with a mass concentration of 2% and 400 mL tap water through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 70±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 23
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 25 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 2% and 5 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.2% into the flocculation mixer consecutively; mix the substances for 5 min with a stirrer at the speed of 200 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 100 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 60 min of settling.
Fill 200 mL (approximately 150 g) nano-composite NDA-HFO into a jacketed glass adsorption column (64×320 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 1000 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 200,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 66 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 200 mL sodium hydroxide solution with a mass concentration of 8%, 200 mL sodium hydroxide solution with a mass concentration of 3% and 800 mL tap water through the nano-composite adsorption bed at the flow rate of 200 mL/h at the temperature of 75±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 24
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 10% and 20 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.05% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 60 rpm for 50 min of reaction; guide the mixed solution into a settling tank for 40 min of settling.
Fill 500 mL (approximately 375 g) nano-composite NDA-HMO into a jacketed glass adsorption column (100×360 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 2000 mL/h at the temperature of 10±5° C.; the treatment capacity is kept at 400,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 59 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 500 mL sodium hydroxide solution with a mass concentration of 10%, 500 mL sodium hydroxide solution with a mass concentration of 3% and 2000 mL tap water through the nano-composite adsorption bed at the flow rate of 500 mL/h at the temperature of 80±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 25
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 10 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 5% and 10 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.1% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 50 rpm for 60 min of reaction; guide the mixed solution into a settling tank for 30 min of settling.
Fill 200 mL (approximately 150 g) nano-composite NDA-HFO into a jacketed glass adsorption column (64×320 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 1000 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 200,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 66 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 200 mL sodium hydroxide solution with a mass concentration of 8%, 200 mL sodium hydroxide solution with a mass concentration of 3% and 800 mL tap water through the nano-composite adsorption bed at the flow rate of 200 mL/h at the temperature of 75±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 26
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 12 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 4% and 6.5 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.15% into the flocculation mixer consecutively; mix the substances for 6 min with a stirrer at the speed of 200 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 70 rpm for 40 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 5 mL (approximately 3.8 g) nano-composite NDA-HMO into a jacketed glass adsorption column (16×160 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 10±5° C.; the treatment capacity is kept at 4,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 61 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 5 mL sodium hydroxide solution with a mass concentration of 6%, 5 mL sodium hydroxide solution with a mass concentration of 1% and 20 mL tap water through the nano-composite adsorption bed at the flow rate of 5 mL/h at the temperature of 45±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 27
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 8 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 6% and 12 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.08% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 80 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 60 min of settling.
Fill 10 mL (approximately 7.5 g) nano-composite NDA-HFO into a jacketed glass adsorption column (16×160 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 100 mL/h at the temperature of 25±5° C.; the treatment capacity is kept at 8,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 65 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 10 mL sodium hydroxide solution with a mass concentration of 6%, 10 mL sodium hydroxide solution with a mass concentration of 2% and 40 mL tap water through the nano-composite adsorption bed at the flow rate of 10 mL/h at the temperature of 55±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 28
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 6.5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 8% and 8 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.12% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 90 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 50 mL (approximately 37.5 g) nano-composite NDA-HFO into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 400 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 50,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 64 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 50 mL sodium hydroxide solution with a mass concentration of 8%, 50 mL sodium hydroxide solution with a mass concentration of 2% and 200 mL tap water through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 60±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 29
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 25 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 2% and 5 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.2% into the flocculation mixer consecutively; mix the substances for 5 min with a stirrer at the speed of 200 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 100 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 60 min of settling.
Fill 100 mL (approximately 75 g) nano-composite NDA-HFO into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 600 mL/h at the temperature of 15±5° C.; the treatment capacity is kept at 80,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 62 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 100 mL sodium hydroxide solution with a mass concentration of 10%, 100 mL sodium hydroxide solution with a mass concentration of 2% and 400 mL tap water through the nano-composite adsorption bed at the flow rate of 100 mL/h at the temperature of 70±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 30
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 10 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 5% and 10 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.1% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 50 rpm for 60 min of reaction; guide the mixed solution into a settling tank for 30 min of settling.
Fill 500 mL (approximately 375 g) nano-composite NDA-HFO into a jacketed glass adsorption column (100×360 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 2000 mL/h at the temperature of 10±5° C.; the treatment capacity is kept at 400,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 59 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 500 mL sodium hydroxide solution with a mass concentration of 10%, 500 mL sodium hydroxide solution with a mass concentration of 3% and 2000 mL tap water through the nano-composite adsorption bed at the flow rate of 500 mL/h at the temperature of 80±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 31
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 8 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 6% and 12 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.08% into the flocculation mixer consecutively; mix the substances for 2 min with a stirrer at the speed of 300 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 80 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 60 min of settling.
Fill 5 mL (approximately 3.8 g) nano-composite NDA-HFO into a jacketed glass adsorption column (16×160 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 10±5° C.; the treatment capacity is kept at 4,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 61 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 5 mL sodium hydroxide solution with a mass concentration of 6%, 5 mL sodium hydroxide solution with a mass concentration of 1% and 20 mL tap water through the nano-composite adsorption bed at the flow rate of 5 mL/h at the temperature of 45±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 32
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 6.5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 8% and 8 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.12% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 90 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 10 mL (approximately 7.5 g) nano-composite NDA-HMO into a jacketed glass adsorption column (16×160 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 100 mL/h at the temperature of 25±5° C.; the treatment capacity is kept at 8,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 65 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 10 mL sodium hydroxide solution with a mass concentration of 6%, 10 mL sodium hydroxide solution with a mass concentration of 2% and 40 mL tap water through the nano-composite adsorption bed at the flow rate of 10 mL/h at the temperature of 55±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 33
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 25 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 2% and 5 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.2% into the flocculation mixer consecutively; mix the substances for 5 min with a stirrer at the speed of 200 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 100 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 60 min of settling.
Fill 50 mL (approximately 37.5 g) nano-composite NDA-P into a jacketed glass adsorption column (32×260 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 400 mL/h at the temperature of 20±5° C.; the treatment capacity is kept at 50,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 64 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 50 mL sodium hydroxide solution with a mass concentration of 8%, 50 mL sodium hydroxide solution with a mass concentration of 2% and 200 mL tap water through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 60±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 34
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 6.5 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 8% and 8 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.12% into the flocculation mixer consecutively; mix the substances for 4 min with a stirrer at the speed of 250 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 90 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 50 min of settling.
Fill 5 mL (approximately 3.8 g) nano-composite NDA-HFO into a jacketed glass adsorption column (16×160 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 50 mL/h at the temperature of 10±5° C.; the treatment capacity is kept at 4,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 61 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 5 mL sodium hydroxide solution with a mass concentration of 6%, 5 mL sodium hydroxide solution with a mass concentration of 1% and 40 mL tap water through the nano-composite adsorption bed at the flow rate of 5 mL/h at the temperature of 45±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch.
Embodiment 35
Guide the effluent (COD: 160 mg/L; chromaticity: 80 times) from the secondary sedimentation tank of a coking wastewater bio-treatment plant into a flocculation mixer; add 25 L/m 3 polymeric ferric sulfate (PFS) with a mass concentration of 2% and 5 L/m 3 polyacrylamide (PAM) with a mass concentration of 0.2% into the flocculation mixer consecutively; mix the substances for 5 min with a stirrer at the speed of 200 rpm; then guide the mixed solution into a flocculation reactor and stir the solution with a stirrer at the speed of 100 rpm for 30 min of reaction; guide the mixed solution into a settling tank for 60 min of settling.
Fill 10 mL (approximately 7.5 g) nano-composite NDA-HMO into a jacketed glass adsorption column (16×160 mm). Filter the supernatant obtained through the flocculation and settling processes and guide the filtrate through the nano-composite adsorption bed at the flow rate of 100 mL/h at the temperature of 25±5° C.; the treatment capacity is kept at 8,000 mL/batch. After the adsorption process, the COD in the effluent is reduced to 65 mg/L, and the chromaticity is reduced to below 20 times.
Consecutively guide 10 mL sodium hydroxide solution with a mass concentration of 6%, 10 mL sodium hydroxide solution with a mass concentration of 2% and 40 mL tap water through the nano-composite adsorption bed at the flow rate of 10 mL/h at the temperature of 55±5° C. for desorption. The high-concentrated desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated adsorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch. | The present invention discloses a method for advanced treatment of bio-treated coking wastewater. It employs polymeric ferric sulfate (PFS) and polyacrylamide (PAM) as the flocculant for the pre-treatment of bio-treated effluent. After the process of precipitation and filtration, the effluent is guided through an adsorption column filled with environmentally-friendly nano-composites whereby the advanced treatment of the bio-treated coking wastewater is achieved. When the absorption process reaches the breakthrough point, the adsorption operation will be stopped and sodium hydroxide solution is used as the desorption reagent for regenerating the nano-composites. The high-concentrated component of the desorption liquid is sent out for incineration or production of coal water slurry, meanwhile the low-concentrated component of the desorption liquid is used to prepare sodium hydroxide solution for the adsorption process of the next batch. | 2 |
RELATED APPLICATIONS
This application claims benefit to U.S. provisional application Ser. No. 61/619,958, filed Apr. 4, 2012, herein incorporated by reference.
FIELD OF THE INVENTION
The present invention relates to specific tricyclic triazole compounds, which selectively inhibit aldosterone synthetase (CYP11B2) with diminished inhibition or affect on steroid-11-β-hydroxylase (CYP11B1) inhibitors. The inventive compounds potentially have utility in treating cardiovascular diseases such as hypertension or heart failure. The present invention also relates to pharmaceutical compositions comprising the inventive compounds as well as processes for their preparation.
BACKGROUND OF THE INVENTION
Aldosterone is a steroid hormone secreted in the adrenal cortex. In primary cells of the distal tubules and collecting ducts of the kidney, aldosterone binding to the mineralocorticoid receptor (MR) results in the retention of sodium and water and excretion of potassium, which in turn leads to increased blood pressure. Aldosterone also causes inflammation that leads to fibrosis and remodeling in the heart, vasculature and kidney. This inflammation may proceed by MR-dependent as well as MR-independent mechanisms (Gilbert, K. C. et al., Curr. Opin. Endocrinol. Diabetes Obes., vol. 17, 2010, pp. 199-204).
Mineralocorticoid receptor antagonists (MRAs), such as spironolactone and eplerenone, have been used previously to block the effects of aldosterone binding to MR. When given in addition to standard therapies such as angiotensin-converting enzyme (ACE) inhibitors and loop diuretics, the nonselective MRA spironolactone and the selective MRA eplerenone significantly reduced morbidity and mortality in patients with heart failure or myocardial infarction (Pitt, B. et al., New Engl. J. Med., vol. 341, 1999, pp. 709-717; Pitt, B. et al., New Engl. J. Med., vol. 348, 2003, pp. 1382-1390). However, the nonselective MRA spironolactone can also bind to and act at other steroid receptors, and as a consequence its use is associated with sexual side effects such as gynecomastia, dysmenorrhoea and impotence (Pitt, B. et al., New Engl. J. Med., vol. 341, 1999, pp. 709-717; MacFadyen, R. J. et al., Cardiovasc. Res., vol. 35, 1997, pp 30-34; Soberman, J. E. et al., Curr. Hypertens. Rep., vol. 2, 2000, pp 451-456). Additionally, both spironolactone and eplerenone are known to cause elevated plasma postassium levels (hyperkalemia) and elevated aldosterone levels.
An alternative method of blocking the effects of aldosterone is to inhibit its biosynthesis. CYP11B2 is a mitochondrial cytochrome P450 enzyme that catalyzes the final oxidative steps in the conversion of 11-deoxycorticosterone, a steroidal precursor, to aldosterone (Kawamoto, T. et al., Proc. Natl. Acad. Sci. USA, vol. 89, 1992, pp. 1458-1462). Compounds that inhibit CYP11B2 should thus inhibit the formation of aldosterone. Such compounds, particularly those of nonsteroidal structure, should provide the beneficial effects of MRAs, without the adverse effects derived from steroid receptor binding or MR-independent inflammatory pathways.
CYP11B1 is a related enzyme that catalyzes the formation of glucocorticoids, such as cortisol, an important regulator of glucose metabolism. Because human CYP11B2 and CYP11B1 are greater than 93% homologous, it is possible for nonselective compounds to inhibit both enzymes (Kawamoto, T. et al., Proc. Natl. Acad. Sci. USA, vol. 89, 1992, pp 1458-1462; Taymans, S. E. et al., J. Clin. Endocrinol. Metab., vol. 83, 1998, pp 1033-1036). It would be preferable, however, for therapeutic agents to selectively inhibit CYP11B2 and the formation of aldosterone with diminished inhibition of, or affect on, CYP11B1 and the production of cortisol.
WO 2009/135651 to Elexopharm describes 6-pyridin-3yl-3,4,-dihydro-1H-quinolin-2-one derivatives as being CYP11B2 inhibitors. Two compounds described therein are lactam derivatives of the formula:
Structurally similar lactam and thiolactam compounds are disclosed by Lucas et al., J. Med. Chem . 2008, 51, 8077-8087; those compounds are said to be potential inhibitors of CYP11B2. Lucas et al. in J. Med. Chem . 2011, 54, 2307-2309 describes certain pyridine substituted 3,4-dihydro-1H-quinolin-2-ones as being highly potent as selective inhibitors of CYP11B2 and WO 2012/012478 to Merck describes benzimidazole analogues as having the ability to CYP11B2. An abstract of a dissertation reports that a series of novel heterocyclic-substituted 4,5-dihydro-[1,2,4]triazolo[4,3a]quinolones was evaluated for its aldosterone synthase activity; one of the compounds is reported as exhibiting excellent selectivity of CYP11B2 over CYP11B1. WO 2012/148808 to Merck and ElexoPharm also discloses tricyclic triazole compounds that possess aldosterone synthase activity.
WO 1999/40094 to Bayer AG describes oxazolidinone derivatives with azol-containing tricycles as possessing antimicrobial activity. An example of one of the compounds disclosed therein is:
The compounds of the invention provide an alternative to previous treatments for elevated aldosterone levels and inhibit CYP11B2.
SUMMARY OF THE INVENTION
In it many embodiments, the present invention provides for specific tricyclic triazole compounds (“compounds of the invention”) selected from the following group of compounds:
or a pharmaceutically acceptable salt thereof, which are inhibitors of CYP11B2, or metabolites, stereoisomers, salts, solvates or polymorphs thereof, processes of preparing such compounds, pharmaceutical compositions comprising one or more such compounds, processes of preparing pharmaceutical compositions comprising one or more such compounds and potentially to methods of treatment, prevention, inhibition or amelioration of one or more disease states associated with inhibiting CYP11B2 by administering an effective amount at least one of the compounds of the invention to a patient in need thereof.
Another aspect of the present invention is pharmaceutical compositions comprising a therapeutically effective amount of at least one compound of the compounds of the invention or a pharmaceutically acceptable salt thereof and a pharmaceutically acceptable carrier.
Another aspect of the present invention is pharmaceutical compositions comprising a therapeutically effective amount of at least one compound of the compounds of the invention or a pharmaceutically acceptable salt thereof, a therapeutically effective amount of at least one additional therapuetic agent and a pharmaceutically acceptable carrier.
It is further contemplated that the combination of the invention could be provided as a kit comprising in a single package at least one compound of the invention or a pharmaceutically acceptable salt thereof in a pharmaceutical composition, and at least one separate pharmaceutical composition, such as, for example a separate pharmaceutical composition comprising a therapeutic agent.
The compounds of the present invention could be useful in the treatment, amelioration or prevention of one or more conditions associated with inhibiting CYP11B2 by administering a therapeutically effective amount of at least one compound of the invention or a pharmaceutically acceptable salt thereof to a mammal in need of such treatment. Conditions that could be treated or prevented by inhibiting CYP11B2 include hypertension, heart failure, such as congestive heart failure, diastolic dysfunction, left ventricular diastolic dysfunction, diastolic heart failure, systolic dysfunction, hypokalemia, renal failure, in particular chronic renal failure, restenosis, metabolic syndrome, nephropathy, post-myocardial infarction, coronary heart diseases, increased formation of collagen, fibrosis and remodeling following hypertension and endothelial dysfunction, cardiovascular diseases, renal dysfunction, liver diseases, vascular diseases, cerebrovascular diseases, retinopathy, neuropathy, insulinopathy, endothelial dysfunction, ischemia, myocardial and vascular fibrosis, myocardial necrotic lesions, vascular damage, myocardial infarction, left ventricular hypertrophy, cardiac lesions, vascular wall hypertrophy, endothelial thickening or fibrinoid necrosis of coronary arteries.
Another embodiment of the present invention is the use of a compound of the invention or a pharmaceutically acceptable salt thereof for the manufacture of a medicament for the treatment, amelioration or prevention of one or more conditions associated with inhibiting CYP11B2 in a patient.
DETAILED DESCRIPTION
As used above, and throughout this disclosure, the following terms, unless otherwise indicated, shall be understood to have the following meanings:
“Patient” includes both human and animals.
“Mammal” means humans and other mammalian animals.
The present invention encompasses all stereoisomeric forms of the compounds of the invention. Centers of asymmetry that may be present in the compounds of the invention can all independently of one another have (R) configuration or (S) configuration. When bonds to the chiral carbon are depicted as straight lines in the structural Formulas of the invention, it is understood that both the (R) and (S) configurations of the chiral carbon, and hence both enantiomers and mixtures thereof, are embraced within the Formula. Similarly, when a compound name is recited without a chiral designation for a chiral carbon, it is understood that both the (R) and (S) configurations of the chiral carbon, and hence individual enantiomers and mixtures thereof, are embraced by the name. The production of specific stereoisomers or mixtures thereof may be identified in the Examples where such stereoisomers or mixtures were obtained, but this in no way limits the inclusion of all stereoisomers and mixtures thereof from being within the scope of this invention.
The invention includes all possible enantiomers and diastereomers and mixtures of two or more stereoisomers, for example mixtures of enantiomers and/or diastereomers, in all ratios. Thus, enantiomers are a subject of the invention in enantiomerically pure form, both as levorotatory and as dextrorotatory antipodes, in the form of racemates and in the form of mixtures of the two enantiomers in all ratios. In the case of a cis/trans isomerism, the invention includes both the cis form and the trans form as well as mixtures of these forms in all ratios. The preparation of individual stereoisomers can be carried out, if desired, by separation of a mixture by customary methods, for example by chromatography or crystallization, by the use of stereochemically uniform starting materials for the synthesis or by stereoselective synthesis. Optionally a derivatization can be carried out before a separation of stereoisomers. The separation of a mixture of stereoisomers can be carried out at an intermediate step during the synthesis of a compound of the invention or it can be done on a final racemic product. Absolute stereochemistry may be determined by X-ray crystallography of crystalline products or crystalline intermediates which are derivatized, if necessary, with a reagent containing a stereogenic center of known configuration. Where compounds of this invention are capable of tautomerization, all individual tautomers as well as mixtures thereof are included in the scope of this invention. The present invention includes all such isomers, as well as salts, solvates (including hydrates) and solvated salts of such racemates, enantiomers, diastereomers and tautomers and mixtures thereof.
Reference to the compounds of this invention as those of a specific formula specific compound described or claimed herein, is intended to encompass the specific compound or compounds falling within the scope of the formula or embodiment, including salts thereof, particularly pharmaceutically acceptable salts, solvates of such compounds and solvated salt forms thereof, where such forms are possible unless specified otherwise.
In the compounds of the invention, the atoms may exhibit their natural isotopic abundances, or one or more of the atoms may be artificially enriched in a particular isotope having the same atomic number, but an atomic mass or mass number different from the atomic mass or mass number predominantly found in nature. The present invention is meant to include all suitable isotopic variations of the claimed compounds For example, different isotopic forms of hydrogen (H) include protium ( 1 H) and deuterium ( 2 H). Protium is the predominant hydrogen isotope found in nature.
Enriching for deuterium may afford certain therapeutic advantages, such as increasing in vivo half-life or reducing dosage requirements, or may provide a compound useful as a standard for characterization of biological samples. Isotopically-enriched compounds of the present invention can be prepared without undue experimentation by conventional techniques well known to those skilled in the art or by processes analogous to those described in the Examples herein using appropriate isotopically-enriched reagents and/or intermediates.
When the compounds of the invention contain one or more acidic or basic groups the invention also includes the corresponding physiologically or toxicologically acceptable salts, in particular the pharmaceutically utilizable salts. Thus, the compounds of the invention that contain acidic groups can be used according to the invention, for example, as alkali metal salts, alkaline earth metal salts or as ammonium salts. Examples of such salts include but are not limited to sodium salts, potassium salts, calcium salts, magnesium salts or salts with ammonia or organic amines such as, for example, ethylamine, ethanolamine, triethanolamine or amino acids. Compounds of the invention that contain one or more basic groups, i.e. groups which can be protonated, can be used according to the invention in the form of their acid addition salts with inorganic or organic acids as, for example but not limited to, salts with hydrogen chloride, hydrogen bromide, phosphoric acid, sulfuric acid, nitric acid, benzenesulfonic acid, methanesulfonic acid, p-toluenesulfonic acid, naphthalenedisulfonic acids, oxalic acid, acetic acid, trifluoroacetic acid, tartaric acid, lactic acid, salicylic acid, benzoic acid, formic acid, propionic acid, pivalic acid, diethylacetic acid, malonic acid, succinic acid, pimelic acid, fumaric acid, maleic acid, malic acid, sulfaminic acid, phenylpropionic acid, gluconic acid, ascorbic acid, isonicotinic acid, citric acid, adipic acid, etc. I Salts can be obtained from the compounds of the invention by customary methods which are known to the person skilled in the art, for example by combination with an organic or inorganic acid or base in a solvent or dispersant, or by anion exchange or cation exchange from other salts. The present invention also includes all salts of the compounds the invention that, owing to low physiological compatibility, are not directly suitable for use in pharmaceuticals but which can be used, for example, as intermediates for chemical reactions or for the preparation of physiologically (i.e., pharmaceutically) acceptable salts.
Furthermore, compounds of the present invention might exist in amorphous form and/or one or more crystalline forms, and as such all amorphous and crystalline forms and mixtures thereof of the compounds of the invention are intended to be included within the scope of the present invention. In addition, some of the compounds of the instant invention may form solvates with water (i.e., a hydrate) or common organic solvents. Such solvates and hydrates, particularly the pharmaceutically acceptable solvates and hydrates, of the instant compounds are likewise encompassed within the scope of this invention, along with un-solvated and anhydrous forms.
Accordingly, the specific compounds described and claimed herein encompass salts, all possible stereoisomers and tautomers, physical forms (e.g., amorphous and crystalline forms), solvate and hydrate forms thereof and any combination of these forms, as well as the salts thereof, pro-drug forms thereof, and salts of pro-drug forms thereof, where such forms are possible unless specified otherwise.
Compounds of the present invention are effective at inhibiting the synthesis of aldosterone by inhibiting CYP11B2 (aldosterone synthase) and they may be therefore useful agents for the therapy and prophylaxis of disorders that are associated with elevated aldosterone levels. Accordingly, an object of the instant invention is to provide a method for inhibiting aldosterone synthase, and more particularly selectively inhibiting CYP11B2, in a patient in need thereof, comprising administering a compound of Formula I to the patient in an amount effective to inhibit aldosterone synthesis, or more particularly to selectively inhibit CYP11B2, in the patient. A selective inhibitor of CYP11B2 is intended to mean a compound that preferentially inhibits CYP11B2 as compared to CYP11B1. The inhibition of CYP11B2, as well inhibition of CYP11B1, by the compounds of the invention can be examined, for example, in the inhibition assay described below. Another object is to provide selective inhibitors for CYP11B2 that are potent.
In general, compounds that have activity as aldosterone synthase inhibitors can be identified as those compounds which have an IC 50 of less than or equal to about 10 μM; preferably less than or equal to about 250 nM; and most preferably less than or equal to about 100 nM, in the V79-Human-CYP11B2 Assay described below. In general, aldosterone synthase inhibitors that are selective for inhibition of CYP11B2 as compared to CYP11B1 are those that show at least 3-fold greater inhibition for CYP11B2 compared to CYP11B1; preferably at least 20-fold inhibition for CYP11B2 compared to CYP11B1; and more preferably at least 100-fold greater inhibition for CYP11B2 compared to CYP11B1, in the V79-Human-CYP11B2 Assay as compared to the V79-Human-CYP11B1 Assay.
Due to their ability to inhibit CYP11B2, the compounds of the present invention may be useful to treat and/or ameliorate the risk for hypertension, hypokalemia, renal failure (e.g., chronic renal failure), restenosis, Syndrome X, nephropathy, post-myocardial infarction, coronary heart diseases, increased formation of collagen, fibrosis and remodeling following hypertension and endothelial dysfunction, cardiovascular diseases, renal dysfunction, liver diseases, vascular diseases, cerebrovascular diseases, retinopathy, neuropathy, insulinopathy, endothelial dysfunction, heart failure (e.g., congestive heart failure), diastolic heart failure, left ventricle diastolic dysfunction, diastolic heart failure, systolic dysfunction, ischemia, myocardial and vascular fibrosis, myocardial necrotic lesions, vascular damage, myocardial infarction, left ventricular hypertrophy, cardiac lesions, vascular wall hypertrophy, endothelial thickening or necrosis of coronary arteries.
The dosage amount of the compound to be administered depends on the individual case and is, as is customary, to be adapted to the individual circumstances to achieve an optimum effect. Thus, it depends on the nature and the severity of the disorder to be treated, and also on the sex, age, weight and individual responsiveness of the human or animal to be treated, on the efficacy and duration of action of the compounds used, on whether the therapy is acute or chronic or prophylactic, or on whether other active compounds are administered in addition to compounds of the invention. A consideration of these factors is well within the purview of the ordinarily skilled clinician for the purpose of determining the therapeutically effective or prophylactically effective dosage amount needed to prevent, counter, or arrest the progress of the condition. It is expected that the compound will be administered chronically on a daily basis for a length of time appropriate to treat or prevent the medical condition relevant to the patient, including a course of therapy lasting days, months, years or the life of the patient.
In general, a daily dose of approximately 0.001 to 30 mg/kg, preferably 0.001 to 20 mg/kg, in particular 0.01 to 10 mg/kg (in each case mg per kg of bodyweight) is appropriate for administration to an adult weighing approximately 75 kg in order to obtain the desired results. The daily dose is preferably administered in a single dose or, in particular when larger amounts are administered, can be divided into several, for example two, three or four individual doses, and may be, for example but not limited to, 0.1 mg, 0.25 mg, 0.5 mg, 0.75 mg, 1 mg, 1.25 mg, 2.5 mg, 5 mg, 10 mg, 20 mg, 40 mg, 50 mg, 75 mg, 100 mg, etc., on a daily basis. In some cases, depending on the individual response, it may be necessary to deviate upwards or downwards from the given daily dose.
Administering of the drug to the patient includes both self-administration and administration to the patient by another person. The patient may be in need of treatment for an existing disease or medical condition, or may desire prophylactic treatment to prevent or reduce the risk of said disease or medical condition.
The term therapeutically effective amount is intended to mean that amount of a drug or pharmaceutical agent that will elicit the biological or medical response of a tissue, a system, animal or human that is being sought by a researcher, veterinarian, medical doctor or other clinician. A prophylactically effective amount is intended to mean that amount of a pharmaceutical drug that will prevent or reduce the risk of occurrence of the biological or medical event that is sought to be prevented in a tissue, a system, animal or human by a researcher, veterinarian, medical doctor or other clinician. It is understood that a specific daily dosage amount can simultaneously be both a therapeutically effective amount, e.g., for treatment of hypertension, and a prophylactically effective amount, e.g., for prevention of myocardial infarction.
In the methods of treatment of this invention, the compound may be administered via any suitable route of administration such as, for example, orally, parenterally, or rectally in dosage unit formulations containing conventional non-toxic pharmaceutically acceptable carriers, adjuvants and vehicles. The term parenteral as used herein includes subcutaneous injections, intravenous, intramuscular, intrasternal injection or infusion techniques. Oral formulations are preferred, particularly solid oral dosage units such as pills, tablets or capsules.
Accordingly, this invention also provides pharmaceutical compositions comprised of a compound of the invention and a pharmaceutically acceptable carrier. For oral use, the pharmaceutical compositions of this invention containing the active ingredient may be in forms such as pills, tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of sweetening agents, flavoring agents, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets contain the active ingredient in admixture with non-toxic pharmaceutically acceptable excipients, which are suitable for the manufacture of tablets. These excipients may be for example, inert diluents, such as calcium carbonate, sodium carbonate, lactose, mannitol, calcium phosphate or sodium phosphate; granulating and disintegrating agents, for example, corn starch, or alginic acid; binding agents, for example starch, gelatin or acacia, and lubricating agents, for example, magnesium stearate, stearic acid or talc. Pharmaceutical compositions may also contain other customary additives, for example, wetting agents, stabilizers, emulsifiers, dispersants, preservatives, sweeteners, colorants, flavorings, aromatizers, thickeners, diluents, buffer substances, solvents, solubilizers, agents for achieving a depot effect, salts for altering the osmotic pressure, coating agents or antioxidants.
Oral immediate-release and time-controlled release dosage forms may be employed, as well as enterically coated oral dosage forms. Tablets may be uncoated or they may be coated by known techniques for aesthetic purposes, to mask taste or for other reasons. Coatings can also be used to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed.
Formulations for oral use may also be presented as hard gelatin capsules wherein the active ingredient is mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin, or as soft gelatin capsules wherein the active ingredients is mixed with water or miscible solvents such as propylene glycol, PEGs and ethanol, or an oil medium, for example peanut oil, liquid paraffin, or olive oil.
Aqueous suspensions contain the active material in admixture with excipients suitable for the manufacture of aqueous suspensions. Oily suspensions may be formulated by suspending the active ingredient in a vegetable oil, for example arachis oil, olive oil, sesame oil or coconut oil, or in mineral oil such as liquid paraffin. The oily suspensions may contain a thickening agent, for example beeswax, hard paraffin or cetyl alcohol. Sweetening agents and flavoring agents may be added to provide a palatable oral preparation. These compositions may be preserved by the addition of an anti-oxidant such as ascorbic acid. Syrups and elixirs may be formulated with sweetening agents, for example glycerol, propylene glycol, sorbitol or sucrose.
The instant invention also encompasses a process for preparing a pharmaceutical composition comprising combining a compound of the invention with a pharmaceutically acceptable carrier. Also encompassed is the pharmaceutical composition which is made by combining a compound of the invention with a pharmaceutically acceptable carrier. The carrier is comprised of one or more pharmaceutically acceptable excipients. Furthermore, a therapeutically effective amount of a compound of this invention can be used for the preparation of a medicament useful for inhibiting aldosterone synthase, inhibiting CYP11B2, for normalizing a disturbed aldosterone balance, or for treating or preventing any of the medical conditions described herein, in dosage amounts described herein.
The amount of active compound of the invention and its pharmaceutically acceptable salts in the pharmaceutical composition may be, for example but not limited to, from 0.1 to 200 mg, preferably from 0.1 to 50 mg, per dose on a free acid/free base weight basis, but depending on the type of the pharmaceutical composition and potency of the active ingredient it could also be lower or higher. Pharmaceutical compositions usually comprise 0.5 to 90 percent by weight of the active compound on a free acid/free base weight basis.
Since the compounds of the invention inhibit aldosterone synthase, apart from use as pharmaceutically active compounds in human medicine and veterinary medicine, they can also be employed as a scientific tool or as aid for biochemical investigations in which such an effect on aldosterone synthase and aldosterone levels is intended, and also for diagnostic purposes, for example in the in vitro diagnosis of cell samples or tissue samples. The compounds of the invention can also be employed as intermediates for the preparation of other pharmaceutically active compounds.
One or more additional pharmacologically active agents (or therapeutic agents) may be administered in combination with a compound of the invention. An additional active agent (or agents) is intended to mean a pharmaceutically active agent (or agents) different from the compound of the invention. Generally, any suitable additional active agent or agents, including but not limited to anti-hypertensive agents, anti-atherosclerotic agents such as a lipid modifying compound, anti-diabetic agents and/or anti-obesity agents may be used in any combination with the compound of the invention in a single dosage formulation (a fixed dose drug combination), or may be administered to the patient in one or more separate dosage formulations which allows for concurrent or sequential administration of the active agents (co-administration of the separate active agents). Examples of additional active agents which may be employed include but are not limited to angiotensin converting enzyme (ACE) inhibitors (e.g, alacepril, benazepril, captopril, ceronapril, cilazapril, delapril, enalapril, enalaprilat, fosinopril, imidapril, lisinopril, moexepril, moveltipril, perindopril, quinapril, ramipril, spirapril, temocapril, or trandolapril); dual inhibitors of angiotensin converting enzyme (ACE) and neutral endopeptidase (NEP) such as omapatrilat, sampatrilat and fasidotril; angiotensin II receptor antagonists (e.g., eprosartan, irbesartan, losartan, olmesartan, telmisartan, valsartan) neutral endopeptidase inhibitors (e.g., thiorphan and phosphoramidon), aldosterone antagonists, renin inhibitors (e.g. urea derivatives of di- and tri-peptides (See U.S. Pat. No. 5,116,835), amino acids and derivatives (U.S. Pat. Nos. 5,095,119 and 5,104,869), amino acid chains linked by non-peptidic bonds (U.S. Pat. No. 5,114,937), di- and tri-peptide derivatives (U.S. Pat. No. 5,106,835), peptidyl amino diols (U.S. Pat. Nos. 5,063,208 and 4,845,079) and peptidyl beta-aminoacyl aminodiol carbamates (U.S. Pat. No. 5,089,471); also, a variety of other peptide analogs as disclosed in the following U.S. Pat. Nos. 5,071,837; 5,064,965; 5,063,207; 5,036,054; 5,036,053; 5,034,512 and 4,894,437, and small molecule renin inhibitors (including diol sulfonamides and sulfinyls (U.S. Pat. No. 5,098,924), N-morpholino derivatives (U.S. Pat. No. 5,055,466), N-heterocyclic alcohols (U.S. Pat. No. 4,885,292) and pyrolimidazolones (U.S. Pat. No. 5,075,451); also, pepstatin derivatives (U.S. Pat. No. 4,980,283) and fluoro- and chloro-derivatives of statone-containing peptides (U.S. Pat. No. 5,066,643), enalkrein, RO 42-5892, A 65317, CP 80794, ES 1005, ES 8891, SQ 34017, aliskiren (2(S),4(S),5(S),7(S)—N-(2-carbamoyl-2-methylpropyl)-5-amino-4-hydroxy-2,7-diisopropyl-8-[4-methoxy-3-(3-methoxypropoxy)-phenyl]-octanamid hemifumarate) SPP600, SPP630 and SPP635), endothelin receptor antagonists, vasodilators, calcium channel blockers (e.g., amlodipine, bepridil, diltiazem, felodipine, gallopamil, nicardipine, nifedipine, niludipine, nimodipine, nisoldipine veraparmil), potassium channel activators (e.g., nicorandil, pinacidil, cromakalim, minoxidil, aprilkalim, loprazolam), diuretics (e.g., hydrochlorothiazide) including loop diuretics such as ethacrynic acid, furosemide, bumetanide and torsemide, sympatholitics, beta-adrenergic blocking drugs (e.g., acebutolol, atenolol, betaxolol, bisoprolol, carvedilol, metoprolol, metoprolol tartate, nadolol, propranolol, sotalol, timolol); alpha adrenergic blocking drugs (e.g., doxazocin, prazocin or alpha methyldopa) central alpha adrenergic agonists, peripheral vasodilators (e.g. hydralazine), lipid lowering agents (e.g., simvastatin, lovastatin, pravastatin, atorvastatin rosuvastatin, ezetimibe); niacin in immediate-release or controlled release forms, and particularly in niacin in combination with a DP antagonist such as laropiprant (TREDAPTIVE®) and/or with an HMG-CoA reductase inhibitor; niacin receptor agonists such as acipimox and acifran, as well as niacin receptor partial agonists; metabolic altering agents including insulin sensitizing agents and related compounds (e.g., muraglitazar, glipizide, stigliptin, metformin, rosiglitazone); or with other drugs beneficial for the prevention or the treatment of the above-mentioned diseases including nitroprusside and diazoxide.
In general, the compounds in the invention may be produced by a variety of processes know to those skilled in the art and by know processes analogous thereto. The invention disclosed herein is exemplified by the following preparations and examples which should not be construed to limit the scope of the disclosure. Alternative mechanistic pathways and analogous structures will be apparent to those skilled in the art. The practitioner is not limited to these methods and one skilled in the art would have resources such as Chemical Abstracts or Beilstein at his or her disposal to assist in devising an alternative method of preparing a specific compound.
The compounds of the present invention can be prepared according to the procedures of the following Schemes using appropriate materials and are further exemplified by the specific Examples which follow. Moreover, by utilizing the procedures described herein, one of ordinary skill in the art can readily prepare additional compounds of the present invention claimed herein.
Throughout the synthetic schemes, abbreviations are used with the following meanings unless otherwise indicated:
BuLi, n-BuLi=n-butyllithium; Celite®=diatomaceous earth; conc, conc.=concentrated; DME=dimethylether; DMEM=Dulbecco's modified eagle medium; DMF=N,N-dimethylformamide; DMSO=dimethylsulfoxide; eq.=equivalent(s); h, hr=hour; HPLC=high pressure liquid chromatography; Lawesson's Reagent=2,4-bis(4-methoxyphenyl)-1,3,2,4-dithiadiphosphetane 2,4-disulfide; LCMS=liquid chromatography-mass spectroscopy; MS=mass spectroscopy; min, min.=minute; NBS=N-bromosuccinimide; NMR=nuclear magnetic resonance; r.t.=room temperature; sat.=saturated; THF=tetrahydrofuran and V=volume.
As will be known to those skilled in the art, in all schemes, the compounds of the invention and all synthetic intermediates may be purified from unwanted side products, reagents and solvents by recrystallization, trituration, preparative thin layer chomatography, flash chomatography on silica gel as described by W. C. Still et al, J. Org. Chem. 1978, 43, 2923, or reverse-phase HPLC. Compounds purified by HPLC may be isolated as the corresponding salt.
Additionally, in some instances the final compounds of Formula I and synthetic intermediates may be comprised of a mixture of cis and trans isomers, enantiomers or diastereomers. As will be known to those skilled in the art, such cis and trans isomers, enantiomers and diastereomers may be separated by various methods including crystallization, chomatography using a homochiral stationary phase and, in the case of cis/trans isomers and diastereomers, normal-phase and reverse-phase chomatography.
Chemical reactions were monitored by LCMS, and the purity and identity of the reaction products were assayed by LCMS (electrospray ionization) and NMR. Data for 1 H NMR are reported with chemical shift (δ ppm), multiplicity (s=singlet, d=doublet, t=triplet, q=quartet, m=multiplet, br s=broad singlet, br m=broad multiplet), coupling constant (Hz), and integration. Unless otherwise noted, all LCMS ions listed are [M+H]. All temperatures are degrees Celsius unless otherwise noted.
EXAMPLE 1
7-(4-cyclopropyl-5-fluoropyridin-3-yl)-9-fluoro-1-methyl-4,5-dihydro-[1,2,4]triazolo[4,3-a]quinoline
Step A. 3-chloro-N-(2-fluorophenyl)propanamide
A solution of 2-fluoroaniline (20.00 g, 180.0 mmol) in tetrahydrofurane (100 mL) and pyridine (22 mL) was stirred for 15 min and then 3-chloropropionyl chloride (25.14 g, 198 mmol) in tetrahydrofurane (50 ml) was added at 0° C. The mixture was stirred for 18 h at room temperature under inert atmosphere. After the completion of the reaction, the mixture was diluted with water. The aqueous layer was separated and extracted with diethylether. The collected organic parts were washed with water and brine and were then dried over Na 2 SO 4 , filtered and concentrated under vacuum to afford the title compound as a white solid. This intermediate was used directly in the next step without further purification and characterization.
Step B. 8-fluoro-3,4-dihydroquinolin-2(1H)-one
A mixture of 3-chloro-N-(2-fluorophenyl)propanamide (1-1, 17.2 g, 85.30 mmol) and aluminium trichloride (56.9 g, 427.0 mmol) was heated at 140° C. for 4 h under inert atmosphere. After cooling the reaction mixture down to 0° C., ice cold water (350 mL) was added slowly. The resulting precipitate was collected by filtration and washed with water and hexane. The crude compound was purified by flash chromatography on silica gel to obtain the title compound as a white solid. This intermediate was used directly in the next step without characterization.
Step C. 6-bromo-8-fluoro-3,4-dihydroquinolin-2(1H)-one
To a stirred solution of 8-fluoro-3,4-dihydroquinolin-2(1H)-one (1-2; 8.30 g, 50.10 mmol) in N,N-dimethylformamide (250 mL) was added N-bromosuccinimide (9.80 g, 55.10 mmol) in N,N-dimethylformamide (120 mL) at 0° C. The reaction mixture was stirred at room temperature for 18 h, cooled, and diluted with ice cold water (500 mL). The resulting precipitated was filtered and dried to obtain the title compound as a white solid; 1 H NMR (DMSO-D 6 , 500 MHz) δ=10.20 (s, 1H), 7.37 (dd, J=2.0 Hz, J HF =10.0 Hz, 1H), 7.26 (s, 1H), 2.93 (t, J=7.0 Hz, 2H), 2.47 (t, J=7.5 Hz, 2H).
Step D. 6-bromo-8-fluoro-3,4-dihydroquinoline-2(1H)-thione
To a suspension of 6-bromo-8-fluoro-3,4-dihydroquinolin-2(1H)-one (1-3, 2.00 g, 8.19 mmol) in toluene (50 mL) was added Lawesson's reagent (1.66 g, 4.10 mmol). After refluxing the reaction mixture for 2 h, the toluene was distilled off to yield the crude product, which was then purified by flash chromatography on silica gel to obtain the title compound as a yellow solid; 1 H NMR (DMSO-D 6 , 500 MHz) δ=12.14 (s, 1H), 7.46 (dd, J=2.0 Hz, J HF =10.0 Hz, 1H), 7.34 (s, 1H), 2.94 (d, J=8.0 Hz, 2H), 2.84 (d, J=8.0 Hz, 2H).
Step E. 7-Bromo-9-fluoro-4,5-dihydro-1-methyl-[1,2,4]triazolo[4,3-a]quinoline
A suspension of 6-bromo-8-fluoro-3,4-dihydroquinoline-2(1H)-thione (1-4, 1.71 g, 6.57 mmol) and acetohydrazide (0.58 g, 7.89 mmol) in n-butanol (7 mL) was refluxed for 18 h under inert atmosphere. After cooling down to ambient temperature, ethyl acetate (10 mL) and water (10 mL) were added. The organic phase was then separated and the water phase was extracted with ethyl acetate (5×10 mL). The combined organic phases were washed with brine and dried over Na 2 SO 4 ; the combined organic layers were then evaporated under reduced pressure to yield the crude product. The crude compound was purified by flash chromatography on silica gel to obtain the title compound as a white solid; 1 H NMR (DMSO-D 6 , 500 MHz) δ=7.79 (dd, J=2.0 Hz, J HF =11.0 Hz, 1H), 7.63 (s, 1H), 2.95 (br s, 4H), 2.46 (d, J HF =8.5 Hz, 3H).
Step F. (9-Fluoro-1-methyl-4,5-dihydro-[1,2,4]triazolo[4,3-a]quinolin-7-yl)boronic acid
7-Bromo-9-fluoro-4,5-dihydro-1-methyl[1,2,4]triazolo[4,3-a]quinoline (1-5, 3.90 g, 13.8 mmol) was dissolved under nitrogen atmosphere in dry THF and cooled to −78° C. A 2.5 M n-BuLi solution in hexane (V=6.60 ml, 16.6 mmol) was added dropwise and stirred at −78° C. for 30 min. Triisopropyl borate (V=4.5 ml, 19.3 mmol) was added in one portion and the temperature raised to −50° C. for additional 30 min. The mixture was allowed to warm up to 0° C. and quenched with a 1M KHSO 4 solution in order to reach pH 3. The solution was basified with a 2M NaOH solution and washed twice with ethyl acetate. The water layer was neutralized with conc. HCl and the precipitate was successively washed with water and ether and dried under reduced pressure to obtain the title compound as a white solid; MS (ESI): m/z=248.04 [M+H] + .
Step G. 7-(4-Cyclopropyl-5-fluoropyridin-3-yl)-9-fluoro-1-methyl-4,5-dihydro-[1,2,4]triazolo[4,3-a]quinoline
3-Bromo-4-cyclopropyl-5-fluoropyridine (462 mg, 2.14 mmol) was dissolved in a mixture of DME (3.55 mL) and water (3.55 mL). Sodium carbonate (226 mg, 2.14 mmol), (9-fluoro-1-methyl-4,5-dihydro-[1,2,4]triazolo[4,3-a]quinolin-7-yl)boronic acid (1-6, 176 mg, 0.71 mmol) and tetrakis triphenylphosphine palladium catalyst (4.11 mg, 3.6 mop were added. The mixture was deoxygenated under reduced pressure, flushed with nitrogen and heated under reflux for 18 h. After cooling to room temperature, ethyl acetate (10 mL) and water (10 mL) were added and the organic layer was separated. The water phase was extracted with ethyl acetate (2×10 mL). The combined organic phases were washed with brine, dried over Na 2 SO 4 , filtered over a short plug of Celite® and evaporated under reduced pressure. The crude compound was purified using preparative thin layer chromatography (ethyl acetate/ethanol 6:4) in order to yield the title compound as a white solid; 1 H NMR (CD 3 SOCD 3 , 500 MHz) δ 8.49 (d, J=2.5 Hz, 1H), 8.35 (s, 1H), 7.60 (dd, J=1.8, 12.0 Hz, 1H), 7.52 (d, J=1.8 Hz, 1H), 3.80 (br. s, 4H), 2.54-2.52 (m, 3H), 1.96-1.95 (m, 1H), 0.89-0.87 (m, 2H), 0.68-0.67 (m, 2H); MS (ESI): m/z=338.97 [M+H] + .
The compounds in Table 1 were prepared using chemistry described in Example 1.
TABLE 1
Example
Structure
IUPAC Name
LCMS
2
9-fluoro-7-(5-fluoro-4- methylpyridin-3-yl)-1-methyl- 4,5-dihydro-[1,2,4]triazolo[4,3- a]quinoline
313.04
3
9-fluoro-7-(5-fluoro-4- isopropylpyridin-3-yl)-1- methyl-4,5-dihydro- [1,2,4]triazolo[4,3-a]quinoline
341.02
4
7-(4-chloro-5-fluoropyridin-3- yl)-9-fluoro-1-methyl-4,5- dihydro-[1,2,4]triazolo[4,3- a]quinoline
332.93
The compounds in Table 2 are prepared using chemistry described in Example 1.
TABLE 2 Example Structure IUPAC Name 5 9-fluoro-7-(5-fluoro-4- (trifluoromethyl)pyridin-3-yl)-1- methyl-4,5-dihydro- [1,2,4]triazolo[4,3-a]quinoline 6 9-fluoro-7-(5-fluoro-4-(2,2,2- trifluoroethyl)pyridin-3-yl)-1- methyl-4,5-dihydro- [1,2,4]triazolo[4,3-a]quinolin 7 1-(3-fluoro-5-(9-fluoro-1-methyl- 4,5-dihydro-[1,2,4]triazolo[4,3- a]quinolin-7-yl)pyridin-4- yl)ethanethione 8 7-(4-(1,1-difluoroethyl)-5- fluoropyridin-3-yl)-9-fluoro-1- methyl-4,5-dihydro- [1,2,4]triazolo[4,3-a]quinoline 9 3-fluoro-5-(9-fluoro-1-methyl- 4,5-dihydro-[1,2,4]triazolo[4,3- a]quinolin-7-yl)-N- methylpyridin-4-amine 10 3-fluoro-5-(9-fluoro-1-methyl- 4,5-dihydro-[1,2,4]triazolo[4,3- a]quinolin-7-yl)-N,N- dimethylpyridin-4-amine 11 9-fluoro-7-(5-fluoro-4- (pyrrolidin-1-yl)pyridin-3-yl)-1- methyl-4,5-dihydro- [1,2,4]triazolo[4,3-a]quinoline
Assay Description:
Compounds of the Examples 1 to 3 were assayed for V79-Human-CYP11B2 and V79-Human-CYP11B1 by modifying the protocol described in J. Steroid Biochem. Mol. Biol . 81; 173-179 (2002). V79MZh11B1 and V79MZh11B2 cells (8×10 5 cells/well) were grown on 24-well culture plates until confluence. Before testing, the DMEM culture medium was removed and 450 μl of fresh DMEM containing the inhibitor was added to each well. After a preincubation step of 60 min at 37° C., the reaction was started by the addition of 50 μl of DMEM in which the substrate deoxycorticosterone (containing 0.15 μCi of [1,2-3H]-deoxycorticosterone in ethanol, final test concentration 100 nM) was dissolved. Incubation times were 25 min for V79MZh11B1 and 50 min for V79MZh11B2 cells at 37° C., respectively. The enzyme reactions were stopped by extracting the supernatant with ethyl acetate. Samples were centrifuged (10.000 g, 5 min) and the solvent was pipetted into fresh cups. After evaporation of the solvent, the steroids were redissolved in 40 μl of methanol (50:50, v/v) and analyzed by HPLC. Detection and quantification of the steroids were performed using a radioflow detector. To first estimate the different IC 50 values, five different concentrations ranging from 1 to 10.000 nM were measured. For the following IC 50 determination, three different concentrations (repeat-determinations) were measured for each 10 50 value of each inhibitor in which the second concentration led to an inhibition of approximately 40 to 60%. The inhibitor concentrations were all in the linear range of the dose-response-curves, so that the coefficients of correlation were at least 0.95 for each determination. The final IC 50 value was estimated as the average of three or four independent IC 50 values and a selectivity factor corresponding to the ratio between the 10 50 values of CYP11B1 and CYP11B2 was calculated for each substance.
TABLE 3
V79 human
V79 human
CYP11B2
CYP11B1
Example
Structure
IUPAC Name
IC 50 nM
IC 50 nM
1
7-(4-cyclopropyl-5- fluoropyridin-3-yl)-9- fluoro-1-methyl-4,5- dihydro- [1,2,4]triazolo[4,3- a]quinoline.
7.3
2293
2
9-fluoro-7-(5-fluoro- 4-methylpyridin-3- yl)-1-methyl-4,5- dihydro- [1,2,4]triazolo[4,3-a] quinoline
6.0
1424
3
9-fluoro-7-(5-fluoro- 4-isopropylpyridin-3- yl)-1-methyl-4,5- dihydro- [1,2,4]triazolo[4,3-a] quinoline
9.5
3971
4
7-(4-chloro-5- fluoropyridin-3-yl)-9- fluoro-1-methyl-4,5- dihydro- [1,2,4]triazolo[4,3- a]quinoline
21.6
9802
While the invention has been described with reference to certain particular embodiment thereof, numerous alternative embodiments will be apparent to those skilled in the art from the teachings described herein. Recitation or depiction of a specific compound in the claims (i.e., a species) without a specific stereoconfiguration designation, or with such a designation for less than all chiral centers, is intended to encompass the racemate, racemic mixtures, each individual enantiomer, a diastereoisomeric mixture and each individual diastereomer of the compound where such forms are possible due to the presence of one or more asymmetric centers. All patents, patent applications and publications cited herein are incorporated by reference in their entirety. | This invention relates to tricyclic triazole compounds or their pharmaceutically acceptable salts. The inventive compounds selectively inhibit aldosterone synthetase. This invention also provides for pharmaceutical compositions comprising the above-cited compounds or their salts as well as potentially to methods for the treatment, amelioration or prevention of conditions that could be treated by inhibiting aldosterone synthetase. | 2 |
FIELD OF THE INVENTION
[0001] The present invention is directed to an automatic container latch and method of operating same, and more specifically, toward a gravity-operated container latch that shifts from a latched to an unlatched position when a container is pivoted from a rest orientation to a dumping orientation.
BACKGROUND OF THE INVENTION
[0002] Facilities that produce substantial amounts of waste often dispose it in large trash receptacles that are emptied periodically by a trash truck. Generally, the receptacles are formed from steel or a similar material and are too heavy to lift manually, especially when full. A trash truck having a special lift is thus normally used to raise and empty these containers. To lift a container, the truck parks so that fingers on a lift arm on the truck can be inserted into special openings on the trash receptacle. The lift arm is then raised in an arc toward an opening in the top or side of the truck and tipped toward the opening until all trash in the receptacle falls out. Such trash receptacles often have lids hingedly connected to the their main bodies, and the lids pivot open as the receptacle is tipped. After the receptacle has been emptied, the lift arm returns it to an upright position and lowers it to the ground.
[0003] Certain trash receptacles are used with trash compactors that have a ram for forcing trash into the receptacle to reduce its volume and increase its density. These rams often push trash into a receptacle from one side, and it is thus necessary to hold the receptacle lid securely in place or the compacted trash will be forced upward by the ram and rise up and out of the receptacle. Even small gaps between the receptacle and its lid may allow unacceptable amounts of trash to escape, especially when the trash has a significant liquid component. These receptacles therefore generally include a latching mechanism that holds the receptacle lid securely closed and allows little or no gap between the container body and the lid even when trash therein is being compressed.
[0004] When such containers are to be emptied by a trash truck, a truck driver or another person must approach the trash container, release the latch, dump the receptacle into the truck and then return to re-latch the container. This latching and unlatching significantly reduces the advantages of using an automatic trash collection truck.
[0005] Automatic latch releases are known from the prior art which may be opened and closed by a radio transmitter, for example. However, such electronic solutions can be expensive to implement and require that the operator of a trash truck carry one or more transmitters for opening any container on his route. Also know from the prior art are containers with latches that are actuated by gravity when the container tips from an upright to a dumping position. Most of these latches, however, are designed either to keep a container lid closed under high wind conditions or to prevent unauthorized persons from gaining access to the trash container and are not suited for use with a compactor receptacle that is subjected to significant internal pressures during use. For example, U.S. Pat. No. 5,094,487 shows a trash receptacle comprising a body and a lid that has a housing mounted on one of the body sidewalls. A hook depends from the lid and extends into the housing when the lid is closed and the container is resting on its bottom. A freely pivotable rod inside the housing includes a projection that engages the hook when the container is horizontal and that pivots away from the hook to release it when the container is tipped. However, the clearances required by this arrangement do not allow the lid to be held completely shut, and thus the lid would open under the application of pressure from within and force trash out of the top thereof. U.S. Pat. No. 4,155,584 shows an automatic lock for a container that includes a pivotable weight which swings though an arc and impacts against a latch to release the latch when the container is inverted. This complex arrangement requires that the weight impact against a release with sufficient force to unhook the latch. If the lid of a receptacle is forced upwardly by pressure from compacted trash inside the container, the unlatching device might not function properly. Furthermore, the swinging arm impacting against a release is likely to lead to wear and may require the device to be replaced or repaired with some frequency.
[0006] There is thus a need for a container latch that automatically unlatches when the container is pivoted from a resting orientation to a dumping orientation and which re-latches when the container is returned to its resting orientation, which latch functions even when the contents of the container are under pressure and which holds the lid of the container securely closed with little or no gap between the lid and the container.
SUMMARY OF THE INVENTION
[0007] These problems are overcome by the subject invention which comprises an automatic latching device for a container such as a trash receptacle. The subject invention is particularly useful for securing the lids of trash receptacles, especially trash receptacles that are used in conjunction with a trash compactor that forces trash into the container under pressure; however the invention could be practiced with other types of dumpable receptacles without departing from the scope of this invention. Thus, while the container described herein is generally referred to a trash receptacle, the use of invention is in no way limited to such containers.
[0008] In the preferred embodiment, the invention is a container having a pivotable lid with a projection near its free end. This projection is engaged by a hook pivotally mounted on the sidewall of the container body. When the hook engages the projection, the lid is held firmly against the top of the container body. Furthermore, because the hook is pivotally mounted, it can resist upward pressure on the lid such as may be exerted when the container receives trash under pressure from a compactor. Also attached to the container sidewall is a weight mounted for pivotal movement about an axis located near the edge of the weight which weight assumes a first position when the container is in an upright position and a second position when the container tips toward a dumping position. The weight is connected to the hook by a rigid rod, and when the weight pivots, it moves the rod and the hook to release the hook or reengage it with the projection. As described more fully hereinafter, the arrangement of the rod and the weight increases the effective force applied against the hook to provide for secure, positive latching.
[0009] Also according to the preferred embodiment, the weight is mounted in a bi-stable manner so that once it becomes unbalanced it shifts from the first position to the second position and does not remain in an intermediate position for a significant amount of time. This helps ensure that the latch is positively engaged or disengaged and not left in some intermediate position. In addition, two stops are provided to limit the pivotal movement of the weight. The relationship between the center of gravity of the weight and the weight's axis of rotation is selected so that once the center of gravity passes over the pivot axis, the weight falls a further distance and impacts against a stop. Thus when the container moves from a rest orientation to a dumping orientation, the weight shifts when the container is tipped at a first angle, and when the container is moved from a dumping orientation to a rest orientation, the weight shifts back when the container is tipped at a second angle. This allows the latch to be latched and unlatched at different points in the travel of the container from a rest orientation to a dumping orientation, depending on the direction that the container is being tipped. Preferably, the lid is kept latched until the container opening is nearly vertical or until the container is inverted to ensure no trash falls from the container before it is properly positioned. However, the lid cannot be re-latched until the lid falls back onto the container body under the force of gravity when the container is relatively horizontal.
[0010] It is therefore a principal object of the present invention to provide a dumpable container having an automatic latch release.
[0011] It is another object of the present invention to provide a gravity-operated latch for a lidded container.
[0012] It is a further object of the present invention to provide a gravity-operated latch for a dumpable container that includes a bi-stably mounted actuating weight.
[0013] It is still another object of the present invention to provide a gravity-operated latch for a dumpable container that includes a weight positively coupled to a fastener to positively shift the fastener between first and second positions as the weight moves.
[0014] It is still a further object of the present invention to provide a method of positively latching and unlatching a container using a gravity-operated actuator.
[0015] It is yet another object of the present invention to provide a method of latching a lid to a container body in a manner that holds the lid securely against the container body using a gravity-operated actuator.
[0016] In furtherance of these objects, a container is provided that comprises a body having an interior, an exterior, a sidewall and a top opening, and a lid having a first end hingedly connected to the body and a second end, the lid being shiftable between a closed position covering the top opening and an open position allowing access to the interior. The lid is secured by a fastener and the fastener is positively shifted between a securing and a releasing position by a gravity-operated actuator that includes a weight mounted on the body exterior for bi-stable movement between a first position and a second position with respect to the sidewall, and a rigid link connecting the weight to the fastener so that the fastener is shifted from the securing position to the releasing position when the weight shifts from the first position to the second position.
[0017] The invention further comprises a container adapted to be moved from a rest orientation to a dump orientation during a dumping operation including a body having an interior and a top opening into the interior and a lid having a first end hingedly connected to the body and shiftable between a closed position covering the top opening and an open position allowing access to the interior. The container assumes a first angular orientation with respect to the ground when it is in a rest orientation and a second angular orientation with, respect to the ground when it is in the dump orientation. The container also includes a fastener for holding the lid in the closed position and substantially preventing movement of the lid when pressure is applied against the lid from the interior and an actuator for positively shifting the fastener between a securing and a releasing position. The actuator includes a weight pivotably mounted on the body for movement to a first position with respect to the sidewall when the container has a first angular orientation with respect to the ground and to a second position with respect to the sidewall when the container has a second angular orientation with respect to the ground and a link rigidly connected between the weight and the fastener for transferring substantially all motion of the weight to the fastener.
[0018] The invention further comprises a method of latching and unlatching a container by changing the orientation of the container with respect to the ground including the steps of providing a container having a lid, providing a fastener shiftable between a first position for securing the lid to the container and a second position for releasing the lid, mounting a weight on the container to pivot bi-stably between first and second positions in response to changes in the orientation of the container, positively coupling the weight to the fastener, pivoting the container in a first direction until the weight shifts to the second position, dumping the contents of the container and pivoting the container from the second position to the first position until the weight shifts to the first position.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] These and other objects and advantages of the invention will be better understood from a reading and understanding of the following detailed description of the invention together with the following drawings.
[0020] [0020]FIG. 1 is a side elevational view of a container with a gravity-operated latch in accordance with the present invention oriented in an upright, resting position.
[0021] [0021]FIG. 2 is a top plan view of the container of FIG. 1 with the container lid in an open position.
[0022] [0022]FIG. 3 is a side elevational view of the container of FIG. 1 showing the container tilted at about an 85 degree angle from the resting position.
[0023] [0023]FIG. 4 is a side elevational view of the container of FIG. 1 showing the container tilted at about a 90 degree angle from the resting position.
[0024] [0024]FIG. 5 is a side elevational view of the container of FIG. 1 showing the container tilted at about a 105 degree angle from the resting position.
[0025] [0025]FIG. 6 is a side elevational view of the container of FIG. 1 showing the container tilted at about a 150 degree angle from the resting position.
[0026] [0026]FIG. 7 is a side elevational view of the container of FIG. 1 showing the container tilted back to about a 60 degree angle after reaching the orientation shown in FIG. 6.
[0027] [0027]FIG. 8 is a side elevational view of a trash truck with a lift arm engaging the container of FIG. 1.
[0028] [0028]FIG. 9 is a side elevational view of the trash truck of FIG. 8 with the lift arm holding the subject container at a 90 degree angle.
[0029] [0029]FIG. 10 is a side elevational view of the trash truck of FIG. 8 with the lift arm holding the container in a dumping position over an opening in the trash truck.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0030] Referring now to the drawings, wherein the showings are for the purpose of illustrating a preferred embodiment of the invention only, and not for the purpose of limiting same, FIGS. 1 and 2 show a container 10 according to the present invention which includes a body portion 12 and a lid 14 connected to the body by a hinge 16 . Lid 14 includes a rear section 18 connected to body 12 by the hinge, a front section 20 , a top wall 22 , preferably outwardly curved to keep water from pooling thereon, a sidewall 24 depending from the top and a bottom wall 26 . Bottom wall 26 includes a rear portion 28 adjacent hinge 16 , first and second side portions 30 extending away from rear portion 28 and a front portion 32 connecting the side portions. Side portions 30 each include an opening 34 near front portion 32 having an interior wall 36 on which a pin 38 is mounted, which pins are engaged by fasteners to be described hereinafter for holding lid 14 securely against body portion 12 .
[0031] Container body portion 12 includes a bottom 44 , a sidewall 46 extending upwardly from the bottom, a top wall 48 extending outwardly from the top edge of sidewall 46 to define a top container opening 50 , and a flange 52 depending from the outer edge of top wall 48 . Top wall 48 includes first and second openings 54 near the front section 20 of the container which are aligned with openings 34 in lid 14 when the lid is closed and lid bottom wall 26 rests on body top wall 48 . First and second sleeves 56 are attached at opposite portions of sidewall 24 for receiving the fingers of a trash truck lift arm and allowing the container to be lifted. The sleeves are parallel to one another, generally normal to the axis of hinge 16 and include open front portions which face the front of the container and top walls 58 that are generally horizontal when the container is in its normal rest orientation with bottom wall 44 facing the ground or other support surface and top opening 50 facing generally upwardly.
[0032] The container includes first and second latching mechanisms, one on each side of the container body. Only one latching mechanism is described and shown herein in detail, it being understood that the latching mechanism on the opposite side of the container is substantially identical to and functions in the same manner as the first mechanism.
[0033] A mounting plate 60 is attached to top wall 58 and a bottom stop 62 is mounted thereon. A top stop 64 is mounted between flange 52 and sidewall 24 directly above bottom stop 62 . A triangular bracket 66 is mounted on mounting plate 60 forwardly of bottom stop 62 , and includes a pair of spaced openings 67 that align with opening 68 in a weight 70 which openings receive a pin 72 to secure the weight to the bracket. Weight 70 comprises a triangular body portion 74 and a polygonal head portion 76 attached thereto or that alternately may be formed integrally therewith. Body portion 74 includes a first side wall 78 connected to the head portion of the weight, a second sidewall 80 , a third side wall 82 and front and rear walls 84 . Spaced openings 67 overlie front and rear walls 84 near the meeting point of second sidewall 80 and third sidewall 82 opposite first sidewall 78 , and second sidewall 80 includes a slot 86 having opposed sidewalls 88 each having a journal opening 90 for supporting the opposite ends of a pin described hereafter. Head portion 76 includes a first wall 92 joined to first sidewall 78 of the body portion, a second wall 94 longer than and parallel to first wall 92 , a third wall 96 extending from second wall 94 and a fourth wall 98 extending from first wall 92 and meeting third wall 96 at a 90 degree angle, a fifth wall 100 parallel to third wall 96 and coplanar with body portion third sidewall 82 and a sixth wall 102 connecting second wall 94 to fifth wall 100 . As will be appreciated from the description of the operation of the subject invention, the shape of weight 70 and the location of its center of gravity 101 with respect to the pivot point formed at pin 72 helps control the movement of the weight and also provides for the multiplication of forces exerted on a container latching mechanism.
[0034] A pin 106 projects from sidewall 24 under top wall 48 and beneath lid pin 38 . A latch 108 having a central opening 110 is mounted on pin 106 with pin 106 pivotally supporting the latch and extending though the latch central opening. The latch includes an attachment portion 112 on one side of central opening 110 and a hook portion 114 on the opposite side of the central opening. A connecting rod 116 includes a first end plate 118 having an opening 120 and a second end plate 122 having an opening 124 connects weight 70 to attachment portion 112 of latch 108 . First end plate 118 of rod 116 extends into slot 86 in weight 70 and is attached thereto by a pin 126 having ends supported in journal openings 90 and passing through opening 120 in plate 118 . Second end plate 122 is pivotally attached to an opening 128 in attachment portion 112 of latch 108 by a pin 130 . Preferably the connecting rod is adjustable in length to that it can be adapted to containers of various sizes.
[0035] Hook portion 114 is dimensioned to engage pin 38 on lid 14 when the lid is closed. As will be appreciated from the foregoing description, when fifth wall 100 of weight 70 rests on bottom stop 62 , hook portion 114 of latch 108 is held in engagement with pin 38 . Weight 70 must be moved so that second wall 94 approaches top stop 64 in order to disengage hook 114 from pin 38 and allow the lid to open. Thus forces from inside the body (caused by compacted trash in the container, for example) pressing up against the lid do not move the latch, and the latch holds the lid securely closed even under significant internal pressures. Furthermore, when latch 108 is engaged with pin 38 , the inner edge 132 of hook portion 114 is angled with respect to top wall 48 of the container, and thus as hook 114 passes over pin 38 into the latching position, the rotation of the latch exerts a downward force on pin 38 tending to hold lid 14 very securely shut.
[0036] In operation, trash is loaded into container 10 through a side opening (not shown) by a compactor (not shown). When the container is ready to be emptied, it is disconnected from the compactor. A trash truck 140 having a lift arm 142 with fingers 144 approaches the container and inserts fingers 144 into sleeves 56 on either side of the container body, and the container is lifted through an upward arc toward an opening 146 in truck 140 into which trash will be discharged. FIGS. 8 - 10 show the movement of the container from a resting orientation on the ground to a dumping orientation over opening 146 .
[0037] The orientation of the container will be described in terms of the angle between a container reference line extending normal to the plane of top opening 54 and a line normal to the ground. When the container is in a resting orientation with the sidewalls generally vertical and the top opening facing generally in an upward direction, the container is positioned at a 0 degree angle and weight 70 is supported by bottom stop 62 and holds latch 114 in engagement with pin 38 on lid 14 .
[0038] [0038]FIG. 3 shows the container positioned at about an 85 degree angle. As can be seen from this figure, the center of gravity 101 of weight 70 still lies between a pivot point at pin 72 and bottom stop 62 and thus weight 70 continues to lie against the bottom stop. However, as shown in FIG. 4, when the container reaches the 90 degree position, the center of gravity of weight 70 moves to the other side of its pivot point, and weight 70 falls against top stop 64 moving rod 116 toward container top wall 48 and pivoting latch 114 to disengage hook 116 from pin 38 .
[0039] [0039]FIG. 5 shows container 10 angled at 105 degrees with respect to the vertical, and in this position, lid 14 swings open under the force of gravity and under the weight of the trash inside the container as it falls toward the opening. Substantially all trash should fall out of container when it is tipped to a 150 degree angle shown in FIG. 6.
[0040] After reaching the dumping orientation shown in FIG. 6, the container is pivoted back toward the 0 degree resting orientation. When the container passes the 90 degree orientation, lid 14 comes into contact with top wall 48 of the container. However, as shown in FIG. 6, even when the container is at a 60 degree orientation shown in FIG. 7 and lid 14 rests on the top wall of the container, weight 70 remains resting on top stop 64 because center of gravity 101 remains on the top stop side of pivot point 72 . Not until the container pivots past about a 45 degree orientation does weight 70 tip back against bottom stop 62 and pull hook 114 back into engagement with pin 38 .
[0041] Advantageously, the shape and mounting of weight 70 described above causes it to shift from the bottom stop to the top stop at a first angular orientation and return from the top stop to the bottom stop at a second orientation. Thus, when dumping a full container, the lid can be held in a closed position until at least a 90 degree orientation to keep trash from prematurely spilling from the container. However, the latch does not reengage pin 38 until the container is more upright and lid 14 is resting solidly on top wall 48 of the container body under the force of gravity. This bi-stable mounting of weight 70 ensures that the latch is either completely engaged or disengaged, and the positive coupling between the weight and the latch, as well as the distance between the center of gravity of weight 70 and the pivot point 72 helps maximize the force applied to rod 116 when the weight begins to move.
[0042] The subject invention has been described in terms of a preferred embodiment, it being understood that obvious modifications and additions to the invention will become apparent to those skilled in the relevant arts upon a reading an understanding of this disclosure. It is intended that all such obvious modifications and additions be included in the subject invention to the extent that they are covered by the several claims appended hereto. | An apparatus for automatically latching and unlatching the lid of a container is disclosed which includes a weight pivotally mounted on the side of the container for movement between first and second positions. The weight is positively connected to a latch by a connecting rod, and as the weight pivots between first and second positions, it move the latch between latching and unlatching positions. Tipping the container causes the weight to shift thus the container is unlatched only when it is being dumped. A method for operating the latch is also disclosed. | 8 |
CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is a non-provisional of U.S. Provisional Patent Application No. 61/900,397, filed Nov. 5, 2013, the entirety of which is expressly incorporated herein by reference it its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to user inputs for the field of wearable virtual projection display devices.
BACKGROUND OF THE INVENTION
[0003] Human computer interaction (HCI) has gained widespread attention because it creates the possibility of users' interacting with computers and environments. Among all input pathways, electrooculography (EOG)-based systems [1-7] show great potential for controlling computers and devices by recognizing the user's eye movements, which is of particular significance to people with disabilities requiring hands-free alternatives (e.g., paralyzed or “locked-in” patients).
[0004] Electrooculography (EOG/E.O.G.) is a technique for estimating eye lateral based on changes in the inferred axis of the corneo-retinal dipole, with the retina having a negative potential. To measure eye movement, pairs of electrodes may be placed above and below or to the eye or to the left and right of the eye. The resting potential may vary based on illumination. Drift of the measured DC baseline potential and inferred axis of the eye. This can be compensated by periodic calibration, or analysis of the EOG signal for movements rather than position. Calibration can be achieved by simply having the user look forward, left and right, up and down, to set the center and range of the signal.
[0005] Some literature applies this label to analysis of electromyographic signals emitted by eye muscles. Note that the EMG signals reveal the activation of the muscle fiber action potentials, and are present as an alternating current signal whose amplitude and frequency spectrum characteristics may vary depending on eye movement, while the dipole measurement of the corneo-retinal dipole is a direct current measurement related to eye position.
[0006] Various efforts have been applied for implementing an EOG controlled human computer interface.
[0007] See (each of which is expressly incorporated herein by reference in their entirety):
[1] S. H. Kwon and H. C. Kim, “EOG-based glasses-type wireless mouse for the disabled,” in Proceedings of the 21st Annual Int'l Conf. of the IEEE Engineering in Medicine and Biology Society (EMBC), pp. 592, 1999. [2] A. Bulling, D. Roggen, and G. Troster, “It's in your eyes: towards context-awareness and mobile HCI using wearable EOG goggles,” in Proceedings of 10th Int'l Conf. Ubiquitous Computing (UbiComp), pp. 84-93, 2008. [3] A. Bulling, D. Roggen, and G. Troster, “Wearable EOG goggles: eye-based interaction in everyday environments,” in Proceedings of CHI Extended Abstracts on Human Factors in Computing Systems (CHI EA), pp. 3259-3264, 2009. [4] X. Zheng, X. Li, J. Liu, W. Chen, and Y. Hao, “A portable wireless eye movement controlled human-computer interface for the disabled,” in Proceedings of Int'l Conf. on Complex Medical Engineering (ICME), pp. 1-5, 2009. [5] X. Yong, M. Fatourechi, R. K. Ward, and G. E. Birch, “The design of a point-and-click system by integrating a self-paced brain-computer interface with an eye-tracker,” IEEE Journal of Emerging and Selected Topics in Circuits and Systems, vol. 1, no. 4, pp. 590-602, 2011. [6] A. Bulling, J. A. Ward, H. Gellersen, and G. Troster, “Eye movement analysis for activity recognition using electrooculography,” IEEE Transactions on Pattern Analysis and Machine Intelligence, vol. 33, no. 4, pp. 741-753, 2011. [7] Y. Hao, M. Controzzi, C. Cipriani, D. B. Popović, X. Yang, W. Chen, X. Zheng, and M. C. Carrozza, “Controlling hand-assistive devices: utilizing electrooculography as a substitute for vision,” IEEE Robotics & Automation Magazine, vol. 20, no. 1, pp. 40-52, 2013. [8] A. B. Usakli and S. Gurkan, “Design of a novel efficient human-computer interface: an electrooculagram based virtual keyboard,” IEEE Trans. on Instrumentation and Measurement, vol. 59, no. 8, pp. 2099-2108, 2010. [9] S. Wu, L. Liao, S. Lu, W. Jiang, S. Chen, and C. Lin, “Controlling a human-computer interface system with a novel classification method that uses electrooculography signals,” IEEE Trans. on Biomedical Engineering, vol. 99, 2013. [10] E. English, A. Hung E. Kesten, D. Latulipe, and Z. Jin, “EyePhone: A mobile EOG-based human-computer interface for assistive healthcare,” in Proceedings of Int'l IEEE EMBS Conf. on Neural Engineering (NER), 2013. Al-Haddad, A. A., R. Sudirman, and C. Omar. “Guiding Wheelchair Motion based on EOG Signals using Tangent Bug Algorithm.” Computational Intelligence, Modelling and Simulation (CIMSiM), 2011 Third International Conference on. IEEE, 2011. Barea, R., L. Boquete, M. Mazo, and E. Lopez. System for assisted mobility using eye movements based on EOG. IEEE Trans. Neural Syst. Rehabil. Eng., 10(4):209{218, December 2002. Barea, Rafael, et al. “Sensory System for Implementing a Human-Computer Interface Based on Electrooculography.” Sensors 11.1 (2010): 310-328. 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SUMMARY OF THE INVENTION
[0052] The present technology explores a synergistic solution to transform emerging wearable virtual projection display devices, e.g., Google Glass, into an eye-controlled mobile human-computer interaction device, which can be seamlessly extended to a hands-free assistive control system for people with disabilities or special needs. The technology detects and removes artifacts from EOG signals, recognizing and distinguishing various types and levels of eye movements. The EOG signals may be used to provide a comprehensive eye movement encoding language for eye-controlled HCI applications.
[0053] However, acquiring clean EOG from a wearable device is difficult, due to bulkiness and inconvenient configurations of existing EOG acquisition devices that may easily loosen electrode connections ( FIGS. 1 and 2 ). To address this obstacle, a human computer interface (HCI) paradigm taking advantage of the recently emerging wearable head-mounted, glass-style computing devices (e.g., Google Glass, FIG. 3 ). Specifically, the design embeds a pair of small electrodes placed inside the arms of an eyeglass frame (arranged as in FIG. 5 ). These electrodes record the electrooculography (EOG; [8,9]) signals in the horizontal direction, and enable users to control the HCI, wirelessly tethered mobile devices, or any other wireless connected devices via intentional eye movements. The technology ensures both reliable EOG signals acquisition and comfortable user experience.
[0054] Vertical EOG tracking is not directly supported, though instead of a single electrode on each temple arm, a pair of electrodes displaced vertically may be provided at the temple, to yield some vertical information. This has the added advantage that the pair of electrodes may be processed together for horizontal tracking to reduce some noise sources, such as EMG signals.
[0055] The movement of the eyes contains a rich source of information and has been widely used as a tool to investigate visual cognition. Existing eye trackers are usually developed using video-based systems [1, 8], which are expensive and also require image processing tasks with bulky auxiliary equipment. Eye movement characteristics such as saccades, fixations, and blinks, have already been investigated for hands-free operation of static human-computer interfaces [3, 4]. However, these existing studies only focused on exploring the links between the tasks and eye movements; little research has been done to use eye movement as a more basic source of information in the HCI system. Under the Google Glass-based mobile HCI paradigm, the eye movements are examined for use in a wide variety of controlling interactions with wearable computing devices, according to a language encoding framework.
[0056] Several algorithmic contributions are provided to address the following technical challenges:
[0057] (1) removal and compensation of artifacts and noise in EOG signals,
[0058] (2) detection of intentional eye-movement events, and
[0059] (3) recognition and encoding of more complex eye gestures consisting of a series of distinct eye movements.
[0060] Moreover, the present approach provides an effective and user-friendly means for people with disabilities or special needs to achieve true “hands-free” control interfaces.
[0061] Eye movements contain resourceful information that may be mapped to control instructions in HCI systems. The limited recognition accuracy and resolution in conventional vision-based eye movement trackers make them less effective in distinguishing finer eye movement amplitudes. In the present technology, the EOG signals can be continuously and accurately measured by the electrodes inside the eyeglass frame arms, which enables the detection of finer eye movements ( FIG. 6 ). Thus eye movements are encoded by mapping saccades with different directions and amplitude to specific controlling instructions.
[0062] It is noted that, assuming the eyes move together, and that only the joint left-right horizontal movement signal is desired, then the two electrodes in the temple arms could provide a sufficient signal. However, a central electrode or electrodes may also be provided at the nose, for example using conductive silicone rubber nose-pads, which then separate the signals coming from each respective eye.
[0063] It is therefore an object to provide an apparatus for detecting electrooculograph (EOG) signals, comprising: a pair of temple pieces connected to a bridging structure; at least one electrode on each temple piece configured to contact the skin at the temple, and to receive an EOG signal from a proximate orbital socket; a reference electrode displaced from each temple; and a processor configured to process signals from the at least one electrode on each temple piece and the reference electrode to detect saccade movements of the eyes.
[0064] The at least one electrode on each temple piece may be configured to contact the skin at the temple comprises at least two electrodes, configured to determine changes in a vertical and horizontal axis of the EOG signal.
[0065] The processor may be configured to characterize an amplitude and a sign of an EOG signal.
[0066] The processor may be further configured to characterize a sequence of states of an EOG signal as a single user command selected from a wordbook of valid user commands.
[0067] The processor may be further configured to perform baseline drift compensation by performing a wavelet transform decomposition of the EOG signal to provide wavelet transform coefficients, estimate a baseline drift based on the wavelet transform coefficients, and to compensate the baseline drift based on the estimated baseline drift.
[0068] The processor may be further configured to: perform an approximated multilevel 1D wavelet decomposition at level nine using Daubechies wavelets on each EOG signal to produce a set of decomposition coefficients; estimating a drift of the EOG baseline using the decomposition coefficients; and subtracting the estimated drift of the EOG baseline from each EOG signal.
[0069] The processor may be further configured to implement median filter denoising, having a window sufficiently small to retain short signal pulses associated with eye blinks.
[0070] The processor may be configured to separately analyze movement of right and left eyes separately.
[0071] The processor may be configured to determine consistency of right and left eye saccadic movements.
[0072] The processor may be further configured to: perform a continuous wavelet transform (CWT) on the EOG signals; applying a threshold on the coefficients of the CWT transform to segment the EOG signal into periods of saccadic movement and fixation; filtering saccadic periods based on duration; and determining a signed saccade amplitude for each filtered period.
[0073] The processor may be further configured to:
[0074] perform a Continuous Wavelet Transform (CWT) on the EOG signals s, wherein the CWT first computes continuous 1D wavelet coefficients at scale 20 using a Haar mother wavelet, wherein: ψ(t) is the mother wavelet;
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[0000] to divide the EOG signal into periods of saccadic (M=1,−1) and fixational (M=0) segments; removing saccadic segments shorter than 20 ms and longer than 200 ms; determining a saccade amplitude SA for each segment as a difference in EOG signal amplitude from a baseline EOG signal amplitude, and determining a saccade direction based on a sign of the corresponding elements in M.
[0075] An amplitude of an EOG signal during a saccade movement may be corrected for a change in baseline by subtracting an amplitude of an EOG signal during a time when a saccade is not detected temporally proximate to the saccade movement.
[0076] It is also an object to provide a method for detecting electrooculograph (EOG) signals, comprising: providing a pair of temple pieces connected to a bridging structure to a human or animal, having at least one electrode on each temple piece configured to contact the skin at the temple, and to receive an EOG signal from a proximate orbital socket and a reference electrode displaced from each temple; and processing electronic signals from the at least one electrode on each temple piece to detect saccade movements of the eyes.
[0077] The processing may further comprise determining a baseline EOG signal amplitude during an absence of saccade movements, and determining an amplitude and a sign of an EOG signal during a saccade movement.
[0078] The method may further comprise characterizing a sequence of a plurality of amplitudes and signs of an EOG signal over a period of time as a single user command selected from a wordbook of valid user commands.
[0079] The at least one electrode on each temple piece may be configured to contact the skin at the temple comprises a plurality of electrodes on each temple piece, configured to determine changes in a vertical and horizontal axis of the EOG signal.
[0080] The method may further comprise: compensating for a drift of the EOG baseline using decomposition coefficients of a wavelet decomposition on each EOG signal; and implementing a median filter to denoise the baseline corrected EOG signal, having a window sufficiently small to retain short signal pulses associated with eye blinks. The method may further still comprise determining, based on coefficients of a continuous wavelet transform of the EOG signals, respective periods of eye saccadic movement and eye fixation; filtering the periods of eye saccadic movement based on duration to eliminate periods of eye saccadic movement below and above respective lower and upper thresholds; and determining a signed saccade amplitude for each filtered period.
[0081] It is a still further object to provide a method for detecting electrooculograph (EOG) signals from eyes of a human or animal, comprising: providing a pair of temple pieces connected to a bridging structure supported by a nose of the human or animal, having at least one electrode on each temple piece configured to contact the skin at the temple, substantially without contacting an infraorbital facial surface, and to receive an EOG signal from a proximate orbital socket and a reference electrode displaced from each temple; processing electronic signals from the at least one electrode on each temple piece and the reference electrode to characterize an amplitude and direction of saccadic movements of the eyes and fixation of the eyes; and interpreting sequences comprising a plurality of characterized amplitudes and directions of saccadic movements of the eyes and fixations of the eyes as a user command.
[0082] The method may further comprise processing electronic signals from the at least one electrode on each temple piece and the reference electrode to characterize electromyographic signals.
[0083] The form factor of the system preferably takes the form of eyeglasses or half-rim (upper) frames, with electrode pads on the temple arms, which may be, for example, conductive carbon powder filled silicone rubber, which may be provided as a single pad, or a split pad, which further may be physically divided as multiple pads, or as a single structure with an insulating barrier. The pad is preferably located near the zygomatic arch. The reference electrode may be provided at the nose bridge, which would generally isolate left and right orbital sockets. The reference may also be provided at or behind the ear. Indeed, signals may be processed from all contact locations. The system may be powered by a primary battery, such as a hearing aid-type battery, a rechargeable battery, a solar cell (e.g., on the outside surface of the temple arm), or other known means. The technology may be embedded into a wearable computer system, such as Google Glass, or other electronic device that requires hand-free control, e.g., an MP3 type music player, GoPro® video camera, or the like. The system may also incorporate a microphone and/or other sensors, such as magnetometer/compass, accelerometer (e.g., 3 axis), anemometer, eye gaze direction sensor/video camera, gyroscope (e.g., 3 axis), inclinometer, GPS/aGPS, RF triangulation, etc., which may provide their traditional functions in addition to integrating to provide added or complementary functionality to the EOG sensor. Similarly, the EOG and sensors may be used for control of a human computer interface, or for other purposes, which may include medical diagnosis or monitoring.
[0084] These and other objects will become apparent from a review of the embodiments described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0085] FIGS. 1 and 2 shows a prior art techniques for measuring EOG signals using self-stick electrodes.
[0086] FIG. 3 shows a prior art Google Glass® frame design.
[0087] FIG. 4 shows a prior art Emotiv® headset design.
[0088] FIGS. 5 and 5B show respectively a perspective and top view of an eyeglass frame according to the present invention.
[0089] FIG. 6A shows graphically eye movement directions and amplitudes.
[0090] FIG. 6B shows eye movement angles reflected in EOG signals.
[0091] FIG. 6C shows a representative diagram of radix-7 encoding for eye movements.
[0092] FIG. 7A shows a graph of EOG signals on a mobile phone display.
[0093] FIG. 7B shows an exemplary display on a mobile phone in which eye movements trigger a distress phone call with accompanying location information.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0094] A system was developed based on an Android smartphone that was wirelessly connected to an Emotive headset ( FIG. 4 ). In this design, an effective approach was implemented to recognize various eye movements and interpret them into control instructions on the mobile device. For instance, chains of eye movement patterns can automatically trigger an emergency call (e.g., three consecutive left and right saccades) or a pre-recorded text message (e.g., jaw clenching for 64 consecutive samples, determined by an EMG signal pattern), with the GPS location ( FIG. 7 ). It is worthy to mention that, in order to achieve a true “hands-free” operation, all functions above were designed to launch using certain head and eye movement patterns, without finger actions.
[0095] EOG signals suffer from the presence of various artifacts or noise, which can be caused, for example, by the measurement circuitry and electrodes, or involuntary muscle movements and electrical activities along the scalp. However, they can be processed to remove artifacts that might hamper eye movement analysis. The processing can take a variety of forms and sequences. One source of interference is externally generated electromagnetic interference (EMI). Typically, the electrodes of the system are close together with respect to the source of the EMI, and therefore the EMI can be rejected as common mode interference. In other cases, external interference can come from local devices, such as the Google Glass device itself, which has an asymmetric topology and therefore emission pattern. Fortunately, the signals of interest in EOG are likely outside the EMI band of the Google Glass, and the interference would be expected to be AC coupled to the electrodes. The EMG signals from nearby muscles and electrocardiographic (ECG) signals may also be present in the electrode signals. While there can often be distinguished by frequency filtering, it may be useful to perform model-based filtering of the signal pattern (e.g., before filtering) to remove identifiable patterns. For example, ECG interference would typically follow an ECG pattern, and this can be intelligently filtered from the signal (or the signal intelligently analyzed to avoid interference from the ECG signal) without substantially degrading the remaining signal or its analysis. Similarly, EMG patterns may also be distinguished. In cases of intermittent strong interference (which in some cases can saturate signal processing components or algorithms), the system may detect the interference and stop processing until the interference ceases. For example, in an adaptive model, during the interference period, the adaptivity ceases, and therefore adaptation is limited to being based on valid signals only. By ceasing processing, rather than merely invalidating the output, recovery from the saturation or interference may be expedited.
[0096] Baseline drift is a slow signal change superposed on the EOG signal, and is caused by factors mostly unrelated to eye movements. Little study has been devoted to EOG signals with nonrepetitive characteristics. An approach based on wavelet transforms [10] may be used. The algorithm first performs an approximated multilevel 1D wavelet decomposition at level nine using Daubechies wavelets on each EOG signal component. The reconstructed decomposition coefficients give a baseline drift estimation. Subtracting this estimation from each original signal component yields the corrected signals with reduced drift offset. Of course, other baseline drift detection and correction systems and algorithms may be employed.
[0097] The nonrepetitive nature of EOG signals prohibits the application of denoising algorithms that make use of structural and temporal knowledge about the signal. However, a median filter may be employed, because it can preserve edge steepness of saccadic eye movements, retain EOG signal amplitudes, and not introduce any artificial signal changes. A critical requirement for the median filter is to choose a window size “Wmf” that is small enough to retain short signal pulses (particularly those caused by blinks), since it removes pulses of a width smaller than about half of its window size.
[0098] A variety of eye movements can be detected from EOG signals. The accuracy and robustness of the algorithms for detecting these eye movements is key to achieving good performance of the human-computer interface (HCI) infrastructure. Among all movement types, saccades (i.e., simultaneous movement of both eyes) are particularly important because the reliable eye movement encoding is highly reliant on it.
[0099] For saccade detection, a Continuous Wavelet Transform (CWT) algorithm may be employed, operating on inputs representing the denoised and baseline drift removed EOG signals. CWT first computes the continuous 1D wavelet coefficients at scale 20 using a Haar mother wavelet. Let s be one of these signal components and ψ(t) the mother wavelet. The wavelet coefficient C b a of s at scale a and position b is defined
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[0100] This step divides EOG in saccadic (M=1,−1) and fixational (M=0) segments. Saccadic segments shorter than 20 ms and longer than 200 ms will be removed, according to the typical physiological saccade characteristics [5]. Given this CWT process, the saccade amplitude SA will be the difference in EOG signal amplitude before and after the saccade, and the saccade direction will be derived from the sign of the corresponding elements in M.
[0101] A particular activity may require saccadic eye movements of different distances and directions. Saccades are detected with two different amplitudes, “small” and “large.” This requires two thresholds, th sd and th sd , to divide the range of possible values of C into three bands:
[0102] no saccade (−th sdsmall <C<th sdsmall ),
[0103] small saccade (−ths dlarge <C<−th sdsmall or th sdsmall <C<th sdlarge ), and
[0104] large saccade (C<−th sdlarge or C>th sdlarge ).
[0105] An “Eye Movement Encoded Human-Computer Interaction Language” is provided. Eye movements contain resourceful information that could be mapped to controlling instructions in HCI systems. For instance, activities such as reading typically involve characteristic sequences of several consecutive eye movements. However, the limited recognition accuracy and resolution in conventional vision-based eye movement trackers make them less effective in distinguishing finer changes of eye movement amplitude, as shown in FIG. 6A .
[0106] According to the present technology, the EOG signals can be continuously and accurately measured by the embedded electrodes inside the glass arms, which enables the possibility of detecting finer eye movements. Thus, eye movements are encoded by mapping saccades with different amplitude to a discrete, number-based representation, as shown in FIG. 6B . Strings of these numbers are then collected in wordbooks that are analyzed to extract sequence information on repetitive eye movement patterns. Specifically, the algorithm takes the CWT saccades as its inputs and denotes the eye movements using the predefined encoding scheme. For example, assuming we can precisely distinguish three amplitude levels of eye movements in one direction, a radix-7 encoding scheme is defined, as shown in FIG. 6C , where “0” represents the look-straight-ahead state, and three different amplitudes of left and right gaze direction are further distinguished. Based on the encoded eye movements, a wordbook analysis assesses repetitive eye movement patterns that is defined as a string of successive numbers.
[0107] As an example with n=4, the pattern “large right→median left→small left→large left” translates to “6315.”
[0108] It is noted that the sequence itself need not be detected in discrete steps. Rather, the available valid sequences may be designed for maximum separation, and to include what is effect an error correction code. Therefore, even if discrimination of the states of the EOG sequence is difficult or erroneous, the sequence of states may nevertheless be validly extracted. For example, because of baseline instability, relative changes in EOG state may be more accurately determined than absolute states. As a result, the sequence of EOG signal changes may be analyzed as a whole, without definitive determining the intermediate states. For example, the sequence “large right→median left→small left→large left” may be offset and appear to be “median right→large left→null→large left”, which translates to “4505.” However, if this is an invalid command, the system can then search for valid commands that have the same or similar transitions, which in this case the original sequences with left as “+”, and right as “−”+3, −5, +3, −4, and the sequence as received is +2, −5, +3, −3. Therefore, by ensuring that the codespace is sparsely populated, and is absent ambiguity with respect to both absolute values and relative change values with respect to an error threshold, a high reliability may be obtained. Further, by combining EOG and EMG signal features (e.g., eyelid clenching), a relatively feature space may be developed.
[0109] A prototype was developed [6] based on a Google Nexus smartphone that was wirelessly connected to an Emotive neuroheadset, shown in FIG. 3 . In this prototype, the smartphone can receive and display real-time EOG data, as shown in FIG. 7A . An effective approach was implemented to recognize various eye movements (e.g., left/right saccades) and interpret them into control instructions on the mobile device. Along with the built-in accelerometer, the prototype can achieve precise control of a moving cursor on the phone screen, just like a mouse. Furthermore, chains of eye movement patterns can automatically trigger an emergency call (three consecutive left and right saccades) or a pre-recorded text message (jaw clenching for 64 consecutive samples), with the GPS location, as shown in FIG. 7B . It is worthy to mention that, in order to achieve a true “hands-free” operation, all above three apps were designed to launch and switch using certain head and eye movement patterns, without body actions.
[0110] The eye movements can also be representative of gestures, such as sweeps,
[0111] The system computer system may be implemented according to designs disclosed in, for example, US Patent Application and Patent Nos. 20140316235; 20140313303; 20140304122; 20140303994; 20140295786; 20140286566; 20140285634; 20140276239; 20140272894; 20140272847; 20140266604; 20140258110; 20140257047; 20140251233; 20140244514; 20140244495; 20140244494; 20140204229; 20140204190; 20140164111; 20140161412; 20140133658; 20140108151; 20140052555; 20140044304; 20140040041; 20140039571; 20140029809; 20130325493; 20130311329; 20130223673; 20130093829; U.S. Pat. Nos. 8,878,749; 8,874,760; 8,867,139; 8,867,131; 8,866,702; 8,862,764; 8,860,787; 8,856,948; 8,854,282; 8,838,708; 8,833,934; 8,831,879; 8,827,445; 8,823,740; 8,820,934; 8,817,379; 8,812,419; 8,811,951; 8,798,336; 8,786,953; 8,775,844; 8,773,599; 8,767,306; 8,767,305; 8,764,185; 8,762,895; 8,760,765; 8,750,541; 8,749,886; 8,738,723; 8,738,292; 8,724,206; 8,705,177; 8,686,924; 8,676,893; 8,670,000; 8,665,178; 8,661,053; 8,659,433; 8,629,815; 8,612,211; 8,611,015; 8,593,795; 8,558,759; 8,542,879; 8,510,166; 8,508,851; 8,506,080; 8,505,090; 8,457,367; 8,411,909; 8,384,617; 8,332,424; 8,319,746; 8,316,319; 8,311,289; 8,303,110; 8,294,994; 8,275,893; 8,235,529; 8,228,315; 8,223,088; 8,223,024; 8,217,856; 8,209,183; 8,203,502; 8,199,126; 8,194,036; 8,190,749; 8,184,070; 8,184,067; 8,179,604; 8,176,437; 8,175,297; and 8,146,156.
[0112] A typical system will provide a quad core ARM architecture processor with GPU, random access memory, flash memory, WiFi and Bluetooth connectivity, optionally 3G, 4G and/or LTE connectivity, an LCD, OLED, and/or heads-up display projecting an image to the eye within the eyeglass frames, a sensor package including still/video cameras, microphone, accelerometer, magnetometer, gyroscope, touchpad, fingerprint scanner, hand-gesture sensor, a rechargeable lithium ion battery, speaker(s), and other standard elements.
[0113] The EOG electronics typically employ instrumentation amplifiers configured to provide a high differential gain with high common mode rejection ratio, and preferably a digitally controllable gain. The amplified signal(s) are digitized, and most complex signal processing performed by a standard processor or digital signal processor.
[0114] The system may be provided as an operating system resource, to provide input for all applications, or through each application individually. In order to provide context-independent functionality, such as emergency calling, operating system level services are preferred.
[0115] The above description of the invention is intended to be illustrative and not limiting. Various changes or modifications in the embodiments described may occur to those skilled in the art. These can be made without departing from the spirit or scope of the invention. | A apparatus for detecting electrooculograph (EOG) signals, comprising: a pair of temple pieces connected to a bridging structure; at least one electrode on each temple piece configured to contact the skin at the temple, and to receive an EOG signal from a proximate orbital socket; a reference electrode displaced from each temple; and a processor configured to process signals from the sensors to detect saccade movements of the eyes. A wavelet-based algorithm permits analysis and coding of the saccade movements. | 6 |
RELATED APPLICATION
This application is claiming the benefit, under 35 U.S.C. 119(e), of the provisional application filed Oct. 29, 2010 under 35 U.S.C. 111(b), which was assigned Ser. No. 61/407,937. This provisional application is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for forming a vehicle window assembly, and the method of using such apparatus to form such vehicle window assembly. More particularly, the invention relates to one or more apparatus and the method(s) of utilizing same to dispose one or more items of hardware onto a dielectric substrate to form a vehicle window assembly.
Induction heating for various types of bonding has been described in the patent literature, for example:
U.S. Pat. No. 6,288,375 describes an induction heating apparatus and method for heating a substantially continuous bondline defined by a length of thermally responsive bonding material positioned between a first member and a second member. The inductive heating apparatus includes a flexible, reshapeable cable assembly positionable adjacent the first member along the first bondline. The flexible, reshapeable cable assembly is capable of being manually shaped to a first shape of the first bondline, and then being manually reshaped to a second shape of a second bondline different than the first shape of the first bondline.
U.S. Pat. No. 6,323,468 describes a static coil induction welding apparatus and method for induction welding thermoplastic composite structures. The apparatus includes a plurality of independent coil segments disposed adjacent one another in side-by-side fashion to form a coil pack. A plurality of such coil packs are disposed in side-by-side fashion to form a coil assembly which covers the entire area of the weld zone. An AC power supply associated with each coil pack applies an AC signal through a switching network to electrically energize its associated coil segments such that the AC signals are in predetermined phase relationships relative to one another, thus generating a plurality of eddy current loops in a susceptor placed between the components being welded. The switching network alternately switches the coil segments such that the AC signals applied to the coil segments are shifted back and forth between adjacently disposed coil segments repeatedly approximately every 0.5 seconds. This produces a back and forth lateral shifting of the induced eddy current loops by about one-half the width of one current loop to provide uniform heating of the susceptor. It is also said to eliminate various drawbacks associated with dynamic coil induction welding systems, and to allow feedback control over the power applied to each coil pack.
U.S. Pat. No. 6,849,837 describes a method for using magnetic fields to heat magnetically susceptible materials within and/or adjacent to adhesives so as to bond, bind or fasten solid materials to one another. The system uses alternating magnetic fields that induce eddy currents and generate heat within susceptors. An induction heating tool is used to emit the magnetic field at its work coil and an electronic controller measures the energy being used by a power converter that generates the alternating current driving the work coil which creates the magnetic field.
U.S. Published Patent Application No. 2008/0164248 describes a method and device for simultaneously soldering plural electrical connections in which contact elements have to be soldered to soldered-connection faces positioned on a non-metallic glazing. A soldering tool is used to emit a magnetic field toward the solder spots to heat them by induction. The size and shape of the soldering tool corresponds to the surface area over which the plural solder spots to be simultaneously heated in the soldering operation are situated. Additionally, the frequency of the AC voltage applied to the loop or coil is matched to the connection geometry but will be a maximum of 150 KHz.
U.S. Pat. No. 7,002,117 describes a device for welding a moving packaging material including a layer that can be heated by electromagnetic induction and a thermoplastic layer incorporating a welding zone which lies in the direction of movement of the packaging material; the welding device includes an alternating current generator, a coil for transforming the alternating current into a magnetic field, a ferromagnetic element for channeling the magnetic field lines in a specific direction, the magnetic field being oriented so as to cross the packaging material in order to induce heating of the layer that can be heated by electromagnetic induction; the welding device being characterized in that it includes a set of ferromagnetic elements which are arranged so that the magnetic field lines cross the packaging material in at least two distinct regions located along the welding zone. By use of such a device, the packaging is said to undergo, in the welding zone, a first heating followed by an interruption and a second heating.
SUMMARY OF THE INVENTION
In today's vehicle manufacturing environment, more than ever, the vehicle manufacturers expect from their suppliers a technologically advanced, high quality product at low cost, that can be readily installed in a vehicle body opening on the vehicle assembly line, with a minimum of effort by vehicle assembly line workers. As more items of hardware, serving various purposes, are disposed on vehicle windows to satisfy the above-noted vehicle manufacturer requirements, it is necessary for the vehicle window assembly supplier to provide a vehicle window assembly on which items of hardware are robustly attached, without penetrating the vehicle window, and are precisely positioned for easy assembly.
To accomplish the previously described objectives in a cost-effective manner, the vehicle window assembly supplier seeks a flexible process, which can produce high-quality vehicle window assemblies in a short cycle time.
The present invention satisfies the foregoing objectives of the vehicle manufacturer and the vehicle window assembly supplier.
The present invention, generally, utilizes a fixture onto which a dielectric substrate, such as glass or plastic, in the form of a vehicle window, is positioned by manual or electromechanical means, e.g., a robot. The fixture can perform multiple functions; that is, one or more functions, in addition to positioning/disposing one or more items of hardware on the substrate, or it may serve one or more functions solely related to the positioning/disposing of one or more, items of hardware on the substrate. It is also within the scope of the invention to provide a workstation for positioning/disposing items of hardware on a substrate, which workstation is not a fixture.
In connection with the present invention, the item(s) of hardware to be disposed on the dielectric substrate may be pre-positioned in an assembly aid, or “nest,” which may operate separately from, but in cooperation with, the fixture/workstation, or may be an integral component of such fixture/workstation.
In accordance with the invention, the preferred means of disposing the one or more items of hardware onto the substrate is by adhesive bonding. A one component adhesive is preferred. In order to minimize the cycle time as much as possible, heating of: the glass, the item of hardware, and/or the adhesive itself, separately or simultaneously, may be desirable. The inventors have found that while one or more methods of heating are possible, induction heating is preferred. In the apparatus of the invention, one or more induction heating coils can be deployed proximate the glass/adhesive/item of hardware. It is preferred that where multiple induction coils are utilized, the coils are independently powered, but controlled by a single master controller to maximize the flexibility of such induction heating system.
In another embodiment of the invention, a manufacturing process, whereby vehicle windows to which items of hardware are to be bonded, are transported by, for example, a continuous conveyor system to an “in-line” fixture including multi-axis glass positioning mechanisms and one or more assembly aids to hold the items of hardware to be bonded. The assembly aids may be movable from a bonding position beneath the vehicle window to a loading position proximate the conveyor system. A shuttle system may be useful to move the one or more assembly aids between such loading and bonding positions.
BRIEF DESCRIPTION OF THE DRAWINGS
The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description when considered in the light of the accompanying drawings in which:
FIG. 1 a - 1 b show perspective views of the assembly fixture with assembly aids without and with a vehicle window disposed thereon, respectively, according to the invention.
FIG. 2 shows a somewhat schematic view of an assembly aid according to the invention.
FIG. 2 a shows a cross-sectional view of FIG. 2 along line A-A, according to the invention.
FIG. 2 b shows a cross-sectional view of an assembly aid as in FIG. 2 , but with multiple induction heating devices, as is within the scope of the invention.
FIG. 3 is a cross-sectional view of a work station, not including a fixture, for induction bonding according to the invention.
FIG. 4 is a plan view of a continuous manufacturing process utilizing the method of positioning and heating an item of hardware according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
As previously mentioned, the invention can be implemented in a manufacturing process for bonding hardware to a substrate, preferably a glass vehicle window, by induction heating with or without the use of a fixture.
Induction heating is the process of heating an object having some degree of electrical conductivity by electromagnetic induction. Eddy currents are generated in the conductive material and electrical resistance leads to heating of the conductive material. An induction heating device as referred to herein comprises an electromagnet through which high frequency alternating current (AC) is passed.
In accordance with an embodiment of the invention, bonding an item of to a glass vehicle window, utilizing a preferred apparatus, is accomplished by pre-positioning one or more items of hardware in one or more assembly aids or “nests” preferably integrated into a fixture which is preferably a part of a work cell. A predetermined amount of a suitable adhesive is preferably pre-applied to the item of hardware or may be applied to the item of hardware in the assembly aid; the glass vehicle window is properly positioned on the fixture and is preferably brought into bonding contact with the item of hardware which has been prepared for bonding. The induction heating system is activated proximate the item(s) of hardware to accelerate curing of the adhesive. As previously noted, the glass substrate, the item of hardware and/or the adhesive may be selectively heated. After a predetermined time sufficient for at least initial curing of the adhesive, the completed vehicle window assembly is removed from the fixture. The various operations of the method may be performed manually, by electromechanical means, e.g. by a robot, or by a combination of same, such as is known for work cells in a manufacturing operation.
Such a fixture, preferably with integrated assembly aids in a work cell, may be advantageously utilized for larger parts such as hinges, brackets and the like, where the cycle time is relatively slow due to the time necessary for at least partial curing of the adhesive to bond the item of hardware to the glass. In such cases, cure times will, typically, be longer than 30 seconds, with current adhesive technology.
In an aspect of the invention where a fixture is not utilized, a framework having a shape substantially similar to the shape of a vehicle window could be utilized as a platform from which one or more induction heating devices 32 could be extended, either above or below, for example, a glass sheet transporting system. Depending on the application, the induction heating devices 32 so disposed can be positioned to heat the item of hardware with adhesive already applied directly, or to heat an area of either major surface of the glass to facilitate bonding of an item of hardware thereto. It is an advantage of induction heating that heating sufficient for bonding may be direct or indirect, in this case, heating directly an area on the surface of the glass to which the item of hardware is to be bonded, or indirectly through the glass by heating of the major surface of the glass opposite that on which the item of hardware is to be bonded.
FIGS. 1 a - 1 b show an assembly fixture 10 in accordance with the invention having at least one induction heating assembly aid as a component thereof.
Referring to FIGS. 1 a and 1 b , the assembly fixture 10 of the invention has a major, preferably substantially horizontal, support surface 14 with at least one preferably resilient, vertical support member 16 attached thereto. The at least one vertical support member 16 supports a vehicle window 18 a predetermined vertical distance above the major support surface 14 . The at least one vertical support member 16 may have one or more passages extending therethrough, which can be connected to a source of gaseous pressure, preferably a source of negative pressure, for example a vacuum pump.
Also attached to the major support surface 14 , and extending a predetermined vertical distance thereabove, is at least one fixed positioning member 20 to contact the peripheral edge of the vehicle window 18 so as to align the vehicle window in an “x” direction prior to adhesive bonding. To assist with aligning the vehicle window 18 in the “y” direction, moveable positioning members 22 may be utilized. Movement of the moveable positioning members is preferably caused by two or more horizontally extending arms 24 which connect the moveable positioning members to a centrally located camming mechanism 26 which is axially affixed to the major support surface 14 , although other movement mechanisms are possible.
Other optional features of the assembly fixture as shown in FIGS. 1 a and 1 b include glass pressure sensor 19 and swing arm mechanisms 21 which when the glass is positioned on the assembly fixture for bonding operations exerts a positive pressure on the vehicle window to assist in maintaining the vehicle window's precise position on the assembly fixture.
Further, one or more assembly aids 12 are preferably affixed to the major support surface in a predetermined location, so as to coincide with the one or more locations of the vehicle window where an item of hardware is to be adhesively bonded. The item of hardware is typically metallic, and is preferably formed of steel. In preferred embodiments, the item or items of hardware may be one or more of clips, pins, brackets, hinges, rails or the like.
Generally, an assembly aid, illustrated in FIGS. 2 , 2 a and 2 b , includes a block of temperature-resistant, preferably polymeric material 28 , in which is formed a receptacle 30 for receiving one or more items of hardware. Preferably, embedded in the polymeric material 28 proximate the receptacle for the items(s) of hardware is one or more induction heating devices 32 and, if necessary, a cooling system (not shown) that typically employs water or air cooling. The induction heating devices 32 may also be proximate the assembly aid 12 , but not embedded in the polymeric material 28 . The assembly aid 12 may also be equipped with a spring-loaded or other type of device (not shown) to allow the assembly aid to move a predetermined distance in the “z” direction. This slight adjustability allows for, for example, variation in glass shape.
In a method of operation in accordance with an embodiment of the invention, a vehicle window 18 is placed onto the assembly fixture 10 by manual or electromechanical means, and is initially positioned on the one or more vertical supports 16 with one peripheral edge of the vehicle window 18 in contact with the at least one fixed positioning member 20 to aid in positioning the vehicle window in the “x” direction. Moveable positioning members 22 are activated to contact opposite peripheral edges of the vehicle window to ensure proper alignment of the vehicle window 18 in the “y” direction. If so equipped, a negative pressure may be applied through, for example, the at least one vertical support member 16 , thus drawing the vehicle window 18 down so as to contact the surface of the assembly aid 12 and place the surface in communication with the at least one receptacle 30 containing the one or more items of hardware previously placed by manual or electromechanical means in the receptacle 30 . Preferably, the one or more items of hardware have a predetermined amount of an adhesive, preferably a one component urethane adhesive, adhered thereto.
A one-component adhesive particularly suitable for use in connection with the invention is a polyurethane adhesive preferably including at least one polymer polyol, such as Terolan 1510™ by Henkel and Efbond™ by Eftec, and further including at least one physically unincorporated or chemically blocked polymerizing component, such as an isocyanate compound, well dispersed within the at least one polymer polyol. The polymerizing component may comprise a percentage of the overall adhesive, for example, 1 wt % to 50 wt % of the total adhesive. An advantage of the preferred adhesive is that it has an initial viscosity of from 10 kilocentipoise to 30 kilocentipoise and, unless subjected to heat at a temperature of 190 F or greater, will maintain a viscosity substantially within the range of the initial viscosity for an indefinite period of time. Thus, such material is pumpable, or otherwise readily deliverable by conventional systems to the desired location during the bonding process. A further advantageous feature of the preferred one component urethane adhesive is that upon exposure to heat at a temperature of 190 F or greater, the adhesives cures rapidly, and achieves a high bond strength quickly. For example, a bond strength of ≧100 psi by lap shear testing is achieved within a time period from 1 minute to 2 minutes, preferably a time period of 0.5 minute to 1 minute.
The one or more induction heating devices 32 are activated for a predetermined time through at least one electronic controller (not shown) which is connected to one or more power supply units (not shown) which, in turn, is connected to the at least one assembly aid 12 . Activation of the one or more induction heating devices 32 creates heat sufficient to initiate curing of the adhesive on the portion of the item of hardware which is in contact with the surface of the vehicle window 18 , for example, 5 sec to 45 sec. The induction heating devices 32 are then deactivated by the at least one electronic controller and, after a predetermined time sufficient for the adhesive to at least partially cure and bond the item of hardware to the vehicle window 18 , the negative pressure is discontinued. The vehicle window 18 with item(s) of hardware bonded thereto can then be removed from the assembly fixture 10 for further processing, or for transport to, for example, a vehicle assembly plant.
It has been found that the implementation of induction heating requires a careful balance between the power of the induction heating device 32 and the time a given induction heating device 32 is activated for a particular heating operation.
More specifically, it has been discovered that rather than it being difficult to generate sufficient heat to cure an adhesive material by induction heating, it is more difficult to avoid overheating the adhesive, thereby actually diminishing the bonding strength of the adhesive and, of course, the strength of the adherence of the item of hardware to the surface of a glass vehicle window 18 . This is clearly undesirable. It has been found that for most applications of the invention, utilizing an induction heating device 32 having an electrical frequency of between 10 KHz and 100 KHz is preferable, and between 20 KHz and 50 KHz is more preferable. It may be possible, however, to utilize an induction heating device 32 of somewhat higher frequency if a heating device in the preferred power range is not available, to achieve acceptable adhesive curing by “pulsing” the heating device 32 ; that is, activating the induction heating device 32 for a first predetermined period of time, deactivating the heating device 32 , for a predetermined period of time, and then reactivating the induction heating device 32 for a second predetermined period of time. For example, a “pulsing” cycle, as described above, may have a duration of 2 sec. heating device 32 on and 2 sec. heating device 32 off, more preferably 1 sec. heating device 32 on and 1 sec heating device 32 off and most preferably 0.5 sec. heating device 32 on and 0.5 sec. heating device 32 off, for a total time of preferably 60 sec., more preferably a time of 45 sec. and most preferably a total time of 20 sec., although other pulsing cycles are possible.
Other reasons pulsing may be desirable include, as a means to gradually increase the temperature of the adhesive or the material to which the adhesive is to be bonded, or to maintain the adhesive or the substrate material at a predetermined temperature, or within a predetermined temperature range.
The “pulsing” of induction heating devices 32 can be utilized with multiple induction heating devices 32 . It is also within the scope of the invention to utilize pulsing cycles of varying duration on different items of hardware being bonded to the same glass substrate 18 . It is also possible to utilize pulsing of induction heaters 32 on one or more items of hardware being bonded to a glass substrate 18 while utilizing a single constant linear heating interval or a variable rate heating method (i.e., some power is continuously applied, but in a non-linear manner, for example, “ramp” type heating) for another item of hardware.
FIG. 3 shows an embodiment of the invention for induction heating in an independent workstation environment; 50 that is, not as a component of an assembly 10 fixture, as elsewhere described herein. In this application, a mounting pin or pins 52 , upon which some device may be subsequently installed, for example, a sensor farm housing 54 , is adhesively bonded to a glass substrate 18 . As illustrated, the mounting pin 52 may be manually or electromechanically positioned in bonding contact on a major surface of a glass substrate 18 . The mounting pin 52 preferably has a pre-applied amount of a suitable adhesive on the portion of the mounting pin 52 in bonding contact with the glass substrate 18 . Induction heating devices 32 are shown in two possible locations, one where the glass is heated to a temperature sufficient to activate the adhesive on the mounting pin 52 , and/or a second induction heating device 32 positioned so as to directly heat the mounting pin 52 and activate the adhesive. While it would not likely be necessary in an application such as the one illustrated, both induction heating devices 32 could be energized substantially simultaneously to initiate bonding of the mounting pin 52 to the glass substrate 18 . Pulsed operation of the one or more induction heating devices in the independent workstation 50 may also be employed.
As with the assembly fixture embodiment of the present invention, operation of the workstation 50 embodiment can also occur through use of manual means, electromechanical devices, or a combination thereof.
FIG. 4 illustrates an embodiment of the invention which may be particularly advantageous for bonding smaller parts to glass, for example, pins, studs, clips and the like. In the illustrated embodiment, rather than having an individual work cell which includes an assembly fixture 60 , the assembly fixture is 60 utilized as an “in-line” component of a manufacturing process whereby vehicle windows 18 to which hardware is to be bonded is transported to and away from the “in-line” fixture by, for example, a continuous conveyor system 62 . Such conveyor system 62 may be any suitable type of conveyor system, for example, a roller conveyor as illustrated in FIG. 4 . At the “in-line” assembly fixture 60 , it is desirable to have mechanisms for example, centering device 64 to precisely position the vehicle window 18 relative to the assembly fixture 60 in an x and y axis, that is, in the direction parallel to and perpendicular to the direction of the conveyor 62 . Some degree of movement of the vehicle window 18 in a z-axis direction may also be desirable to allow the window 18 to be drawn down into bonding contact with the one or more items of hardware to be bonded to the vehicle window 18 . It is preferred that the one or more items of hardware to be bonded to the vehicle window 18 are held in an integrated assembly aid 66 substantially similar to the type previously described herein.
It is also possible, however, to have the one or more assembly aids 66 be a separately movable component which can be moved in, for example, a “y” direction between a loading position, proximate the transport conveyor 62 to a bonding position proximate the in-line fixture 60 . In the bonding position the assembly aid 66 may be capable of movement in a “z” direction to bring one or more items of hardware into bonding contact with a vehicle window 18 positioned in the in-line fixture 60 . Of course the assembly aid 66 preferably also includes one or more induction heating devices 32 positioned so as to heat the item of hardware, the glass of the vehicle window 18 , or both, to initiate curing of the adhesive utilized to bond the item of hardware to the vehicle window 18 . The induction heating devices 32 may also be a component of the in-line fixture 60 , rather than being incorporated into the assembly aid 66 .
In the loading position, the movable assembly aid may be loaded with one or more items of hardware to be bonded. Such items of hardware may have had a predetermined amount of adhesive previously applied to the bonding surface thereof, or a predetermined amount of adhesive might be applied subsequent to the items of hardware being loaded in the movable assembly aid.
As previously noted, the in-line fixture 60 is typically utilized for small parts which, generally, have shorter adhesive curing times, found by the inventors, to be on the order of 25-30 seconds. In order to have an optimized manufacturing process with a minimum cycle time relative to the cure time of the adhesive, it is preferable to be able to convey vehicle windows 18 to the in-line fixture 60 at a rate not currently possible with the work cell type fixture 50 previously described herein, for example, 30 parts/hr to 120 parts/hr.
In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiments. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope. | A method and apparatus for forming a vehicle window assembly utilizes one or more induction heating devices to adhesively bond an item of hardware to a glass substrate, which substrate is then adapted to fill an opening in a vehicle body. Preferably, the induction heating device(s) and one or more assembly aids are components of an assembly fixture which allows for automated or semi-automated production of such vehicle window assemblies. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates in general to a variable displacement compressor piston, and, more particularly, to a variable displacement compressor piston having a hollow piston body axially aligned and integral with an actuator rod.
Variable displacement compressor pistons are used in a variety of applications including, for example, compressors used in automobile air conditioning systems. One method of producing such a piston involves forging a solid piston body with an accompanying integral actuator arm. A piston ring is added to the solid piston body to maintain sufficient air compression as the piston slides in a bore in a reciprocal fashion during compressor operation. The two components of such a piston must be manufactured separately and be later assembled thereby increasing production time and cost. Further, the solid piston body has a relatively large mass which increases reciprocating inertia in the system, and thus, reduces efficiency of the piston.
Another method of producing a variable displacement piston involves manufacturing a hollow piston body, typically by extrusion, and welding the hollow piston body to an actuator arm, which is typically formed by forging. The outer surface of the hollow piston body is machined along its length such that a piston ring is not required to maintain sufficient air compression during piston strokes. However, two parts still must be manufactured and assembled. Further, the piston body and actuator arm require machining to produce an appropriate surface at the joint where the two parts are welded together. The machining operation requires that the piston body and the actuator arm be precisely aligned during welding which is difficult. Improper alignment, due to lack of straightness, concentricity, perpendicularity and runout can result in unusable pistons once the machining operation is performed.
Accordingly, there is a need for a process of producing variable displacement compressor pistons which can be machined with little or no possibility of rendering the pistons unusable due to the machining operations. Preferably, such a process would produce pistons having relatively little mass and requiring no piston rings. Further, to improve manufacturing efficiency and accordingly expense, the process should require fewer and/or more simplified manufacturing steps.
SUMMARY OF THE INVENTION
The present invention meets this need by providing a process for producing variable displacement compressor pistons more efficiently and wherein hollow piston bodies are integrally formed with associated actuator arms to ensure proper alignment of the bodies and rods and thereby substantially eliminate machining problems associated with prior art pistons. The process utilizes a two-axis press to first form a pair of actuator arms by working a blank of metallic material along a first axis between opposing members of a die assembly. With the die assembly still closed after formation of the actuator arms, a pair of hollow piston bodies are formed by extruding the remainder of the blank of metallic material along a second axis. The hollow piston bodies are axially aligned and integrally formed with respective ones of the actuator arms. A piston head is welded to the end of each hollow piston body which is then machined and the actuator arms are separated from each other. A pair of variable displacement compressor pistons having hollow piston bodies axially aligned and integrally formed with respective actuator arms are thus formed.
According to a first aspect of the present invention, a process for forming a piston having an integral actuator arm comprises providing a blank of metallic material. The blank of metallic material is worked along a first axis so as to form at least one actuator arm. The blank of metallic material is also worked along a second axis so as to form at least one hollow piston body axially aligned with and integrally formed with the one actuator arm.
The step of working the blank of metallic material along a first axis so as to form at least one actuator arm may comprise the step of working the blank of metallic material along the first axis so as to form interconnected first and second actuator arms while the step of working the blank of metallic material along a second axis so as to form at least one hollow piston body axially aligned with and integrally formed with the at least one actuator arm may comprise the step of working the blank of metallic material along the second axis so as to form a first hollow piston body axially aligned with and integrally formed with the first actuator arm and a second hollow piston body axially aligned with and integrally formed with the second actuator arm. The process may further comprise coupling a first piston head to the first hollow piston body and coupling a second piston head to the second hollow piston body. The step of coupling a first piston head to the first hollow piston body may comprise the step of welding the first piston head to the first hollow piston body and the step of coupling a second piston head to the second hollow piston body may comprise the step of welding the second piston head to the second hollow piston body. The process may further comprise the step of separating the first and second interconnected actuator arms. The step of separating the first and second interconnected actuator arms may comprise the step of severing the blank of metallic material between the first and second interconnected actuator arms.
The step of working the blank of metallic material along a first axis so as to form at least one actuator arm may comprise positioning the blank of metallic material in a first stationary portion of a split die assembly. A second portion of the split die assembly is positioned over the first portion of the split die assembly with the first and second portions of the split die assembly forming a cavity. A first portion of the cavity has a shape corresponding to the shape of the at least one actuator arm. Pressure is applied to the second portion of the split die assembly along the first axis thereby forcing the second portion of the split die assembly towards the first portion of the split die assembly and working the blank of metallic material between the first and second portions of the split die assembly.
The step of working the blank of metallic material along a second axis so as to form at least one hollow piston body axially aligned with and integrally formed with the at least one actuator arm may comprise inserting at least one punch through a second portion of the cavity of the split die assembly positioned substantially adjacent the first portion of the cavity and having a diameter corresponding to an outer diameter of the first hollow piston body. The punch has a diameter corresponding to an inner diameter of the hollow piston body. Pressure is applied with the punch along the second axis to the blank of metallic material thereby back extruding the hollow piston body over the punch. The step of inserting at least one punch through the second portion of the cavity of the split die assembly and applying pressure with the punch along the second axis to the metallic material are preferably carried out with the second portion of the split die assembly engaging the first portion of the split die assembly.
The step of providing a blank of metallic material may comprise providing a block of metallic material having first and second surfaces forming planes that are generally perpendicular to the first axis and third and fourth surfaces forming planes that are generally perpendicular to the second axis. A portion of the block of metallic material is removed from the first side along a central portion of the block of metallic material. The step of removing a portion of the block of metallic material along a central portion of the block of metallic from the first side of the block of metallic material may comprise the step of forming a plurality of notches thereby forming at least a pair of generally symmetrical ribs. Preferably, the blank of metallic material comprises aluminum.
According to another aspect of the present invention, a process for forming a pair of pistons having integral actuator arms comprises providing a blank of metallic material. The blank of metallic material is worked along a first axis so as to form interconnected first and second actuator arms. The blank of metallic material is also worked along a second axis so as to form a first hollow piston body axially aligned and integral with the first actuator arm and a second hollow piston body axially aligned and integral with the second actuator arm. A first piston head is coupled to the first hollow piston body and a second piston head is coupled to the second hollow piston body. The first and second interconnected actuator arms are separated thereby forming a first piston having the first hollow piston body axially aligned and integral with the first actuator arm and a second piston having the second hollow piston body axially aligned and integral with the second actuator arm.
The step of coupling a first piston head to the first hollow piston body may comprise the step of welding the first piston head to the first hollow piston body and the step of coupling a second piston head to the second hollow piston body may comprise the step of welding the second piston head to the second hollow piston body. The step of separating the first and second interconnected actuator arms may comprise the step of sawing the blank of metallic material between the first and second interconnected actuator arms. The step of separating the first and second interconnected actuator arms may be performed prior to coupling a first piston head to the first hollow piston body and coupling a second piston head to the second hollow piston body.
The step of working the blank of metallic material along the first axis thereby forming interconnected first and second actuator arms may comprise positioning the blank of metallic material in a first stationary portion of a split die assembly. A second portion of the split die assembly is positioned over the first portion of the split die assembly with the first and second portions of the split die assembly forming a cavity. A first portion of the cavity has a shape corresponding to a shape of the interconnected first and second actuator arms. Pressure is applied to the second portion of the split die assembly along the first axis thereby forcing the second portion of the split die assembly towards the first portion of the split die assembly and working the blank of metallic material between the first and second portions of the split die assembly.
The step of working the blank of metallic material along the second axis thereby forming a first hollow piston body and a second hollow piston body may comprise inserting first and second punches through second and third portions of the cavity of the split die assembly. The second and third portions of the cavity are positioned substantially adjacent opposing ends of the first portion of the cavity and have diameters corresponding to the outer diameter of the first and second hollow piston bodies, respectively, while the first and second punches have a diameter corresponding to the inner diameter of the first and second hollow piston bodies. Pressure is applied with the first and second punches along the second axis to the blank of metallic material thereby back extruding the first and second hollow piston bodies over the first and second punches, respectively. The steps of inserting first and second punches through second and third portions of the cavity of the split die assembly and applying pressure with the first and second punches along the second axis to the third and fourth ends of the blank of metallic material are preferably carried out with the second portion of the split die assembly engaging the first portion of the split die assembly.
The step of providing a blank of metallic material may comprise providing a block of metallic material having first and second surfaces forming planes that are generally perpendicular to the first axis and third and fourth surfaces generally perpendicular to the second axis. A central portion of the block of metallic material is removed from the first side of the block of metallic material. The step of removing a central portion of the block of metallic material from the first side of the block of metallic may comprise the step of forming a plurality of notches thereby forming at least a pair of generally symmetrical ribs. Preferably, the blank of metallic material comprises aluminum.
Accordingly, it is an object of the present invention to provide a process for producing a variable displacement compressor piston more efficiently. It is another object of the present invention to provide a process for producing a variable displacement compressor piston wherein a hollow body is properly aligned with an associated actuator rod so that machining of the piston does not destroy the piston. It is yet another object of the present invention to provide a process that produces a piston having relatively little mass and no piston ring. It is still another object of the present invention to provide a process that produces a piston using fewer and/or more simplified steps.
Other features and advantages of the invention will be apparent from the following description, the accompanying drawings and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 1A are a side view and a perspective view, respectively, of a variable displacement compressor piston manufactured according to the present invention;
FIG. 2 is a side view of a blank of metallic material used to form the piston of FIG. 1;
FIG. 3 is a side view of a block of metallic material used to form the blank of FIG. 2;
FIG. 3A is a bottom view of the block of metallic material of FIG. 3 .
FIG. 4 is a cross-sectional view of a two-axis press used to form the piston of FIG. 1;
FIG. 5 is a cross-sectional view of the two-axis press of FIG. 4 with the blank of metallic material positioned therein;
FIG. 6 is a cross-sectional view of the two-axis press of FIG. 4 with the blank of metallic material worked along a first axis;
FIG. 7 is a cross-sectional view of the two-axis press of FIG. 4 with the blank of metallic material worked along a second axis;
FIG. 8 is a side view of interconnected pistons formed using the two-axis press of FIG. 4; and
FIG. 9 is a cross-sectional view of a piston head covering a hollow piston body of the piston of FIG. 1 .
DETAILED DESCRIPTION OF THE INVENTION
While the present invention is applicable in general to the formation of pistons having hollow piston bodies axially aligned and integral with actuator arms, it will be described herein with reference to a piston for use with a variable displacement compressor in an automobile air conditioning system for which it is particularly attractive and in which it is initially being utilized. One such piston 10 is illustrated in FIGS. 1 and 1A and comprises a hollow piston body 12 , an actuator arm 14 , a piston head 16 and a connection rod 17 . As illustrated, the hollow piston body 12 is integrally formed and axially aligned with the actuator arm 14 along an axis A. By ensuring proper alignment of the hollow piston body 12 with the remainder of the piston, the piston 10 can be machined without destruction of the integrity of the piston which occurred in prior art pistons whenever the piston body was misaligned which, unfortunately, could be frequent.
In the illustrated embodiment, the hollow piston body 12 and the actuator arm 14 are integrally formed from a preformed blank 18 of metallic material shown in FIG. 2 . The blank 18 of metallic material is formed from a generally rectangular block 20 of metallic material shown in FIG. 3 . The block 20 comprises first and second surfaces 20 A, 20 B forming planes 22 , 24 extending into the drawing and are generally perpendicular to a first axis 26 . The block 20 also comprises third and fourth surfaces 20 C, 20 D forming planes 28 , 30 extending into the drawing and are generally perpendicular to a second axis 32 . In the illustrated embodiment, the first axis 26 is substantially perpendicular to the second axis 32 . The blank 18 is formed by removing a central portion 20 E from the block 20 through the first side 20 A.
As shown in FIG. 2, upon removal of the central portion 20 E from the first side 20 A of the block 20 , a cavity 34 is formed with a pair of ribs 36 , 38 extending therein. The ribs 36 , 38 are spaced and sized to aid in the formation of a corresponding pair of connector rods 17 as described herein. For descriptive purposes, the blank 18 includes first and second surfaces 18 A, 18 B forming the planes 22 , 24 and third and forth surfaces 18 C, 18 D forming the planes 28 , 30 . It should be apparent from the ensuing description that the hollow piston body 12 and the actuator arm 14 may be formed from other blanks of metallic material having a variety of shapes and configurations. In the illustrated embodiment, the blank 18 of metallic material comprises 4000 series aluminum. It will be appreciated by those skilled in the art that the blank 18 may also comprise other suitable metals and alloys as required for given applications.
Referring now to FIGS. 4-8, a pair of interconnected first and second pistons 10 ′, 10 ″, see FIG. 8, are formed using a split die assembly 40 and working the blank 18 of metallic material along the first axis 30 and then working the blank 18 along the second axis 32 . As shown in FIG. 8, the pair of interconnected first and second pistons 10 ′, 10 ″ comprise interconnected first and second actuator arms 14 ′, 14 ″, first and second hollow piston bodies, 12 ′, 12 ″, first and second piston heads 16 ′, 16 ″ and first and connection rods 17 ′, 17 ″. For descriptive purposes, the first and second axes 30 , 32 referenced in FIGS. 2 and 3 correspond to the axes of working of the blank 18 within the die assembly 40 illustrated in FIGS. 4-7.
Referring again to FIGS. 4-7, the split die assembly 40 comprises a first stationary portion 42 , a second moveable portion 44 , a first punch 46 and a second punch 48 . The second portion 44 of the die assembly 40 moves relative to the first portion 42 along the first axis 30 while the first and second punches 46 , 48 move towards each other along the second axis 32 . The first portion 42 of the die assembly 40 includes a first die block 52 and the second portion 44 of the die assembly 40 includes a second die block 54 . The first and second die blocks 52 , 54 are aligned with each other and together form a cavity (not referenced) having a shape corresponding to the shape of the interconnected first and second actuator arms 14 ′, 14 ″. The first die block 52 is centered within the first portion 42 of the die assembly 40 and positioned between third and fourth die blocks 56 , 58 . Similarly, the second die block 54 is centered within the second portion 44 of the die assembly 40 and positioned between fifth and sixth die blocks 60 , 62 . As shown in FIG. 6, the third and fifth die blocks 56 , 60 are aligned with each other and together form a cavity 64 having a diameter corresponding to an outer diameter of the first hollow piston body 12 ′. Similarly, the fourth and sixth die blocks 58 , 60 are aligned with each other and together form a cavity 66 having a diameter corresponding to an outer diameter of the second hollow piston body 12 ″.
As shown in FIG. 5, the blank 18 is positioned over the first die block 52 within the first portion 42 of the die assembly 40 . Referring to FIG. 6, the second portion 44 of the die assembly 40 is aligned with the first portion 42 by a pair of guide posts (not shown) and moved towards the first portion 42 along the first axis 30 by a hydraulic press (not shown) thereby working the blank 18 between the first, second, third, fourth, fifth and sixth die blocks 52 , 54 , 56 , 58 , 60 , 62 . The interconnected first and second actuator arms 14 ′, 14 ″ are thus formed between the first and second die blocks 52 , 54 . The first and second hollow piston bodies 12 ′, 12 ″ are also partially formed within the cavities 64 , 66 as portions of the blank 18 within the cavities 64 , 66 are slightly rounded between the third, fourth, fifth and sixth die blocks 56 , 58 , 60 , 62 . However, it will be appreciated by those skilled in the art that the first and second hollow piston bodies 12 ′, 12 ″ can be formed without partially rounding or otherwise processing the portions of the blank 18 within the cavities 64 , 66 as the blank 18 is worked along the first axis 30 .
Referring now to FIG. 7, the first and second punches 46 , 48 are inserted into the cavities 64 , 66 and engage respective portions of the blank 18 . As illustrated in FIG. 7, the first and second punches 46 , 48 are inserted into the cavities 64 , 66 with the second portion 44 of the die assembly 40 fully engaged with the first portion 42 (i.e., with the die assembly 40 closed). The first and second punches 46 , 48 are driven towards each other along the second axis 32 by hydraulic presses (not shown). The first and second punches 46 , 48 work the respective portions of the blank 46 , 48 thereby causing the first and second hollow piston bodies 12 ′, 12 ″ to be back extruded over the punches 46 , 48 . A first portion 46 A of the first punch 46 has a diameter corresponding to the inner diameter of the first hollow piston body 12 ′ while a first portion 48 A of the second punch 48 has a diameter corresponding to the inner diameter of the second hollow piston body 12 ″. A second portion 46 B of the first punch 46 and a second portion 48 B of the second punch 48 each have a diameter corresponding to the diameter of each respective cavity 64 , 66 so as to maintain the proper position of each punch 46 , 48 within the die assembly 40 during the back extrusion process. It should be apparent that the thickness of the first and second hollow piston bodies 12 ′, 12 ″ is controlled by the diameters of the cavities 64 , 66 and the diameters of the first portions 46 A, 48 A of the first and second punches 46 , 48 .
As illustrated in FIG. 7, the first and second hollow piston bodies 12 ′, 12 ″ are completely formed once the first and second punches 46 , 48 are fully extended within the cavities 64 , 66 . As formed, the first actuator arm 14 ′ is axially aligned and integral with the first hollow piston body 12 ′ while the second actuator arm 14 ″ is axially aligned and integral with the second hollow piston body 12 ″ as the actuator arms 14 ′, 14 ″ and the piston bodies 12 ′, 12 ″ are formed from the same blank 18 of metallic material. The first and second punches 46 , 48 are removed from the cavities 64 , 66 and the second portion 44 of the die assembly 40 is disengaged from the first portion 42 exposing the interconnected first and second pistons 10 ′, 10 ″. The interconnected first and second pistons 10 ′, 10 ″ are forced out of the first portion 42 by pins 68 .
The interconnected first and second pistons 10 ′, 10 ″ are separated from each other, for example by sawing the actuator arms 14 ′, 14 ″ between the connection rods 17 ′, 17 ″. The piston heads 16 ′, 16 ″ are then welded to the first and second hollow piston bodies 12 ′, 12 ″, respectively thereby forming two separate pistons.
As shown in FIG. 9, the piston head 16 includes a base portion 70 having a button portion 72 extending from a first surface 16 A thereof and an annular ring 74 extending from a second surface 16 B thereof. A shoulder 16 C is formed between the annular ring 72 and the base portion 70 . The base portion 70 has a diameter corresponding to the outer diameter of the hollow piston body 12 while the annular ring 72 has an outer diameter corresponding the inner diameter of hollow piston body 12 . The shoulder 16 C of the piston head 16 thus engages the hollow piston body 12 with the annular ring 74 maintaining the orientation of the piston head 16 within the hollow piston body 12 prior to welding. The pistons are then machined as required.
It will be appreciated by those skilled in the art that the piston head 16 may be attached to the hollow piston body 12 using other suitable methods. In the illustrated embodiment, the piston head 16 comprises 6000 series aluminum. However, it will be appreciated by those skilled in the art that the piston head 16 may also comprise other suitable metals and alloys as required for a given application.
Having described the invention in detail and by reference to preferred embodiments thereof, it will be apparent that modifications and variations are possible without departing from the scope of the invention defined in the appended claims. | Variable displacement pistons are produced wherein hollow piston bodies are integrally formed with associated actuator arms to ensure proper alignment of the bodies and rods. The process utilizes a two-axis press to first form a pair of actuator arms by working a blank of metallic material along a first axis between opposing members of a die assembly. With the die assembly still closed after formation of the actuator arms, a pair of hollow piston bodies are formed by extruding the remainder of the blank of metallic material along a second axis. The hollow piston bodies are axially aligned and integrally formed with respective ones of the actuator arms. A piston head is welded to the end of each hollow piston body which is then machined. By separating the actuator arms from one another, a pair of variable displacement compressor pistons having hollow piston bodies axially aligned and integrally formed with respective actuator arms are thus formed. | 8 |
FIELD OF THE INVENTION
This invention relates to a method for producing a sterile, preservative-free, aerosol saline solution product for use by contact lens wearers, and more particularly to a method which utilizes a preservative together with means for converting the preservative into an inert substance which becomes the propellant of the aerosol product.
BACKGROUND OF THE INVENTION
Wearers of contact lenses, must regularly rinse their lenses with a saline solution prior to inserting the lenses for continued use. For example, contact lenses must be rinsed after subjecting the lenses to a variety of chemical disinfection regimens necessary to rid the lenses of pathogenic micro-organisms. The saline solution typically has the same isotonicity as human tears to minimize occular irritation in the user. Rinsing the lenses with a normal saline solution will wash away potentially harmful and irritating chemicals remaining on the lenses as a result of a disinfection regimen.
Contact lens users generally react unfavourably, by experiencing untoward reactions, to the presence of a variety of preservatives commonly used in contact lens solutions, including normal saline solutions. It is desirable therefore to be able to produce contact lens products, including normal saline solutions, which are sterile, yet free of preservatives. Such solutions must be sterile in order not to introduce harmful micro-organisms into the eyes of the contact lens user.
It is known in the prior art (see Giefer, U.S. Pat. No. 4,585,488 issued 29 Apr. 1986) to place a saline solution preserved with hydrogen peroxide into a container together with a disk coated with platinum. The platinum reacts (as a catalyst) with the hydrogen peroxide to cause this preservative to become inert by splitting it into water (H 2 O) and oxygen (O 2 ) gas. The complete reaction is as follows:
2H.sub.2 O.sub.2 +Platinum Catalyst→2H.sub.2 O.sub.2 +O.sub.2
The prior art method utilizing the above reaction involves the contact lens user adding the solution preserved with hydrogen peroxide to a non-sterile container, placing the platinum coated disk into the container, adding the contact lenses to the container and leaving the lenses to soak over night, so that by the next morning, the hydrogen peroxide will have been converted into inert water and the lenses will be soaking in pure saline solution. The contact lens user would then merely insert the lenses without risk of irritation from chemical preservatives. This prior art method is however, cumbersome, awkward and time consuming.
It is also known in the prior art to modify the aforesaid method by utilizing sodium pyruvate to decompose the hydrogen peroxide (see Houlsby, U.S. Pat. No. 4,521,375 issued 4 June, 1985). The sodium pyruvate reacts with the hydrogen peroxide to produce inert by-products including water and carbon dioxide.
It is further known in the prior art to fill an aerosol can with normal saline solution and a propellant, and then to subject the sealed aerosol can to terminal sterilization by irradiating it with gamma rays. This results in a sterile aerosol product containing normal saline solution, and free of any chemical preservatives. Such prior art aerosol products require the addition of a propellant, such as nitrogen, in order to achieve the pressure levels necessary for proper aerosol functioning. The disadvantages of such prior art irradiated aerosol products are several. Firstly, it is very expensive to conduct terminal sterilization by irradiation using gamma rays. Secondly, there are safety and hence political concerns relating to the use of radiation to sterilize products for use in the human body. Lastly, there are several practical problems related to the use of radiation, including the need to irradiate the aerosol product very shortly after the aerosol container has been filled and the fact that use of radiation on some chemicals will cause the chemicals to breakdown. This limits which chemicals may be used in such products to be sterilized by radiation.
An additional problem present in the prior art aerosol products relates to the difficulty in obtaining U.S. Federal Drug Administration approval for aseptic packaging of unpreserved solutions for ophthalmic use.
It is desirable to have sterile, preservative-free ophthalmic product in aerosol dispensing containers in order to maintain product sterility during use. Because the aerosol container is under pressure, there is minimal risk of micro-organisms being able to enter the sterile environment inside the aerosol can during its use. Ophthalmic solutions housed in plastic squeeze bottles may easily become contaminated during use, due to reflux action of the liquid during dispensing of the solution by the contact lens user. As a result of the aforesaid disadvantages, there is a need for an economical, safe and effective ophthalmic saline solution in aerosol packaging, which is free of chemical preservatives at the time of use of the solution by the contact lens wearer, without having been subjected to radiation exposure.
SUMMARY OF THE DISCLOSURE
In its broadest aspect, this invention teaches combining a preservative in an aerosol container with means for converting the preservative into an inert or inactive substance, which substance is suitable to act as the propellant of the aerosol product.
More particularly, this invention provides a method for producing a sterile preservative-free aerosol saline solution comprising; aseptically filling a pre-sterilized aerosol container with a saline solution preserved with sufficient hydrogen peroxide; aseptically introducing into the aerosol container means for converting the hydrogen peroxide into inert or inactive substances one of which is a suitable propellant; and sealing and storing the container for a time sufficient to complete the inactivation of the hydrogen peroxide and creation of the suitable propellant.
The invention is particularly applicable to making products for use by contact lens users including saline solutions. The invention is further applicable to the preparation of aseptic medicinal burn (or other medicinal) sprays and aerosol food products (where the food product is compatible with hydrogen peroxide). Still further the invention is applicable to the preparation of preservative-free cosmetic products in aerosol or atomizer type containers.
The means utilized for converting the hydrogen peroxide into inert by-products may be several. Preferred is the use of platinum which acts as a catalyst to convert the hydrogen peroxide into aqueous water and oxygen gas. Sufficient hydrogen peroxide must be used in order to provide acceptable preservation of the solution and furthermore to produce sufficient oxygen gas by-product to act as the propellant of the solution in the aerosol product. Also preferred is the use of catalase enzyme as the means for converting the hydrogen peroxide to inert substances.
Other means for converting the hydrogen peroxide to inert substances include the use of sodium pyruvate. When sodium pyruvate is used, the resulting propellant is carbon dioxide gas.
The invention also contemplates aerosol type products produced by the various method disclosed herein.
DETAILED DESCRIPTION OF THE INVENTION
In the most preferred embodiment the invention utilizes the following chemical reaction: :
2H.sub.2 O.sub.2 +Platinum Catalyst→2H.sub.2 O+O.sub.2
The hydrogen peroxide is aseptically added to the normal saline or other type of solution in a pre-sterilized aerosol type container which is often a can. The platinum catalyst may be utilized in a variety of forms including a disk coated with platinum and commercially available and known as they AO Disc (registered trade mark of CIBA Vision Corporation). Sufficient hydrogen peroxide must be added to obtain the desired preservation characteristics. Furthermore, sufficient hydrogen peroxide must be present to provide enough oxygen (or other suitable) gas to act as propellant of the ultimate aerosol product. Sufficient propellant must be present to expel, under pressure substantially the entire contents of the aerosol or other type of spray product. The platinum catalyst when employed as a platinum coated disc may be inserted into the aerosol container where it is free to move about the contents thereof when the container is agitated. As a catalyst, the platinum is utilized in the chemical reaction without contaminating the solution being the end product of the reaction resulting from the inactivation of the hydrogen peroxide.
Once all ingredient components have been added to the container, it is aseptically sealed and stored for a time sufficient to allow for both the inactivation of the hydrogen peroxide to be completed and the creation of sufficient propellant, all prior to use of the product by the contact lens wearer (as the case may be).
By way of examples set out hereinafter, there are variations of the method of the invention as well as calculations employed in determining quantities of preservative to be used.
EXAMPLE 1
When using catalase enzyme to inactivate the hydrogen peroxide, the following chemical reaction takes place:
2H.sub.2 O.sub.2 +Catalase Enzyme→2H.sub.2 O+O.sub.2
The catalase enzyme promotes the decomposition of the hydrogen peroxide to water and oxygen gas. Catalase enzymes are available from a variety of sources such as animals, plants, bacteria and fungi. Because catalase reacts immediately with hydrogen peroxide, when using catalase the following procedure is recommended. The can should be capped after being filled with hydrogen peroxide and normal saline (or other substance). Thereafter the catalase may be injected through the valve into the can preferrably using aseptic technique in a clean room.
EXAMPLE 2
When sodium pyruvate is employed in the performance of the method of the invention, the following chemical reaction occurs:
H.sub.2 O.sub.2 +CH.sub.3 COCO.sub.2 Na→CH.sub.3 CO.sub.2 Na+CO.sub.2 +H.sub.2 O
It will be apparent from the above chemical reaction, that the use of sodium pyruvate to inactivate the hydrogen peroxide results in the propellant being carbon dioxide gas instead of oxygen.
EXAMPLE 3
The following calculations illustrate the quantity of hydrogen peroxide required to pressurize an aerosol can containing saline solution.
assume that the can has an internal volume of 560 ml.
if the can is filled with 360 ml of solution, the resulting headspace will be 200 ml.
assume that the oxygen produced by the decomposition of peroxide behaves like an ideal gas.
therefore by the ideal gas law.
PV=nRT
where P=pressure (atmospheres)
V=volume (cm 3 )
n=amount of gas (gram moles)
T=temperature (Kelvins)
R=gas constant - 82.05 ##EQU1## assuming the following conditions: V=200 ml
P=90 psig (6.12 atm)
T=20° C. (293° K.)
by the ideal gas law, n=0.0509 g.moles of oxygen.
based on the stochiometry of the reaction, the required amount of hydrogen peroxide is 0.102 g.moles; this converts to 3.46 g of hydrogen peroxide.
typically, the hydrogen peroxide is in a 35% w/v solution.
therefore the required volume of solution is 9.9 ml.
This calculation has shown that in order to pressurize a can to an internal pressure of 90 psig at 20° C., 9.9 ml of 35% (w/v) peroxide solution should be added to the saline solution.
Experiments have shown that these calculations are an accurate representation of the actual reaction.
Presently the only unpreserved contact lens solutions marketed are either blow fill sealed or are subjected to terminal sterilization by irradiation. The blow fill sealed technique is currently used for aseptically packaged unpreserved solutions since the process involves no human intervention. When using terminal sterilization, the product is not aseptically filled but rather the packaged product is subjected to sterilization by irradiation with gamma rays which will destroy all microbiological activity.
In a conventional bottle filling operation, human intervention in a clean room prevents FDA approval of packaging aseptically unpreserved solutions.
The method of the instant invention has overcome the prior art problems by utilizing the method of the invention as hereinbefore described.
The instant invention contemplates not only the method described herein, but in addition contemplates the end product, namely a preservative free aerosol product when prepared by the method described.
It will be apparent to those skilled in the art that other catalysts or reducing agents, beyond those mentioned herein, may be utilized in the working of this invention.
Furthermore, it should be noted that this invention has application beyond the preparation of contact lens solutions. For example, burn products are preferred in aerosol form, in order to provide uniform and painless application to the burn area. Using the methods of the instant invention, it is possible to provide a sterile, preservative-free aerosol burn spray as follows:
Medicament+2H.sub.2 O.sub.2 +Platinum Catalyst→2H.sub.2 O+O.sub.2 +Medicament
The method of the instant invention has further application to food products. Utilizing the invention it is possible to incorporate food products compatible with hydrogen peroxide into an aerosol or other spray type container. After the hydrogen peroxide has been inactivated by a catalyst or reducing agent, the food product may be sprayed from the container and incorporated into other foods or directly consumed by humans, for example, in accordance with the following chemical reaction:
2H.sub.2 O.sub.2 +catalyst or +compatible→2H.sub.2 O+O.sub.2 +food
reducing agent food
Many users of cosmetic products suffer allergic (dermatological reactions) to ingredients of such products including preservatives. Using the methods of the instant invention, it is possible to provide a sterile, preservative-free cosmetic spray product. An example of such a reaction follows:
2H.sub.2 O.sub.2 +catalyst+compatible cosmetic→2H.sub.2 O+O.sub.2 +cosmetic
It should further be obvious to those skilled in the art that such aerosol products need not be restricted to substances conventionally regarded as "solutions", but rather may include, foams, a variety of emulsions or any other liquid or semi-liquid composition compatible with an aerosol or other spray type of product.
It will also be obvious to those skilled in the art that the invention herein may also work with preservatives other than hydrogen peroxide, as long as such preservatives are capable of reaction to inert substances one of which is a propellant. | Described is a method, and resulting product, for producing a sterile preservative-free areosol contact lens solution comprising; aseptically filling a pre-sterilized aerosol container with a contact lens solution preserved with sufficient hydrogen peroxide; aseptically introducing into the container means, such as a catalyst, for converting the hydrogen peroxide into inert or inactive substances one of which is a suitable propellant; and sealing and storing the container for a time sufficient to complete the inactivation of the hydrogen peroxide and creation of the suitable propellant. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Taiwan Patent Application No. 102100988, filed on Jan. 10, 2013, in the Taiwan Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a measuring system, in particular to an image-based diopter measuring system.
[0004] 2. Description of the Related Art
[0005] Currently, the applications of the diopter are relatively extensive, for example, a sugar meter that measures the juice sweetness or measures the water salinity that both may use the diopter principle. The conventional sugar refractive index meter or the diopter in circulation such as the refractometers disclosed by Republic of China Patent D111526 or D127363. The refractometer is basically a round pipe body that a duckbill shaped portion of the front end is a measure end, which having a head shaped lift cover and having a rectangular lens therein, the round pipe body may drop the liquid into the lens, and the intermediate round pipe body is a gripping portion, the terminal end is a drum-shaped eyecup end, which may view the scale on the lens to know the predicting refractive index or the concentration. In the conventional technology, the user has to visually interpret the scale on the lens by the eye, so as to know the predicting refractive index and the concentration of the predicting analyte. In the long-term use of the environment, it is easy to cause the occupational injury for the user's eyes.
[0006] In addition, the sugar detection meter in the Republic of China Patent M398117 and the juice sweetness detection device in the Republic of China Patent M395161, are arranged for measuring the diopter by the optical manner. However, the sugar detection meter uses the grating spectrometer parts and the infrared detection element architecture, which lead to the complexity of the system design and costly. Therefore, it is more complex in manipulation and the higher cost is the biggest deficiency while using such type of meter.
SUMMARY OF THE INVENTION
[0007] In view of the drawbacks of the prior art, one object of the present invention is to provide an image-based dipoter measuring system comprising at least an optical device and an electronic device. The optical device may guide an external light passed through an analyte. The electronic device comprises an image capture module, an image analyze module and a display module. The image capture module may generate a first image by capturing the external light source. The image analyze module is connected to the image capture module, and may receive the first image and analyze the first image in order to generate an analytical result comprising a diopter of the analyte. The display module is connected to the image analyze module, and may receive and display the analytical result. Wherein, the optical device is detachably engaged to the electronic device, so as to guide the external light into the image capture module.
[0008] Preferably, the image analyze module may include a pixel conversion unit, a contrast line space coordinate detection unit, a contrast line space-parameter space coordinate conversion unit, a full-pixel parameter space coordinate comparison unit, a contrast line slant angle determining unit, and a diopter control unit. The pixel conversion unit may convert the first image in order to obtain a second image via a pixel conversion formula. The contrast line space coordinate detection unit is connected to the pixel conversion unit, and may analyze the second image in order to obtain a gradient value G of each pixel point (x,y) in the second image, and may determine at least one the pixel point (x,y) to be a contrast line characteristic point when the gradient value G of the pixel point (x,y) is greater than a threshold value K, and calculate an average value of each coordinate of all the contrast line characteristic points in the second image to obtain a contrast line of the second image and a contrast line space coordinate thereof. The contrast line space-parameter space coordinate conversion unit is connected to the contrast line space coordinate detection unit, and may convert all the contrast line characteristic points into a plurality of parameter space coordinate mapping curves according to a coordinate converting formula. The full-pixel parameter space coordinate comparison unit is connected to the contrast line space-parameter space coordinate conversion unit, and may accumulate the parameter space coordinate mapping curves by an accumulator in order to obtain a maximum parameter space coordinate of the parameter space coordinate mapping curves in a polar coordinate, so as to obtain a slant angle of the contrast line. The contrast line slant angle determining unit is connected to the full-pixel parameter space coordinate unit, and may determine whether the slant angle is smaller than a default value predetermined by the contrast line slant angle determining unit. When the slant angle is smaller than the default value, the diopter of the analyze is obtained by a diopter control unit according to a correspondence base of contrast line space coordinate and the diopter, and when the slant angle is greater than the default value, the display module generates a reminding signal.
[0009] Preferably, a color signal of the first image may be converted to a grayscale signal by the pixel conversion formula in order to obtain the second image, the pixel conversion formula is in compliance with following equation: gr=0.299*Ri+0.587*Gi+0.114*Bi; wherein, Ri, Gi and Bi are color gradation values of red, green and blue respectively in the first image, gr is a grayscale value in the second image, the grayscale value may range from 0 to 255.
[0010] Preferably, a convolution calculation is conducted to each pixel point (x,y) in the second image with a horizontal Sobel operation mask (Mask_i) and a vertical Sobel operation mask (Mask_j), respectively, by the contrast line space coordinate detection unit in order to obtain a horizontal gradient strength (Gi) and a vertical gradient strength (Gj) of each pixel) point (x,y), the gradient value satisfies G=√{square root over ((G i ) 2 +(G j ) 2 )}{square root over ((G i ) 2 +(G j ) 2 )}.
[0011] Preferably, the coordinate conversion formula is in compliance with the following equation: r=x cos θ+y sin θ; wherein, r is a distance between any pixel point (x,y) and pole of the polar coordinate, θ is an angle between a polar axis and the line segment of the pixel point (x, y) and the pole of the polar coordinate.
[0012] Preferably, the optical device comprises a prism base, a transparent window, a prism capable of producing a full reflection, an adapter lens, a coupling element, and a lens barrel. The prism base includes an accommodating space therein. The transparent window may be obliquely laminated on one side of the prism base. The prism may be disposed in the accommodating space of the prism base and laminated obliquely on the transparent window. A side of the adapter lens may face to a terminal face of the prism. The coupling element may be disposed as facing the adapter lens near an opposite side of the terminal face of the prism. The lens barrel is a hollow structure, and may female joint the prism base to substantially accommodate the prism, the adapter lens and the coupling element. Wherein, the optical device is detachably engaged to the electronic device may through the coupling element.
[0013] Preferably, the coupling element may be a magnetic component.
[0014] Preferably, the electronic device may further comprise a sound reminding module that issues a high-frequency sound signal and a low-frequency sound signal respectively according to the comparison between a reference value and the diopter.
[0015] Preferably, the sound reminding module issues the high-frequency sound signal when the diopter is higher than a reference value or the sound reminding module issues the low-frequency sound signal when the diopter is not higher than the reference value.
[0016] The image-based diopter measuring system according to the present invention may have the following advantages:
[0017] According to the image-based diopter measuring system of the present invention, the optical device only needs to be simply disposed in the electronic device that having an image capturing function, and the dioptor of the analyte would be quickly and accurately obtained by the image processing manner, which not only reduces the manufacturing costs, but also does not require complex steps, and greatly enhances the simplicity of use for the user.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a first schematic diagram of the image-based diopter measuring system according to the present invention.
[0019] FIG. 2 is a second schematic diagram of the image-based diopter measuring system according to the present invention.
[0020] FIG. 3 is a third schematic diagram of the image-based diopter measuring system according to the present invention.
[0021] FIG. 4 is a flow diagram of the image-based diopter measuring system according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] With reference to FIG. 1 and FIG. 2 , in which FIG. 1 is a first schematic diagram of the image-based diopter measuring system and FIG. 2 is a second schematic diagram of the image-based diopter measuring system according to the present invention. As show in FIG. 1 , the image-based diopter measuring system 1 of the present invention includes an optical device 10 and an electronic device 20 . As show in FIG. 2 , the electronic device 20 includes an image capture module 200 , an image analyze module 210 , and a display module 220 . The optical device 10 includes a prism base 100 , a transparent window 110 , a prism 120 capable of producing total internal reflection, an adapter lens 130 , a coupling element 140 , and a lens barrel 150 . Wherein, with the prism base 100 having an accommodating space therein, the transparent window 110 may be obliquely laminated on one side of the prism base 100 , the prism 120 may be disposed in the accommodating space of the prism base 100 and laminated obliquely on the transparent window 110 , a side of the adapter lens 130 may face to a terminal face 1202 of the prism 120 , the coupling element 140 may be disposed to face the adapter lens 130 near an opposite side of the terminal face 1202 of the prism 120 . The lens barrel 150 may be a hollow structure, and may joint to the prism base 100 to substantially accommodate the prism 120 , the adapter lens 130 and the coupling element 140 . In addition, the optical device 10 is detachably engaged to the electronic device 20 may through the coupling element 140 , the coupling element 140 may be a magnetic component.
[0023] It is worth noting that the electronic device 20 may further include a sound reminding module 230 that issues a high-frequency sound signal and a low-frequency sound signal respectively according to the comparison between a reference value and the diopter.
[0024] Wherein, the sound reminding module 230 issues the high-frequency sound signal when the diopter is higher than a reference value or the sound reminding module 230 issues the low-frequency sound signal when the diopter is not higher than the reference value.
[0025] With reference to FIG. 3 , in which a third schematic diagram of the image-based diopter measuring system according to the present invention is depicted. As show in FIG. 3 , the image analyze module 210 may include a pixel conversion unit 2100 , a contrast line space coordinate detection unit 2110 , a contrast line space-parameter space coordinate conversion unit 2120 , a full-pixel parameter space coordinate comparison unit 2130 , a contrast line slant angle determining unit 2140 , and a diopter control unit 2150 . The pixel conversion unit 2100 may convert the first image in order to obtain a second image via a pixel conversion formula. The contrast line space coordinate detection unit 2110 is connected to the pixel conversion unit 2100 , and may analyze the second image in order to obtain a gradient value G of each pixel point (x,y) in the second image, and may determine the pixel point (x,y) to be a contrast line characteristic point when the gradient value G is greater than a threshold value K, and calculate an average value of a coordinate of all the contrast line characteristic points in the second image to obtain a contrast line of the second image and a contrast line space coordinate thereof. The contrast line space-parameter space coordinate conversion unit 2120 is connected to the contrast line space coordinate detection unit 2110 , and may convert all the contrast line characteristic points into a plurality of parameter space coordinate mapping curves according to a coordinate converting formula. The full-pixel parameter space coordinate comparison unit 2130 is connected to the contrast line space-parameter space coordinate conversion unit 2120 , and may accumulate the parameter space coordinate mapping curves by an accumulator in order to obtain a maximum parameter space coordinate of the parameter space coordinate mapping curves in a polar coordinate, so as to obtain a slant angle of the contrast line. The contrast line slant angle determining unit 2140 is connected to the full-pixel parameter space coordinate unit 2130 , and may determine whether the slant angle is smaller than a default value predetermined by the contrast line slant angle determining unit 2140 . When the slant angle is smaller than the default value, the diopter of the analyte is obtained by a diopter control unit 2150 according to a correspondence base of contrast line space coordinate and the diopter, and transmit to the display module 220 . When the slant angle is greater than the default value, the display module 220 may generate a reminding signal, so as to remind users whether the linkage between the optical device 10 and the electronic device 20 is deflected. That is, if the slant angle is greater than the default value, users are reminded to adjust the detachably optical device 10 , and to recapture the image.
Embodiment
[0026] With reference to FIG. 4 , in which a flow diagram of the image-based diopter measuring system according to the present invention is depicted. In the figure, first, the user switches on the image capture module 200 of the electronic device 20 to capture the light passing the analyte which is disposed in the optical device 10 , and gather the external light via the analyte to generate the first image. The first image is a color two-dimensional image g(x,y) received by the image analyze module 210 which includes RGB three color components. A second image may be obtained after the image analyze module 210 executes the image pixel color conversion by a pixel conversion formula. The second image is a grayscale image h(x,y), the grayscale value is ranged from 0 to 255 . After the image pixel color conversion is completed, the grayscale image is entered into the contrast line space coordinate detection unit 2110 . The contrast line space coordinate detection unit 2110 conducts a convolution calculation with a horizontal Sobel operation mask (Mask_i) and a vertical Sobel operation mask (Mask_j), respectively, in order to obtain a horizontal gradient strength (Gi) and a vertical gradient strength (Gj) of each pixel point (x,y), the gradient value satisfies G=√{square root over ((G i ) 2 +(G j ) 2 )}{square root over ((G i ) 2 +(G j ) 2 )}. The largest pixel point of the gradient strength G is the image edge and is also the pixel point of the contrast line.
[0027] It is worth noting,
[0000]
Mask_i
=
[
1
2
1
0
0
0
-
1
-
2
-
1
]
,
Mask_j
=
[
-
1
0
1
-
2
0
2
-
1
0
1
]
.
[0028] Wherein, the horizontal gradient strength satisfies Gi=Mask_i*h(x,y), the vertical gradient strength satisfies Gj=Mask_j*h(x,y). If the threshold value K is a positive number and when the gradient value G of the image is smaller than the threshold value K, it is indicated that the device is abnormal. The user is informed that the check status is entered, the user checks whether the analyte is invalid or malfunction of other devices and re-capture images. When the gradient value G is larger than the threshold value K, the pixel points with the gradient value G larger than the threshold value K are regarded as contrast line characteristic points. An average value of the coordinate of all the contrast line characteristic points in the second image is calculated in order to obtain a contrast line of the second image and a contrast line space coordinate thereof to finish the determining of the contrast line and the mark of the position coordinate in the contrast line.
[0029] After the determination of the edge of the image contrast line and the mark of the contrast line position coordinate are completed, the process of conversion from the image contrast line space coordinate to the parameter space coordinate is performed. The contrast line space-parameter space coordinate conversion unit 2120 is arranged for converting all the contrast line characteristic points into a plurality of parameter space coordinate mapping curves according to a coordinate converting formula. The coordinate conversion formula is in compliance with the following equation: r=x cos θ+y sin θ; wherein, r is a distance between any pixel point (x,y) and the pole of the polar coordinate, θ is an angle between a polar axis and the line segment of the pixel point (x, y) and the pole of the polar coordinate.
[0030] If there is a tilt angle between the detachably optical device 10 and the electronic device 20 , the contrast line of the analyte in the first image would also be skew. If the skew is more than the certain angle value, it represents that the optical device 10 and the electronic device 20 is overly tilt and the correctness of the measure of the refractive value may be affected. Therefore, the contrast line space-parameter space coordinate conversion unit 2120 may draw a parameter space coordinates mapping curve according to each characteristic point, and the full-pixel parameter space coordinate comparison unit 2130 is arranged for accumulating the parameter space coordinate mapping curves by an accumulator. That is, in the full-pixel parameter coordinate image, each pixel parameter coordinate Ii(r, θ) of each pixel all in the pixel space size may be checked and aligned one-by-one. If each pixel parameter coordinate Ii(r, θ) is not a maximum parameter space coordinate I MAX (r MAX , θ MAX ), the process will be skipped to the next point (I=I+1, the initial value of I is 1) to continue checking. If the pixel parameter coordinate Ii(r, θ) is the maximum parameter space coordinate (MAX), the pixel parameter coordinate Ii(r, θ) of the maximum parameter space coordinate (MAX) is firstly stored, and the next point (I=I+1) would be checked until each pixel parameter coordinate Ii(r, θ) of all pixels in the pixel space size in order to obtain the maximum parameter space coordinate I MAX (r MAX , θ MAX ) which is an intersection of the parameter space coordinates mapping curve. The θ MAX in the maximum parameter space coordinate I MAX (r MAX , θ MAX ) is a maximum slant angle. Wherein, the initial value of the maximum parameter space coordinate I 0 (r 0 , θ 0 ) is 0.
[0031] It is worth noting that the contrast line slant angle determining unit 2140 may determine whether the slant angle is smaller than a default value. If the slant angle is smaller than the default value, the diopter of the analyte is obtained by the diopter control unit 2150 according to a correspondence base of the contrast line space coordinate and the diopter, and the diopter is generated by the display module 220 . On the contrary, the display module 220 will be generating a reminding signal to remind the user that the detachably optical device 10 should be adjusted and the image recaptured.
[0032] It is worth noting that the described above embodiment used the electronic device with a color image sensor, if the diopter measuring system is implemented with the electronic device with a black-and-white image sensor, that would not exceed the scope of the present invention. The diopter in the present invention may be utilized to detect the concentrations may be sugar content, sweetness or salinity.
[0033] While the means of specific embodiments in present invention has been described by reference drawings, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope and spirit of the invention set forth in the claims. The modifications and variations should in a range limited by the specification of the present invention. | An image-based diopter measuring system comprises an optical device and an electronic device. The optical device is used to guiding an external light which is passed through an analyte. The electronic device comprises an image capture module, an image analyze module and a display module. The image capture module generates a first image by capturing the external light source. The image analyze module connects to the image capture module to receive the first image, and analyzes the first image in order to generate an analytical result comprising the diopter of the analyte. The display module connects to the image analyze module to receive and display the analytical result. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to improvements in dryer drums for paper making machines, and more particularly to an improved mechanism for removing the water condensate which forms on the inner surface of the drum shell from condensing steam and which reduces the heat transfer from the steam within the shell to the surface of the shell for drying a traveling fibrous web.
In a drying drum for a paper making machine, the mechanism includes a cylindrical shell with heads that have shafts for rotational mounting of the drum. A steam supply gland is provided to direct heated steam into the interior of the drum and generally dipper tubes or straws are positioned adjacent the inner surface of the drum to remove condensate which forms against the drum. In the formation of a relatively wide web of paper, the length of the drums has to be substantial, and it is essential for uniform drying that the drum have uniform heat along its length. Since the layer of condensate which forms within the drum reduces heat transfer from the steam to the metal of the drum shell, it is essential that this condensate layer be maintained as thin as possible, but more importantly, that it may be maintained of uniform thickness because if nonuniformity exists, different rates of heat transfer will exist along the length of the drum resulting in temperature differences and differences in dryness of the paper web along its width.
It is accordingly an object of the present invention to provide a means for removing a maximum amount of rimming condensate and removing it very uniformly to maintain a uniform thickness layer and to avoid the adverse effects of heat expansion and contraction which change the spacing between the condensate removal means and the inner surface of the drum shell.
Drying drums for paper making machines are often provided internally with narrow circumferential grooves spaced axially along the inner surface of the shell to leave a series of ribs or lands therebetween. These ribs strengthen the relatively thin shell of the dryer drum, and permit the safe use of a significantly thinner shell through which heat transfer is improved with a consequent increase in efficiency of the drying action on the paper or other web. Condensate is removed from within such drying cylinders through one or more header tubes carrying a plurality of dipper pipes or straws extending into the grooves and drawing off the condensate as it collects in such grooves.
It has been found that, with wide machines having axially long drying cylinders, uneven moisture profiles of the dried web are often present, due to an uneven drying effect across the width of the machine. This uneveness is undesirable, particularly in thin webs, such as tissues, and it is believed that it results from uneven extraction of the condensate due to distortion of the dipper-carrying, condensate-removal header pipes. If, as is generally the case, these pipes are of substantial length, extending across substantially the full axial length of the cylinder, there is a tendency for them to distort locally when hot, and their spacing relative to the inner periphery of the cylinder shell to vary across the width of the cylinder. In this way the positioning of the dipper tubes or straws within the grooves varies, and hence condensate removal through these tubes may vary across the cylinder, producing temperature gradients across the smooth outer drying surface of the cylinder. Attempts to minimize this disadvantage by altering the lengths of the dipper tubes or straws has proved unsuccessful as the temperature gradient across the cylinder may vary according to running conditions of the machine.
The present invention seeks to obviate or reduce the aforementioned difficulty by maintaining the setting distance between the end of each dipper and the inner surface of its associated groove in the shell of the dryer thereby to achieve an even depth of condensate layers. This is achieved by splitting the dipper-carrying tubes into several individual sections, each serving a part-only of the condensate removal across the width of the cylinder, whereby any distortion is minimized.
According to the present invention the dipper tubes or straws across the or each condensate collection region within an internally grooved drying cylinder are carried from a plurality of individual short header tubes which together extend across substantially the whole axial width of the cylinder at said collecting region, the individual short header tubes being connected to one or more common header pipes arranged to lead condensate away from the individual short header tubes into a condensate discharge.
Conveniently the short header tubes are slightly staggered across the width of the cylinder at the or each collection region to facilitate mounting of the tubes while still ensuring that each groove across the region has a dipper tube or straw projecting therein.
Preferably the connections between each short header tube and the common header pipe are flexible, and this eliminates or reduces problems resulting from expansion of the tubes and pipes.
The short header tubes are fastened to the shell locally and hence are able to follow changes in the shape of the dryer resulting from the application of a wet sheet thereto which tends to cause distortion of the dryer especially at the ends. With this local fastening it is possible to maintain the same accurate setting distance of the dipper tubes or straws within their respective grooves. An additional advantage stems from the use of separate common header pipes because flooding of the header in the vicinity of the riser tubes is thereby avoided.
By using a plurality of short header tubes overall manufacture is less exacting inasmuch as accurate location of the dipper tubes or straws within the grooves is less difficult with the short sections than with a single long length. Moreover, the use of short sections of header tube enables internal erosion plates to be changed without removing the headers from the shell.
While the above discussion relates primarily to dryer cylinders or drums which have grooves on the inner surface, the concepts of the invention apply equally to drums which have a smooth inner surface inasmuch as the objective must be to maintain uniform heat transfer from the steam to the metal of the drum shell at all axial locations and to maintain this by maintaining a uniform thickness of condensate at all axial locations along the drum length. It is an object of the present invention to provide a condensate removal means which is so constructed that heat expansion and contraction of the parts will not cause axial displacement of the condensate removal means either axially or radially relative to the drum surface.
It is a further object of the invention to provide an improved mechanism which provides dipper straws with open condensate receiving ends adjacent the inner surface of the shell of a dryer drum wherein the straws are individually divided, or divided in groups, which individual straws or groups are rigidly positioned relative to the inner surface of the shell so that heat expansion of the individual straws or individual groups along a relatively long length of dryer drum does not displace the straws or groups of straws so as to change their effective location with respect to their ability to remove condensate.
Other objects, advantages and features, as well as equivalent structures which are intended to be covered herein, will become more apparent with the teaching of the principles of the invention in connection with the disclosure of the preferred embodiments thereof in the specification, claims and drawings, in which:
DRAWINGS
FIG. 1 is a diagrammatic plan view of the inside of a dryer cylinder shell provided with an arrangement according to the invention;
FIG. 2 is a similar schematic view taken along the line II--II of FIG. 1;
FIG. 3 is an end view along a dryer cylinder shell fitted with an arrangement according to the invention;
FIG. 4 is a plan view taken along the section line IV--IV of FIG. 3;
FIG. 5 is a fragmentary section taken along the line V--V of FIG. 3;
FIG. 6 is a view taken along the line VI--VI of FIG. 4; and
FIG. 7 is an enlarged detail showing a short header tube with associated dipper tubes located in a groove of the shell.
DESCRIPTION
In FIG. 5 a portion of a dryer drum, which also may be referred to as a dryer cylinder, is shown with an outer annular shell 10 with heads 32 and 33. The shell has a smooth outer surface 41 and the inner surface 42 has a series of circumferentially extending ribs with grooves 12 therebetween.
The heads 32 and 33 have hubs, not shown, and one of the hubs is provided with a steam inlet fitting for supplying heated steam, indicated by the label "Steam Delivery", to the interior of the drum for heating the shell, and a condensate outlet fitting will also be provided to lead the condensate being removed out through the drum end.
With a very long drum, slight deflection along the length can occur. With the present structural arrangement, an objective is to isolate the condensate removal conduit means leading out through a hub from the small dipper tubes or straws which perform the removal adjacent the inner surface of the shell so that the individual straws retain a fixed position in a radial direction and a fixed position in an axial direction. The straws or tubes have an open outer end and it is essential that the open outer ends of each of the straws remain at the same distance from the inner surface of the drum for throughout its axial length whether it is smooth or grooved (the drawing showing a grooved inner surface). If any of the tubes along the length change in distance from the inner surface of the shell, a change will occur in the thickness of the layer of condensate which will result in a change in temperature of the outer surface of the shell.
It is equally important when a grooved drum is used that the individual straws retain their fixed relative axial position so that they do not rub on the side of the grooves.
Referring to FIG. 1, the internal grooves of a shell 10 have not been shown for the sake of clarity although they are indicated by the reference 12 in FIG. 2. Dipper tubes or straws 14 depend from a plurality of short header tubes 16 each of which is flexibly connected at 18 to a common header pipe 20. As more clearly seen in FIG. 2 the individual dipper tubes or straws 14 are located within grooves 12 formed in the internal surface of the shell 10 so that their inlets are located in the region in which the condensate collects when the dryer is in operation.
A practical arrangement of the invention is shown in FIGS. 3 to 7 and here again it will be seen that the individual dipper tubes 14 are carried from a plurality of short header tubes 16 which are flexibly connected at 18 to common header pipes 20. In turn these header pipes 20 are connected to riser pipes 22 into a condensate discharge 24 extending through the cylinder and leading away out of the cylinder through the usual seals through the hub of the drum.
As can be clearly seen in FIGS. 6 and 7 the dipper tubes or straws 14 extend into the grooves 12 of the shell 10 and carry the condensate away through systems 20, 22 and 24, normally as a result of an increased pressure existing within the drying cylinder. Because each short header tube 16 extends only partially across the width or axial length of the cylinder it is not susceptible to deformation as it would be if it extended across the whole width and consequently the positioning of the dipper tubes 14 within the grooves 12 is maintained and a constant heat gradient across the surface of the roll in the region of condensate collection is maintained. Moreover, because the common header pipe or conduit 20, extending substantially across the entire width of the cylinder, is joined to the short header tubes 16 by flexible connections 18, any deformation or misalignment of pipe 20 is not transmitted to the tubes 16. The individual short header tubes 16 are held in position by means of clamps 26 and securing brackets 28.
It will be seen that the number and location of the short header tubes 16 (FIG. 4) is such that there is a slight overlap between the ends thereof thereby ensuring that there is a dipper tube provided at each condensate collection region for each groove. From FIGS. 3 and 4 it will be seen that each collection region is provided with two common header pipes at spaced locations subtending an arcuate angle of about 45° and normally four such locations would be provided around the drying cylinder. The short header tubes 16 carried by one of these pipes 20 provide dipper tubes or straws 14 for each alternate groove 12 (FIG. 6), while the short header tubes 16 of the other pipe 20 provide those for the remaining grooves so that each groove has one tube at each of the four locations. As will be seen from the drawings, each dipper straw is initially adjustable in a radial direction so that its open end will be at a fixed dimension from the surface of the bottom of the groove. Once this adjustment is made, because its header is firmly clamped in position, it will retain that position to maintain the predetermined uniform thickness of condensate at the bottom of the groove.
The whole of the condensate removal system described is secured to the inner face of the cylinder and rotates with it.
Thus, it will be seen that I have provided an improved dryer drum assembly and condensate drainage arrangement which meets the objectives and advantages above set forth and provides for uniform temperature along the length of the dryer drum and improvement in the paper web product produced. | A dryer drum for a paper making machine with a shell and end heads and steam delivery means and a plurality of headers extending axially and uniformly circumferentially spaced a relatively short length each carrying a row of dipper straws projecting adjacent the inner surface of the shell with the headers fixed to the shell surface and flexible tubes connecting the headers to a main conduit for removal of the condensate. | 3 |
This application claims the benefit of the Korean Patent Application Nos. 10-2005-0057734 and 10-2005-0057735, filed on Jun. 30, 2005, which are hereby incorporated by reference as if fully set forth herein.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a washer, and more particularly, to a drum type washer. Although the present invention is suitable for a wide scope of applications, it is particularly suitable for a lift having an improved structure.
2. Discussion of the Related Art
Generally, a drum type washer is a device that washes a laundry by rotating a drum by a drive force of a motor while a detergent, water and laundry are put in the drum. The drum type washer is advantageous in causing little damage to the laundry, preventing the laundry from being raveled and bringing washing effects of beating and rubbing.
A drum type washer according to a related art is explained in detail with reference to FIGS. 1 to 3 as follows.
FIG. 1 is a cross-sectional diagram of a drum type washer according to a related art, FIG. 2 is a perspective diagram of a drum of the drum type washer shown in FIG. 1 , and FIG. 3 is a perspective diagram of a lift installed on an inner surface of the drum shown in FIG. 2 .
Referring to FIG. 1 , a drum type washer according to a related art consists of a body 1 having a laundry entrance provided to its front side, a door 2 provided to the body 1 to open/close the laundry entrance, a tub 3 provided within the body to store water therein, a motor assembly 4 installed at the tub 3 to generate a drive force, a washing shaft connected to the motor assembly 4 , and a drum 6 connected to the washing shaft 5 to wash a laundry by the drive force transferred from the motor assembly 4 .
The tub 3 is supported by a damper (not shown in the drawing) and a spring (not shown in the drawing). The damper and spring play a role in attenuating a vibration generated from the rotations of the motor assembly and drum 4 and 6 .
The motor assembly 4 adopts an indirect drive mechanism for rotating the drum 6 by transferring the drive force generated from a motor to the washing shaft 5 via a belt or a direct drive mechanism for rotating the drum 6 by transferring the drive force generated from the motor to the washing shaft 5 directly.
The drum 6 is made of a stainless steel based material. A spider 8 is provided to a closed rear lateral side of the drum 6 to reinforce solidity of the rear lateral side of the drum 6 . And, the washing shaft 6 is joined to a rotational center of the spider 8 .
The spider 8 is formed by die-casting to prevent the drum 6 from being torn or transformed by the rotation of the washing shaft 5 . In particular, a portion of the rear lateral side of the drum 6 , where the spider 8 is installed, is inwardly projected to further reinforce the solidity of the drum 6 .
Referring to FIG. 2 , at least one lift 7 is provided to an inner surface of the drum 6 to be almost parallel with the washing shaft 5 .
In this case, the at least one lift 7 is built in the drum 6 to expose one portion of a washing ball 7 a that will be rotated by coming into contact with a laundry. And, the washing ball 7 a is formed of a ceramic based material to facilitate its rotation in being embedded in the lift 7 .
A bottom part of the lift 7 , as shown in FIG. 1 and FIG. 2 , is fixed to the drum 6 by at least one locking member 7 b fitted into an outer circumference of the drum 6 .
And, a rear end part of the lift 7 is fixed to the portion of the rear lateral side of the drum 6 at which the spider 8 is installed.
The above-configured drum type washer performs a washing work by executing a series of a washing cycle, a rinsing cycle and a dewatering cycle in sequence.
And, the washing, rinsing or dewatering cycle can be selectively carried out according to a user's selection.
Moreover, it is understandable that a laundry can be washed in various ways according to its type.
Once the drum type washer executes the washing cycle, the drum 6 is rotated at a low speed centering around the washing shaft 5 by the drive force transferred from the motor assembly 4 .
In doing so, the laundry is lifted up while the lift 7 rotates to arrive at a prescribed height. The laundry then falls down after arriving at the prescribed height. Thus, the lift 7 repeats a process of lifting the laundry to fall in rotating the drum 6 during a prescribed time. This process enables the laundry to be washed.
Once the drum type washer executes the dewatering cycle, the drum 6 rotates at a high speed centering on the washing shaft 5 . In doing so, the laundry accommodated within the drum 6 is dewatered by a centrifugal force.
However, the related art drum type washer has the following problems.
First of all, the lift, as shown in FIG. 1 , is fixed to the drum by fitting the locking member in the outer circumference of the drum. So, in case that the washing ball formed of the ceramic based material is broken, the drum needs to be completely dissembled from the tub and the motor assembly to replace the broken washing ball.
So, the drum type washer needs to be sent to a manufacturer or service center for the replacement of the broken washing ball, whereby a transport cost, a repair cost and a repair time increase.
Secondly, the difficulty in replacing a trivial part may reduce user's reliance on a product.
SUMMARY OF THE INVENTION
Accordingly, the present invention is directed to a drum type washer that substantially obviates one or more problems due to limitations and disadvantages of the related art.
An object of the present invention is to provide a drum type washer, by which a replacement of a washing ball provided to a lift is facilitated.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
To achieve these objects and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, a drum type washer according to the present invention includes a tub, a drum rotatably provided within the tube, and a lift provided within the drum, the lift including a base part detachably assembled to an inner surface of the drum and a cover part detachably assembled to the base part to enable a replacement of a washing ball, wherein an exposing hole is provided to a surface of the cover part to expose a portion of the washing ball and wherein a width of the cover part is decreased toward a front side of the cover part from a rear side of the cover part.
Preferably, the cover part has an upwardly convex shape to cover an upper side of the base part.
Preferably, a guide piece is provided to either an edge of the base part or a lower edge of the cover part and a guide recess is provided to either the lower edge of the cover part or the edge of the base part to have the guide piece slid to be inserted therein.
More preferably, the base part and the cover part are locked to each other by a locking bolt.
Preferably, a hook is provided to either a lower surface of the base part or an inner circumference of the drum and a recess to have the hook inserted therein is provided to the inner circumference of the drum or the lower surface of the base part.
Preferably, the base part is locked by a locking bolt to be fixed to an inner circumference of the drum.
Preferably, a rear end of the base part is upwardly projected and the rear end of the base part is locked to a rear side of the drum by a locking bolt.
More preferably, a solidity-reinforcing rib is provided to the rear end of the base part.
Preferably, the drum type washer further includes a supporter detachably provided to a lower side of the cover part, the supporter having a support recess rotatably supporting a lower portion of the washing ball.
More preferably, a hook part is provided to both ends of the supporter, a locking part is provided to the lower side of the cover part, and the hook part is fitted into the locking part to be fixed thereto.
More preferably, the locking part includes a pair of extensions extending to oppose each other and a hanging portion projected from at least one of a pair of the extension.
More preferably, the hook part includes a support portion extending from the supporter, a connecting portion extending from the support portion vertically, the connecting portion inserted between a pair of the extensions to be fixed thereto, and an insertion-guide portion extending from the connecting portion vertically to be guided along inner walls of the extensions.
More preferably, an end portion of the hook part is projected to have a ‘ ’ shape. And, a direction of the end portion of the hook part projected from one end of the supporter is opposite to that from the other end of the supporter.
Preferably, at least one portion of an upper surface of the base is configured to have a same profile of a lower surface of the supporter.
In another aspect of the present invention, a lift in a washer includes a base part fixed to an inner circumference of a drum and a cover part detachably assembled to the base part to enable a replacement of a washing ball, wherein an exposing hole is provided to a surface of the cover part to expose a portion of the washing ball and wherein a width of the cover part is decreased toward a front side of the cover part from a rear side of the cover part.
In a further aspect of the present invention, a lift in a washer includes a base part fixed to an inner circumference of a drum, a cover part detachably assembled to the base part to enable a replacement of a washing ball, wherein an exposing hole is provided to a surface of the cover part to expose a portion of the washing ball and wherein a width of the cover part is decreased toward a front side of the cover part from a rear side of the cover part, and a supporter detachably provided to a lower side of the cover part to support a lower portion of the washing ball rotatably, the supporter having a support recess rotatably supporting a lower portion of the washing ball.
It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this application, illustrate embodiment(s) of the invention and together with the description serve to explain the principle of the invention. In the drawings:
FIG. 1 is a cross-sectional diagram of a drum type washer according to a related art;
FIG. 2 is a perspective diagram of a drum of the drum type washer shown in FIG. 1 ;
FIG. 3 is a perspective diagram of a lift installed on an inner surface of the drum shown in FIG. 2 ;
FIG. 4 is an exploded perspective view of a lift according to the present invention;
FIG. 5 is a cross-sectional diagram of a fixed structure of a lift according to the present invention;
FIG. 6 is a layout of a rear side of a base part of a drum type washer according to the present invention;
FIG. 7A is a perspective diagram of a rear side of an assembly of a cover part and a supporter according to the present invention;
FIG. 7B is a magnified perspective diagram of a fixing part provided to a rear side of a cover part according to the present invention;
FIG. 7C is a layout of a fixing part and a hook part according to the present invention; and
FIG. 8 is a perspective diagram of an assembly of a base part and a cover part according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference will now be made in detail to the preferred embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
FIG. 4 is an exploded perspective view of a lift according to the present invention, FIG. 5 is a cross-sectional diagram of a fixed structure of a lift according to the present invention, and FIG. 6 is a layout of a rear side of a base part of a drum type washer according to the present invention.
FIG. 7A is a perspective diagram of a rear side of an assembly of a cover part and a supporter according to the present invention, and FIG. 7B is a magnified perspective diagram of a fixing part provided to a rear side of a cover part according to the present invention.
FIG. 7C is a layout of a fixing part and a hook part according to the present invention, and FIG. 8 is a perspective diagram of an assembly of a base part and a cover part according to the present invention.
Referring to FIG. 4 , a drum type washer according to the present invention includes a drum (cf. ‘ 6 ’ in FIG. 2 ) and at least one lift 100 .
The at least one lift 100 preferably includes a cover part 120 , a base part 101 and a supporter 130 .
The drum 6 is rotatably provided within a tub. And, the at least one lift 100 is preferably provided to an inner circumference of the drum in a circumferential direction to be projected with an interval of a prescribed angle.
The lift 100 plays a role in lifting up a laundry to fall while the drum is rotating. In order to prevent the laundry from being damaged, at least one washing ball 103 is provided to an upper surface of the lift 100 to be smoothly rotated in case of coming contact with the laundry. In this case, the at least one washing ball 103 is installed to have its portion projected and exposed. Preferably, the at least one washing ball 103 is formed of a ceramic based material to enable its rotation attributed to friction with the laundry.
In order to facilitate a replacement of the washing ball 103 that is broken, it is preferable that the lift 100 can be dissembled. For this, the cover part 120 is detachably assembled to the base part 101 . In this case, each of the cover part 120 and the base part 101 is preferably formed long along a length direction of the drum.
In particular, the base part 101 is fixed to the inner circumference of the drum and the cover part 120 is detachably attached to a lower end portion of the base part 101 .
A separation-preventing hole 121 is provided to the cover part 120 to enable a portion of the washing ball 103 to be exposed toward an inside of the drum. Preferably, a rim of the separation-preventing hole 121 is rounded to come into contact with the washing ball 103 smoothly.
So, the washing ball 103 projected toward the inside of the drum via the separation-preventing hole 121 is able to prevent the laundry from being damaged in case of a high-speed rotation of the drum, while being rotated in coming into contact with the laundry.
Preferably, the cover part 120 is formed tapered toward its front side from its rear side. This is to increase a volume of the drum. By reducing a width of the cover part 120 , the volume of the drum can be increased in proportion to the reduced width without decreasing sizes of the body and drum.
Meanwhile, if the base part is projected convex upwardly, if the cover part is formed narrow along the area having the washing ball formed therein, and if the cover part is assembled to an upper end of the base part, a gap can be generated from the assembled area. So, a problem that the laundry is stuck in the gap may be caused.
To prevent the problem from being caused, the cover part 120 of the present invention is configured convex upwardly in one body to cover the upper portion of the base part 101 completely.
Preferably, the lift 100 , as shown in FIG. 4 , further includes a supporter 130 supporting a lower portion of the washing ball 103 rotatably.
More preferably, the supporter 130 is provided between the cover part 120 and the base part 101 to be detachable under the cover part 120 .
A support recess 130 a is formed on the supporter 130 to support the lower portion of the washing ball 103 rotatably.
The support recess 130 a has a hemispherical shape having an almost same diameter of the washing ball 103 . So, the washing ball 103 can be rotatably supported between the cover part 120 and the supporter 130 .
The supporter 130 , as shown in the drawing, can be independently provided to the base part 101 to be assembled thereto. Alternatively, the supporter 130 can be built in one body of the upper portion of the base part 101 .
Explained in the following description is a structure that the base part 101 is fixed to the inner circumference of the drum.
FIG. 5 is a cross-sectional diagram of a fixed structure of a lift according to the present invention, and FIG. 6 is a layout of a rear side of a base part of a drum type washer according to the present invention.
Referring to FIGS. 4 to 6 , hooks 106 are 106 provided to both sides of a lower portion of the base part 101 , respectively. And, recesses are provided to portions of the drum 6 to oppose the hooks 106 , respectively. So, the hooks 106 are elastically fitted into the recesses to be locked together, respectively.
Hence, a pre-assembly between the base part 101 and the drum is achieved and a position for a locking of a locking member 105 such as a fixing bolt can be automatically aligned.
Alternatively, the hooks 106 are provided to the drum and the recesses for the hooks 106 can be provided to the lower surface of the base part 101 .
A rear portion 101 a of the base part 101 , as shown in the drawings, is projected upward and is fixed to the rear side of the drum by a locking of a fixing member 104 such as a fixing bolt 104 .
For this, a locking hole 104 a is formed at the rear portion 101 a of the base part 101 . The fixing member 104 passes through the rear side of the drum to be locked into the locking hole 104 a.
Preferably, the fixing member 104 is locked to the portion where the spider (cf. ‘ 8 ’ in FIG. 1 or FIG. 2 ) joining the drum and a bearing housing together in the rear lateral side of the drum.
Preferably, a locking boss 105 a is provided to a front portion of the base part 101 to be externally locked with the locking member 105 such as a bolt.
Hence, if the fixing member 105 is locked into the locking boss 105 a to enable the front and rear portions of the base part 101 to be stably fixed to the inner circumference of the drum.
Referring to FIG. 6 , for the reinforcement of a rear support structure of the lift to which the fixing member 104 is locked, a solidity reinforcing rib 112 a is preferably provided to the rear side of the base part 101 by injection molding.
Hence, even if an intensive stress is structurally concentrated on the locking hole 104 a , it is able to prevent the locking hole 104 a from being damaged.
FIG. 7A is a perspective diagram of a rear side of an assembly of a cover part and a supporter according to the present invention, FIG. 7B is a magnified perspective diagram of a fixing part provided to a rear side of a cover part according to the present invention, and FIG. 7C is a layout of a fixing part and a hook part according to the present invention.
Referring to FIG. 7A , a pair of hook parts 135 are provided to both ends of the supporter 130 , respectively. And, a pair of locking parts 123 are provided to a lower surface of the cover part 120 . So, the hook parts 135 are fitted into the locking parts 123 to be fixed thereto, respectively.
Referring to FIG. 7B , each of the locking parts 123 includes a first extension 123 a and a second extension 123 b opposing each other. And, the corresponding hook part 135 is fitted into the locking hole 124 between the first and second extensions 123 a and 123 b.
A hanging portion 123 c is provided to either the first extension 123 a or the second extension 123 b to catch the fitted hook part 135 .
So, if the hook part 135 is pushed between the first and second extensions 123 a and 123 b , the hanging portion 123 c is elastically retreated to enable the hook part 135 to be inserted between the first and second extensions 123 a and 123 b to be locked therein.
Alternatively, the hook parts 135 are provided to one side of the base part 101 and the locking parts 123 are provided to the lower surface of the cover part 120 .
Referring to FIG. 7C , each of the hook parts 135 includes a support portion 135 a , a connecting portion 135 b and an insertion guide portion 135 c.
The support portion 135 a extends from the supporter 130 and the connecting portion 135 b extends in a direction vertical to the support portion 135 a.
So, the connecting portion 135 b is inserted between a pair of the extensions 123 a and 123 b and is then postured in the locking hole 124 to be fixed thereto.
The insertion guide portion 135 c vertically extends from the connecting portion 135 b to be guided along inner walls of the extension portions 123 a and 123 b.
Preferably, the insertion guide portion 135 c extends in both directions vertical to an end portion of the connection portion 135 b to a prescribed length. Alternatively, the insertion guide portion 135 c is able to extend in one direction only.
If the fixed supporter 130 is pulled by a prescribed external force, the hook part 135 can be detached from the locking part 123 . So, the hook part 135 can be separated from the fixing part 123 . Through this, the supporter 130 can be detached from the cover part 120 with ease.
For a more stable fixing structure, as shown in FIG. 4 and FIG. 5 , a locking boss 102 a can be provided to the base part 101 and a locking member 102 such as a bolt can extend through a locking hole 122 in the cover part 120 and be locked into the locking boss 102 a to fix the cover part 120 and the supporter 130 to the base part 101 from the upper side of the cover part 120 .
Through this, both ends of the supporter 130 can be fixed to the lower surface of the cover part 120 .
Once the cover part 120 is assembled to the upper side of the base part 101 , the lower surface of the supporter 130 can be stably supported by the upper surface of the base part 101 . For this, it is preferable that the lower surface of the supporter 130 has the same profile of at least one portion of the upper surface of the base part 101 . And, it is a matter of course that a profile portion 108 a , as shown in the drawing, having the same profile of the lower surface of the supporter 130 can be projected or recessed from the upper surface of the base part 101 .
FIG. 8 is a perspective diagram of an assembly of a base part and a cover part according to the present invention.
Referring to FIG. 8 , at least one guide piece 124 is provided to a lower edge of the cover part 120 and at least one guide recess 107 is provided to an edge of the base part 101 . So, the guide piece 124 is inserted in the guide recess 107 to be locked therein.
In particular, the cover part 120 postured on a prescribed position of the upper surface of the base part 101 is slid, the guide piece 124 is fitted into the guide recess 107 to prevent the base part 101 from being separated from the cover part 120 .
Alternatively, the guide piece is provided to the edge of the base part 101 and the guide recess 107 is provided to the lower edge of the cover part 120 .
Preferably, a first locking piece 109 and a second locking piece 125 are provided to rear side edges of the base part 101 and the cover part 120 to be locked together by having ‘┐’ shapes, respectively. By the first and second locking pieces 109 and 125 , the lower edge of the cover part 120 and the edge of the base part 101 are locked together.
Preferably, a rib 108 for solidity reinforcement is projected from the lower surface of the base part 101 .
A process for assembling the above-configured lift according to the present invention is explained as follows.
First of all, the base part 101 is fixed to the inner circumference of the drum.
In particular, the hook 106 provided to the base part 101 is pre-assembled to the recess provided to the drum. In doing so, since locking positions of the locking members 104 and 105 are automatically aligned, the locking members 104 and 105 are locked into the aligned positions to enable the base part 101 to be stably fixed to the inner circumference of the drum.
Preferably, the step of fixing the base part 101 to the drum is carried out before the drum is installed within the tub.
Subsequently, the washing ball 103 is inserted in the support recess 130 a of the supporter 130 . The supporter 130 is then assembled to the lower surface of the cover part 120 . For this, the hook parts 135 provided to both of the ends of the supporter 130 are fitted into the locking parts 123 provided to the lower surface of the cover part 120 , respectively. So, the supporter 130 is detachably assembled to the lower surface of the cover part 120 .
The cover part 120 having the supporter 130 assembled thereto is slid on the base part 101 to be detachable assembled thereto.
In particular, the guide piece 124 provided to the lower edge of the cover part 120 is slid into the guide recess 107 provided to the edge of the base part 101 , thereby completing the pre-assembly. The locking member 102 is then locked from the upper side of the cover part 120 , thereby completing the locking between the cover part 120 and the base part 101 .
Meanwhile, if the washing ball is broken in operating the drum type washer, the cover part and the supporter are disassembled to facilitate the replacement of the broken washing ball.
Accordingly, the present invention provides the following effects or advantages.
First of all, since the lift is detachably provided within the drum, it is able to replace the washing ball of the lift and the like without dissembling the drum, the tub, the motor assembly and the like. In particular, since the supporter is detachably fixed to the cover part by the hook locking mechanism, it is able to separate the supporter from the cover part with ease. Hence, the repair time and cost of the washer can be considerably reduced.
Secondly, since the hook parts projected in opposite directions from both ends of the supporter are joined to the locking part, it is able to effectively prevent the supporter from rocking back and forth or right to left.
Thirdly, since the cover part in one body is projected to cover the whole upper portion of the base part, it is able to prevent the laundry from being stuck in the assembled part of the lift.
Fourthly, unlike the related art lift, the lift of the present invention has the width tapered toward its front side, thereby increasing the volume of the drum.
Finally, the lift of the washer according to the present invention is applicable to a dryer.
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. | A drum type washer is provided in which replacement of a washing ball provided in a drum lift device may be simplified, and in which a volume of the drum may be increased. The washer may include a tub, a drum rotatably provided within the tub, and a lift provided within the drum. The lift may include a base detachably coupled to an inner surface of the drum and a cover detachably coupled to the base. An exposing hole may be formed in a surface of the cover to expose a portion of the washing ball positioned between the cover and the base. A width of the cover may be gradually decreased from a rear end portion to a front end portion thereof so as to minimize a size of the lift and increase an interior volume of the drum. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Fields of the Invention
[0002] The present invention relates to a cordless blinds assembly, and more particularly, to a control device located in the bottom box to control the cordless blinds assembly.
[0003] 2. Descriptions of Related Art
[0004] The conventional window blinds assemblies are developed to include several different styles such as Roman shades, blinds assemblies and curtains assemblies. The control and operation of these window blinds assemblies are catalogued into cordless operation devices and cord-operational devices. The control device is received in the top box and connected to the operation cords which hang downward and located on two sides of the blinds. However, the operation cords may be wrapped around limbs of children playing the operation cords.
[0005] The present invention intends to provide a control device of a cordless blinds assembly and the control device is received in the bottom box of the blinds assembly to eliminate the shortcomings mentioned above.
SUMMARY OF THE INVENTION
[0006] The present invention relates to a cordless blinds assembly and comprises a top box, a bottom box and multiple slats connected between the top box and the bottom box. Multiple cords are connected to the top box and extend through the slats and extend through the cord holes in the top of the bottom box. The bottom box has two fixed plates located therein and located close to two ends of the bottom box. Each of the two fixed plates has a connection tube through which a rectangular hole is defined. The two cord holes are respectively defined through the top of the bottom box and located close to the two ends of the bottom box. Two outlets are defined through the top of the bottom box and located between the two cord holes.
[0007] A control device includes a rod unit having an operation unit, multiple scrolling belt units and multiple transmission rods, wherein the operation unit has a first case, a second case, a button, an engaging member and a coil spring plate seat. The first case has a first room defined therein which communicates with an opening at the inside of the first case. A first side hole is defined through the outside wall of the first case. A first pivotal hole is defined in the end face of the top wall of the first case. An engaging plate is located in the first room.
[0008] The second case has a second room defined therein which communicates with an opening at the inside and a portion of the top of the second case. A second side hole is defined through the outside wall of the second case. A second pivotal hole is defined through the outside wall of wall of the second case. A stud extends from the top of the front wall of the second room. A resilient member is mounted to the stub. The button has a protrusion extending from the underside thereof.
[0009] The engaging member has a contact plate extending from the front thereof, and a pawl is connected to the rear side of the engaging member. Two pivots respectively extend from two sides of the engaging member.
[0010] The coil spring plate seat has a central rod which is connected between two restriction plates. A coil spring plate is wrapped around the central rod between the two restriction plates. Each of the two restriction plates has an axial tube extending from the outside thereof. Each axial tube has a rectangular hole defined in the end face thereof. A gear is connected to one of the restriction plates and located between the restriction plate and the axial tube corresponding to the restriction plate. The two axial tubes of the coil spring plate seat are pivotably connected to the first and second side holes. One end of the coil spring plate is engaged with the engaging plate in the first room of the first case. The two pivots of the engaging member are pivotably connected to the first and second pivotal holes. The underside of the contact plate of the engaging member contacts the resilient member on the stub of the second case, and the pawl of the engaging member is engaged with the gear of the coil spring plate seat. The first and second cases are connected to each other at the two respective insides thereof.
[0011] The scrolling belt units each have a housing, a cover and a belt wheel, wherein the housing has a first through hole defined in the outside wall thereof. A belt slot is defined in the rear side wall thereof. The cover has a second through hole defined centrally therethrough. A scrolling belt is scrolled to the belt wheel which has a tube extending from each of the two ends thereof. Each of the tubes of the belt wheel has a rectangular hole defined in the end face thereof. The two tubes of the belt wheel respectively extend through the first and second through holes. One end of the scrolling belt extends through the belt slot. The cover is connected to the housing.
[0012] Each of the transmission rods has two ends which respectively inserted into the rectangular hole of the coil spring plate seat and the rectangular hole of the scrolling belt unit corresponding thereto. Each of the transmission rods extends through the rectangular hole of the connection tube of the fixed plate corresponding thereto. The cords extend through the cord holes and are connected to the transmission rods. The scrolling belts extend through the outlets and are connected to the top box.
[0013] By pushing the button to disengage the pawl of the engaging member from the gear of the coil spring plate seat. When releasing the button, the resilient member pushes the contact plate of the engaging member, and the pawl of the engaging member is engaged with the gear of the coil spring plate seat. The coil spring plate seat of the operation unit drives the transmission rods and the belt wheels of the scrolling belt units by the force created from the coil spring plate so that the blinds assembly is lifted/lowered and positioned. There will be no operation cords needed.
[0014] The present invention will become more obvious from the following description when taken in connection with the accompanying drawings which show, for purposes of illustration only, a preferred embodiment in accordance with the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] FIG. 1 is a perspective view to show the blinds assembly with the control device of the present invention;
[0016] FIG. 2 is a perspective view to show the rod unit of the control device of the present invention;
[0017] FIG. 3 is an exploded view to show the rod unit of the control device of the present invention;
[0018] FIG. 4 is an exploded view to show the operation unit of the rod unit of the control device of the present invention;
[0019] FIG. 5 is an exploded view to show the scrolling belt unit of the rod unit of the control device of the present invention;
[0020] FIG. 6 is a side view to show the blinds assembly with the control device of the present invention;
[0021] FIG. 7 shows that the pawl of the engaging member is engaged with the gear of the coil spring belt seat of the control device of the present invention;
[0022] FIG. 8 shows that the pawl of the engaging member is disengaged from the gear of the coil spring belt seat of the control device of the present invention by pushing the button;
[0023] FIG. 9 shows a partial cross sectional view of the control device of the present invention by pushing the button, and
[0024] FIG. 10 is a cross sectional view to show the connection of the contact plate of the engaging member and the button of the control device of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] Referring to FIGS. 1 to 7 , the cordless blinds assembly 10 of the present invention comprises a top box 11 , a bottom box 20 and multiple slats 13 connected between the top box 11 and the bottom box 20 . Multiple cords 12 are connected to the top box 11 and extend through the slats 13 and extend through cord holes 22 defined through the top of the bottom box 20 .
[0026] The bottom box 20 is located next to the lowest slat 13 and has two fixed plates 21 located therein and located close to two ends of the bottom box 20 . Each of the two fixed plates 21 has a connection tube 210 through which a rectangular hole 211 is defined. The two cord holes 22 are respectively defined through the top of the bottom box 20 and located close to the two ends of the bottom box 20 . The cords 12 extend through the cord holes 22 and are connected to the transmission rods 33 which will be described later. Two outlets 23 are defined through the top of the bottom box 20 and located between the two cord holes 22 .
[0027] A control device includes a rod unit 30 which has an operation unit 31 , multiple scrolling belt units 32 and multiple transmission rods 33 as mentioned above. In this embodiment, the operation unit 31 is located between the two scrolling belt units 32 , and two transmission rods 33 are respectively connected between the operation unit 31 and the two scrolling belt units 32 .
[0028] The operation unit 31 has a first case 310 , a second case 311 , a button 312 , an engaging member 313 and a coil spring plate seat 314 . The first case 310 has a first room 310 A defined therein which communicates with an opening at the inside of the first case 310 . A first side hole 310 B is defined through the outside wall of the first case 310 , and a first pivotal hole 310 C is defined in the end face of the top wall of the first case 310 . An engaging plate 310 D is located in the first room 310 . The first case 310 of the operation unit 31 has multiple first fixing holes 310 E defined along sides of the inside thereof.
[0029] The second case 311 has a second room 311 A defined therein which communicates with an opening 311 D at the inside and a portion of the top of the second case 311 . A second side hole 311 B is defined through the outside wall of the second case 311 . A second pivotal hole 311 B is defined through the outside wall of wall of the second case 311 . A stud 311 E extends from the top of the front wall of the second room 311 A. A resilient member 311 F is mounted to the stub 311 E. The button 312 has a protrusion 312 A extending from the underside thereof and the protrusion 312 A has an engaging slot as shown in FIG. 10 . The second case 311 has multiple second fixing holes 311 G defined along sides of the inside thereof. Multiple bolts 311 H extend through the second fixing holes 311 G and are fixed to the first fixing holes 310 E.
[0030] The engaging member 313 has a contact plate 313 A extending from the front thereof, and a pawl 313 B is connected to the rear side of the engaging member 313 . The contact plate 313 A is engaged with the engaging slot of the protrusion 312 A as shown in FIG. 10 . Two pivots 313 C respectively extend from two sides of the engaging member 313 .
[0031] The coil spring plate seat 314 has a central rod 314 A which is connected between two restriction plates 314 B. A coil spring plate 314 is wrapped around the central rod 314 A between the two restriction plates 314 B. Each of the two restriction plates 314 B has an axial tube 314 D extending from the outside thereof. Each axial tube 314 D has an rectangular hole 314 E defined in the end face thereof. A gear 314 is connected to one of the restriction plates 314 B and located between the restriction plate 314 B and the axial tube 314 D corresponding to the restriction plate 314 B. The two axial tubes 314 D of the coil spring plate seat 314 are pivotably connected to the first and second side holes 310 B, 311 B. One end of the coil spring plate 314 C is engaged with the engaging plate 310 D in the first room 311 A of the first case 311 . The two pivots 313 C of the engaging member 313 are pivotably connected to the first and second pivotal holes 310 C, 311 C. The underside of the contact plate 313 A of the engaging member 313 contacts the resilient member 311 F on the stub 311 E of the second case 311 , and the pawl 313 B of the engaging member 313 is engaged with the gear 314 H of the coil spring plate seat 314 . The first and second cases 310 , 311 are connected to each other at the two respective insides thereof.
[0032] The scrolling belt units 32 each have a housing 320 , a cover 321 and a belt wheel 322 , wherein the housing 320 has a first through hole 320 A defined in the outside wall thereof. A belt slot 320 B is defined in the rear side wall thereof. The cover 321 has a second through hole 321 A defined centrally therethrough. A scrolling belt 322 A is scrolled to the belt wheel 322 which has a tube 322 B extending from each of the two ends thereof. Each of the tubes 322 B of the belt wheel 322 has a rectangular hole 322 C defined in the end face thereof. The two tubes of the belt wheel 322 respectively extend through the first and second through holes 320 A, 321 A. One end of the scrolling belt 322 A extends through the belt slot 320 B and the slots 120 of the slats 13 and is connected to the top box 11 . The housing 320 has multiple connection holes 320 C defined along sides of the inside thereof, and the cover 321 has multiple holes 321 B. Multiple bolts 321 C extend through the holes 321 B of the cover 321 and are connected to the connection holes 320 C of the housing 320 , such that the cover 321 is connected to the housing 320 .
[0033] Each of the transmission rods 33 has two ends which respectively are inserted into the rectangular hole 314 E of the coil spring plate seat 314 and the rectangular hole 322 C of the scrolling belt unit 32 corresponding thereto. Each of the transmission rods 33 extends through the rectangular hole 211 of the connection tube 210 of the fixed plate 21 corresponding thereto. The cords 12 extend through the cord holes 22 and are connected to the transmission rods 33 . The scrolling belts 322 A extend through the outlets 23 and are connected to the top box 11 . Each of the two axial tubes 314 D of the coil spring plate seat 314 has a radial hole 314 F which communicates with the rectangular hole 314 E of the axial tube 314 D corresponding thereto. A bolt 314 G as shown in FIG. 3 extends through each of the radial hole 314 F. Each of the transmission rods 33 has a passage 33 A defined therethrough in one end thereof which is inserted into the rectangular hole 314 E of the axial tube 314 D of the coil spring plate seat 314 . The bolt 314 G extending through the radial hole 314 F is connected to the passage 33 A.
[0034] As shown in FIGS. 7 to 10 , when in operation, the user pushes the button 312 to disengage the pawl 313 B of the engaging member 313 from the gear 314 H of the coil spring plate seat 314 . When releasing the button 312 , the resilient member 311 F pushes the contact plate 313 A of the engaging member 313 , and the pawl 313 B of the engaging member 313 is engaged with the gear 314 H of the coil spring plate seat 314 . The coil spring plate seat 314 of the operation unit 31 drives the transmission rods 33 and the belt wheels 322 of the scrolling belt units 32 by the force created from the coil spring plate 314 C so that the blinds assembly is lifted/lowered and positioned. There will be no operation cords needed.
[0035] While we have shown and described the embodiment in accordance with the present invention, it should be clear to those skilled in the art that further embodiments may be made without departing from the scope of the present invention. | A control device of a cordless blinds assembly includes a bottom box and a rod unit which is received in the bottom box. The rod unit is cooperated with the operation unit in the bottom box. The operation unit is cooperated with a pawl which is engaged with or disengaged from a gear of the coil spring plate seat so as to control the operation of the blinds assembly without using any operation cord. | 4 |
This is a divisional of application Ser. No. 10/372,836 filed Feb. 26, 2003, now U.S. Pat. No. 7,158,546. The entire disclosure of the prior application, application Ser. No. 10/372,836 is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to a composite laser rod, a fabricating method of the composite laser rod, and a laser device that uses the composite laser rod. In particular, the composite laser rod can improve deterioration of the positional stability and output stability of a laser beam that is caused by thermal fluctuation and vibration of a laser rod during laser oscillation, can enhance an absorption efficiency of light that excites the laser rod and thereby can improve the oscillation efficiency, and can enhance a cooling efficiency and thereby can suppress the thermal lens effect.
2. Description of the Related Art
For laser rods that generates laser beam that is employed in welding, boring, repairing, micro-fabrication and so on, crystalline materials are usually used. Among these, single crystals that have garnet structure such as yttrium aluminum garnet (YAG) and so on are mainly used. To the laser rod, a laser active element such as neodymium, ytterbium, thulium, and erbium is doped.
Recently, a laser material that is obtained by doping a laser active element in a transparent material of ceramic YAG that is obtained by baking powder having a YAG composition has been developed and confirmed to have the laser characteristics identical to the single crystal. For instance, Japanese Unexamined Patent Publications (JP-A) H10-67555, H5-235462, H5-286761 and H5-294723 disclose that the transparent ceramic material can be obtained by baking, in a vacuum, powder having a composition of yttrium aluminum garnet (YAG).
Furthermore, in The Review of Laser Engineering, vol. 27, 1999, pp. 593-598, the laser characteristics are reported. Still furthermore, in a YAG single crystal rod, an upper limit of a concentration of Nd that can be introduced is substantially 1.3 atomic %. However, Proceedings (Digest of Technical Papers) of 21st Annual Meeting of The Laser Society of Japan (2001, pp. 40, Lecture No. 30pV3) disclose that the concentration in the ceramic YAG laser rod can be increased to 2% or more. Still furthermore, Y 2 O 3 (yttria) or Sc 2 O 3 that cannot be grown, according to an ordinary crystal growth method, into a crystal excellent in quality and large in size owing to a higher melting point, having thermal conductivity of substantially 20 W/mK that is substantially twice that of YAG, is promised as a laser crystal. When fine and uniform powder of the Y 2 O 3 or Sc 2 O 3 is baked in a vacuum, a transparent and high quality ceramic material can be obtained. It is reported in Proceedings (Digest of Technical Papers) of 22 nd Annual Meeting of the Laser Society of Japan (2002, pp. 40, Lecture No. B3-24PI2) that when Nd or Yb is doped in the ceramic material, the ceramic material can obtain laser oscillation.
The laser rod can be excited by use of a flush lamp or a laser diode from a side surface or an end surface, beam emitted therefrom is resonated in a resonator, and thereby a laser oscillation is realized. All energy of the excitation light that is absorbed by the laser active element during the laser oscillation is not converted into energy of laser beam but part thereof is converted into heat. As a result, the laser rod is heated during the laser oscillation and then a temperature is raised. When a temperature of the laser rod varies during the laser oscillation, the refractive index of the laser rod varies. As a result, such problems as that the positional stability of an oscillating laser beam may be deteriorated, and the output strength may fluctuate largely are caused. Accordingly, it is customary to bring the laser rod into close contact with water or a heat sink to cool so that the temperature of the laser rod may be maintained as constant as possible.
Since the laser rod is cooled from a surface thereof, it is inevitable that a temperature gradient in a radial direction is established. When a temperature gradient is generated in the radial direction, since the refractive index also varies according to the temperature, the laser rod exhibits an effect similar to a lens. As a result, light in the rod cannot propagate straight. In order to overcome the thermal lens effect, it is considered to cover a periphery of a single crystal laser rod in which a laser active element is doped with a non-doped single crystal layer. There are proposed several methods for fabricating this composite laser rod. For instance, a method in which a non-doped single crystal layer in which an active element is not doped is disposed around the laser rod of a single crystal in which an active element is doped according to a liquid phase epitaxial growth (LPE) method is disclosed in JP-A-62-140483. Furthermore, a method in which a laser material in which an active element is added and a laser material in which an active element is not added are laminated or thermo-compression bonded is disclosed in U.S. Pat. Nos. 5,441,803 and 5,563,899. Still furthermore, a method in which a hole is bored in a non-doped crystal and a doped crystal to be a core is inserted therein followed by integrating is disclosed in JP-A S63-085152 or JP-A H9-172217.
Recent years, higher precision and higher speed in the laser processing is in demand. For instance, there is a need of forming 1000 holes that has a size of 50 μm in a second at the precision of ±1 μm on a printed wiring board. In order to perform fine processing with high precision in such a short period of time, an improvement in the positional stability and a suppression of the fluctuation of the output strength in a single mode laser beam outputted from a laser oscillator are in demand more than ever.
For the fine processing, since a shorter laser wavelength is more suitable, in many cases, a single mode laser beam is wavelength-converted by use of a wavelength conversion element and used. The wavelength conversion efficiency varies in proportion to a square of an output of the laser beam until the conversion efficiency saturates. Accordingly, when there is a fluctuation in an output of the laser beam of a fundamental wave, the conversion efficiency may vary in proportion to a square of the fluctuation thereof. Furthermore, when an angle of light incident on a non-linear element varies, a light component whose phase matching angle cannot be attained increases. Accordingly, when the positional stability of the beam varies, an output of the wavelength converted light largely varies. From these reasons, in the case of a laser processor that employs the wavelength-converted light, the positional stability of the laser beam that is a fundamental wave has to be improved and the fluctuation of the output strength has to be lowered as large as possible.
One countermeasure to overcome the problems is to maintain a cooling power of cooling water and a heat sink that cool the laser rod at a constant level. However, since when the cooling power is controlled, a temperature at a temperature measurement point is controlled so as to be in a tolerable temperature range, it is impossible to set this temperature range at ±0 degree centigrade. Furthermore, in particular when the cooling water is used, since once elevated water temperature is controlled by returning the cooling water to a chiller, it is very difficult to make completely zero the fluctuation of the water temperature.
Furthermore, there is variation of water pressure when the water is circulated. Accordingly, by devising only a cooling method of the laser rod, required positional stability of the laser beam or output stability thereof can be satisfied with difficulty.
Furthermore, when the laser rod is cooled with the water, there is a problem that a vibration due to a water stream contains a component that matches with a resonant frequency of the laser rod, accordingly the rod begins to vibrate. Still furthermore, also when a heat sink that fixes the rod is air-cooled, the laser rod picks up the vibration due to a cooling fan and so on, as a result, it becomes a factor deteriorating the positional stability of the laser beam and the output stability thereof.
When the laser rod is made larger in its diameter and thereby a volume of the laser rod is increased, a resonant frequency of the laser rod may be lowered, and thereby a problem of the vibration may be overcome. However, when a single mode laser beam that is necessary for fine laser processing is oscillated, a diameter of the laser rod can be made larger only up to substantially 2 mm. Accordingly, the laser rod cannot be made larger up to a diameter that is less influenced by the external vibration due to such as the cooling water or the cooling fan.
Furthermore, it is also a big target to improve the laser oscillation efficiency. In order to facilitate a single mode laser beam to oscillate, it is necessary to concentrate excitation light in the neighborhood of a center of the laser rod. However, in that case, the conversion efficiency from the excitation light to oscillation light becomes such low as substantially 10 to 15%. Accordingly, it is a task to facilitate the laser rod to efficiently absorb the excitation light and thereby to enhance the oscillation efficiency of the single mode laser beam.
Furthermore, when the single mode laser beam is oscillated, since heat addition is concentrated into a slender rod, the thermal lens effect results, as a result, an output laser beam cannot go straight. In order to overcome the problem, as the existing technology, it is considered to dispose a single crystal non-doped layer in the periphery of a single crystal laser rod. However, in the existing technology, it was very difficult to dispose the single crystal non-doped layer to a laser rod having a diameter of 2 mm or less that enables to obtain a single mode.
Accordingly, the invention intends to provide a composite laser rod in periphery of which, a non-doped pipe is bonded, as a structure that can overcome such problems and is less influenced by variation of cooling capacity of cooling water and a heat sink that cool the laser rod and the vibration from a cooling medium. That is, the invention intends to provide a composite laser rod that allows realizing a laser device excellent in the output stability and the beam positional stability, thereby allows improving performance such as processing precision and processing speed of a laser processor, allows improving the oscillation efficiency, and furthermore allows oscillating laser beam excellent in beam quality; a fabricating method thereof; and a laser device therewith.
SUMMARY OF THE INVENTION
In the invention, a composite laser rod in which in order to realize a laser device excellent in the output stability and the positional stability of a beam so as to improve performance such as processing precision and processing speed, and to allow a laser rod to efficiently absorb excitation light and thereby to improve the oscillation efficiency, the refractive index of the laser rod is made higher than that of a non-doped pipe disposed in the periphery thereof, and, in order to suppress the thermal lens effect and thereby to allow oscillating laser beam high in the beam quality, a non-doped pipe that is higher in the thermal conductivity than that of the laser rod is connected to the periphery of the laser rod; a fabricating method thereof; and a laser device therewith are disclosed.
In the laser rod, a portion that absorbs the excitation light and generates heat is a portion where an active element is doped. Accordingly, when cooling water or a heat sink comes into direct contact with the portion, variation of the cooling capacity has direct influence on variation of the refractive index of the laser rod. Accordingly, when the periphery of a laser rod that is doped with a laser active element is enveloped with a non-doped pipe, an influence of the variation of the cooling capacity, without being directly communicated to the rod, is communicated through the non-doped pipe. Accordingly, since a slight variation of the cooling capacity is averaged over the non-doped pipe, the temperature variation of the rod where the active element is doped can be suppressed.
Furthermore, when a diameter of a laser rod in which the active element is doped is made smaller than 2 mm to obtain a single mode and a pipe of a non-doped layer is disposed in the periphery thereof, while maintaining the single mode of the laser oscillation, a diameter of the rod can be made larger. Since as the diameter of the rod is made larger, the characteristic frequency of the rod shifts to a lower frequency side, a component that resonates with a high frequency oscillation component from the cooling water and the cooling fan outside of the rod can be suppressed. As a result, the vibration of the laser rod can be suppressed, resulting in an appreciable improvement in the characteristics such as the positional stability and output stability of the laser beam.
As the methods for fabricating a structure in which a non-doped pipe is attached to the periphery of such laser rod, there are various kinds of proposals according to patent publications such as mentioned above. In all of the proposals, a single crystal laser rod and a single crystal non-doped layer are bonded. In the bond structure of the crystal and crystal, it is very difficult to completely integrate the laser rod and the non-doped layer in the periphery thereof.
In a composite laser rod according to the invention, a ceramic material that has a crystal structure the same as that of the laser rod is used as a pipe of a non-doped layer. As a result, the laser rod and the non-doped pipe can be completely integrated. For this, firstly, ceramic powder in which an active element is not doped is pre-baked to form a hollow ceramic pipe. Subsequently, a laser rod is inserted into the pipe followed by baking. As a result, during the baking, the pipe shrinks in its diameter, and thereby the laser rod and the pipe are integrated and bonded. Since the laser rod and the ceramic pipe have the same crystal structure, at an interface between these, slight element diffusion is caused, resulting in integrating these. By processing the integrated material into a predetermined shape followed by polishing, a composite laser rod can be fabricated.
When the composite laser rod that is fabricated by bonding the non-doped ceramic pipe to the periphery of the laser rod is used, an influence due to the vibration from the outside of the rod and heat generation of the rod can be suppressed. Accordingly, the positional stability and the output stability of the laser beam oscillated from the laser rod can be improved.
For the laser rod, other than the single crystal rod that has been used, a ceramic laser rod can be used.
Furthermore, when a laser rod having garnet structure is used in the laser rod according to the invention, a trioxide, other than Nd 2 O 3 or Yb 2 O 3 of the laser active element, elements such Lu 2 O 3 of rare-earth element, Ga 2 O 3 or the like can be added. That is, as proposed in Optics Communications, vol. 115, 1995, pp. 491 or Journal of Crystal Growth, vol. 128, 1993, pp. 966, in both of the crystal and ceramic laser rods, the refractive index can be changed.
This means that when, in order to give difference of the refractive index at an interface with the non-doped pipe, the refractive index of the laser rod is made higher than that of the non-doped pipe in the periphery thereof, the excitation light inputted into the laser rod can be suppressed from leaking to the non-doped pipe. As a result, an effect confining the excitation light within the laser rod at a center can be enhanced, in comparison with the case where the refractive index difference is not given, an absorption efficiency of the excitation light in the laser rod can be increased, resulting in an improvement in the oscillation efficiency to oscillation light.
As a method of making larger the refractive index of the laser rod than that of the non-doped pipe, in the laser rod, gadolinium gallium garnet (GGG) that is a laser material higher in the refractive index than YAG may be used, and in the pipe, YAG may be used. Other than this, when the laser rod is made higher in the refractive index than the ceramic pipe by combining materials having cubic system crystal structure, the oscillation efficiency can be improved. When the laser rod has the refractive index higher by 0.3% or more than that of the ceramic pipe, light propagating inside of the laser rod begins to be reflected at the interface with the ceramic pipe, and when the refractive index difference becomes larger than that, a light confinement effect becomes further larger.
Furthermore, in a laser oscillator, a portion that holds the laser rod, because of incapable of absorbing the excitation light from a side surface, does not contribute to the oscillation. The active element in the laser rod in the portion that cannot be excited, because of absorbing the oscillation light, causes a decrease in the oscillation efficiency. As means for solving the problem, in, for instance, IEEE Journal of Quantum Electronics, vol. 33, 1997, pp. 1592, a method in which to both end portions of the laser rod that are not excited a non-doped single crystal having the same structure as that of the laser rod is bonded is disclosed. When, by applying the structure to the composite laser rod according to the invention, non-doped ceramic rods are bonded to both ends of the laser rod, together with an improvement in the positional stability and suppression of the output fluctuation, an improvement in the oscillation efficiency can be attained.
Furthermore, when the thermal conductivity of the ceramic pipe that is bonded to the periphery of the laser rod is made higher than that of the laser rod, the laser rod can be efficiently cooled. The thermal conductivity of Y 2 O 3 or Sc 2 O 3 is substantially twice that of garnet system materials. Accordingly, when an Y 2 O 3 system ceramic pipe is bonded to the periphery of the garnet system laser rod, the thermal lens effect of the laser rod can be suppressed.
As mentioned above, when a non-doped ceramic pipe is bonded to the periphery of a laser rod, improvements in the positional stability, output stability, and oscillation efficiency, and suppression of the thermal lens effect can be attained.
In the following, operations thereof will be explained.
A single crystal described in the invention is a material that is grown from a molten melt according to a crystal growth method such as a pulling method and so on and has no grain boundary. Furthermore, ceramic is a material that is an agglomeration of single crystal fine particles of millimeter or less in dimension, has grain boundaries, and can be obtained, without completely melting powder particles to be a raw material, by sintering and thereby grain growing.
The ceramic pipe used in the invention can effectively operate when the crystal system of particles that constitute the ceramic is cubic system (or isometric system). This is because a lattice constant of a crystal of the cubic system is three-dimensionally isotropic, thermal expansion coefficient is also three-dimensionally isotropic. From this reason, whatever direction grains of the particles that constitute the ceramic material are bonded each other, after sintering and integration, there is no residual strain. Since the physical properties of the sintered ceramic are substantially the same as that of a single crystal, when the single crystal and ceramic are integrated, no strain is generated at the interface.
As crystals applicable as the laser crystals, other than ones having the garnet structure, materials belonging to the cubic system among oxides of trivalent metals such as Re (rhenium) and so on, for instance, Re 2 O 3 , Y 2 O 3 , Sc 2 O 3 and so on can be cited, the invention can be applied thereto. Furthermore, even when the laser rod and the ceramic pipe have different compositions or crystal structures, when the laser rod and the ceramic pipe are made of materials of the cubic system and have no anisotropy in the thermal expansion and the difference of the thermal expansion coefficients thereof is within 10%, these can be bonded.
When the ceramic powder is sintered and facilitated to exhibit the physical properties the same as that of a crystal, voids have to be removed. In order to obtain the ceramic material having such crystal physical properties, it is very important to prepare a starting raw material that is excellent in the compositional uniformity and particle shape uniformity. It is desired that diameters of particles of starting raw material are several μm or less, and the smaller the particle diameter, the better. When there is the difference in the particle diameters, the difference of the sintering behavior due to the difference of the particle diameters is caused, nonuniformity in the dimensions of grains results after the baking, and in some places mechanical properties vary. When the dispersion of particle sizes is suppressed to ±1 μm or less, the above problem can be overcome.
As a method of obtaining a starting raw material having uniform particle diameters, there are two approaches. In one of the two, raw materials, after weighing so as to have a composition the same as that of a crystal, are mixed and pre-baked followed by pulverizing again down to nano order by means of a ball mill. By repeating the process several times, ultra-fine particles having the composition the same as that of the crystal are obtained. In the other approach, by use of a chemical reaction in a solution, a salt having a composition the same as that of the crystal is co-precipitated. After weighed raw material powder is dissolved in a solution, by adjusting to a predetermined pH, a plus electric charge and a negative electric charge react one to one, and thereby a ceramic raw material that is excellent in the compositional uniformity can be obtained. By processing the precipitation, a raw material of ceramic can be obtained.
In raw material of the ceramic pipe, the ceramic material obtained as mentioned above is agitated together with an organic binding material called a binder and a solvent such as water or alcohol, or toluene or xylene, and thereby a low viscosity state called slurry is obtained and used. After water is removed from the slurry followed by pre-baking, a pipe structure can be obtained. In this state, individual particles constituting the ceramic are not completely bonded. However, by carrying out actual baking, individual particles constituting the ceramic are sintered each other, spaces at interfaces of particles are narrowed and finally disappear. When the particle sizes are uniform, without grain-growing irregularly, an entirety of particles grows uniformly.
The pre-baked ceramic pipe, until coming into contact with a rod inserted inside thereof, continues deforming in a direction in which an inner diameter contracts. However, when the contraction proceeds to a certain extent and the ceramic pipe comes into contact with the laser rod inserted therein, a contracting force of the pipe does not work in a direction in which the force compresses the laser rod, but disperses in a radial direction of the pipe. This is called a plastic deformation effect that is exhibited when the ceramic particles are sintered. The composite laser rod according to the invention utilizes a large plastic deformation that is a characteristic phenomenon exhibited when the ceramic particles are sintered. Accordingly, without causing compression strain on the laser rod inserted in a center of the ceramic pipe, the laser rod can be completely integrated with the surrounding ceramic pipe. Plasticity is an effect by which even in the case of a hard material, at the bonding between atoms or particles constituting the material, defects are caused and displacement is caused, and thereby the material is deformed. When the ceramic is sintered, a bonding-state between the particles changes, and thereby the plastic deformation is caused.
The laser rod at the center, being chemically stable at temperatures where the ceramic is sintered, does not change in its shape. However, at a portion where the laser rod is bonded with the ceramic pipe, atomic diffusion is slightly caused, resulting in bonding. Accordingly, after the integration, the laser rod does not come off the ceramic pipe.
Although a distance of the atomic diffusion at a bonding interface is determined according to a temperature at and period of time for which the laser rod and the ceramic pipe are sintered, an effect of the temperature is larger. When the sintering temperature is higher, the laser active element doped in the laser rod diffuses into the ceramic pipe, resulting in deteriorating the laser oscillation mode. In the invention, however, a temperature at which the composite laser rod is formed is set at 90% or less the melting point of the laser rod in a center thereof. At the temperature, the laser active element in the laser rod hardly diffuses to a ceramic pipe side and the laser oscillation mode is not deteriorated.
The laser oscillation mode is determined by a diameter of the laser rod or the thermal lens effect caused by heat generated in the laser rod, and furthermore by an excitation method or the respective curvatures of an output mirror and a rear mirror that constitute a resonator. The laser oscillation mode from the laser rod that is excited from a side surface mainly depends on a diameter of the laser rod in which the laser active element is contained. When the single mode laser is desired to be excited by use of the side surface excitation, the diameter of the laser rod is necessary to be 2 mm or less. When the rod diameter is 2 mm or less, since the crystal can be solidly fixed with difficulty, problems such as thermal fluctuation or the vibration are caused, resulting in causing problems in the output stability and the positional stability of the beam. However, when the ceramic pipe is bonded to the laser rod of 2 mm, a composite laser rod having the oscillation beam of the single mode and a diameter of 2 mm or more can be realized. Accordingly, owing to the invention, the problems concerning the output stability and the positional stability can be overcome.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A to 1C are diagrams showing one implementation mode for explaining a first half of a manufacturing process according to the invention.
FIGS. 2A to 2C are diagrams showing one implementation mode for explaining a second half of a manufacturing process according to the invention.
FIG. 3 is a diagram showing one mode of a configuration in a laser oscillator in which a composite laser rod is used.
FIG. 4 is a diagram showing one example of the stability of a pulse-to-pulse output of a 2 mm-diameter crystal YAG rod.
FIG. 5 is a diagram showing one example of the stability of the pulse-to-pulse output of a 3 mm-diameter crystal YAG rod.
FIG. 6 is a diagram showing one mode of a configuration in which a wavelength conversion function of excitation light is added in the laser oscillator in FIG. 3 to obtain a third harmonic.
FIG. 7 is a diagram showing one example of fluctuation of an irradiation position of a third harmonic laser beam in each of a composite YAG rod and a crystal YAG rod.
FIG. 8 is a diagram showing one example of a laser oscillator configuration in which a diameter of an oscillation laser beam is provided by a laser rod diameter in the composite laser rod.
FIG. 9 is a diagram showing one example of a laser oscillator configuration in which a diameter of an oscillation laser beam is provided by an aperture in a resonator.
FIGS. 10A to 10C are diagrams showing one implementation mode for explaining a manufacturing process according to another invention different from one in FIGS. 1A to 1C and FIGS. 2A to 2C .
FIGS. 11A and 11B are diagrams showing one example of each of a composite laser rod configuration different from ones explained with reference up to FIGS. 10A to 10C and a configuration of a laser oscillator therewith.
FIG. 12 is a diagram showing one example of a composite laser rod configuration different from ones explained with reference up to FIGS. 11A and 11B .
FIGS. 13A and 13B are diagrams showing one example of a composite laser rod configuration different from ones explained with reference up to FIG. 12 and portions different in the manufacturing process therefrom.
FIG. 14 is a diagram showing one example of a composite laser rod configuration different from ones explained with reference up to FIGS. 13A and 13B .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In order to further detail the invention, the invention will be explained with reference to the attached drawings.
Embodiment 1
FIGS. 1A to 1C and 2 A to 2 C are diagrams showing, with perspective views, one implementation mode in a manufacturing process of a composite laser rod according to the invention.
According to the fabricating method of a composite laser rod shown in FIGS. 1A to 1C , firstly, particles containing a composition to be Y 3 Al 5 O 12 that is a YAG composition are prepared according to a co-precipitation method, the precipitated particles are recovered and baked, and thereby fine particles having a YAG composition and a particle diameter of 100 nm are obtained. The powder is mixed together with an organic binder and a solvent (alcohols, toluene, xylene and so on) in a ball mill to prepare slurry 4 of the YAG fine powder. Thus prepared slurry 4 is filled (STEP S 1 - 1 ) in a hole 2 of gypsum 1 as shown in FIG. 1A and held for 1 hour therein, and thereby water in the slurry 4 is partially absorbed (step S 1 - 2 ) by the gypsum 1 . Thereafter, a bottom lid 3 of the hole 2 of the gypsum 1 is removed, and the slurry 4 remaining in a center portion as shown in the drawing and rich in the water is exhausted from the hole 2 . An amount of the slurry 4 being exhausted is determined according to a degree to which the water is absorbed by the gypsum 1 . When a period of time during which the slurry 4 is held in the hole 2 is accurately controlled, an exhaustion amount of the slurry 4 can be controlled.
That is, the exhaustion amount determines a diameter of a center portion of a flesh portion 5 formed out of the slurry 4 remained in the hole 2 . Accordingly, by controlling a hold time of the slurry 4 in the gypsum 1 , a dimension of the hole 2 of the flesh portion 5 can be accurately controlled. A time during which the slurry 4 flows out after the bottom lid 3 is opened is 0.1 s or less, and an inner wall surface of a pipe-like flesh portion 5 remained in the hole 2 is obtained as a smooth surface. The flesh portion 5 remained on an inner surface of the hole 2 of the gypsum 1 , after water is completely removed by dehydration (step S 1 - 3 ), is taken out of the gypsum 1 .
Subsequently, the pipe-like flesh portion 5 is pre-baked (step S 1 - 4 ) at 800 degree centigrade for 10 hour to degrease, and thereby a pre-baked ceramic YAG pipe 6 having an inner diameter of 2.1 mm, an outer diameter of 4 mm and a length of 50 mm is generated.
In the next place, as shown in FIGS. 2A to 2C , a single crystal YAG laser rod 7 that has a diameter of 2 mm and a length of 35 mm and in which an active element, Nd, is added at a concentration of 1 atomic % is inserted in the pre-baked pipe 6 (step S 1 - 5 ). A side surface of the laser rod 7 is mirror polished before the insertion. When the pre-baked pipe 6 into which the laser rod 7 is inserted is baked at 1700 degree centigrade for 10 hour (step S 1 - 6 ), the pre-baked pipe contracts owing to the baking, and thereby a baked ceramic pipe 8 results. As a result, owing to the action of the plastic deformation effect, the laser rod 7 and the ceramic pipe 8 can be integrated at a bonding interface. The bonded interface, as a result of detailed investigation, is confirmed that only in a region of several tens angstroms that correspond to several atomic layers, the laser rod 7 and the ceramic pipe 8 are bonded owing to the diffusion, and that the diffusion of Nd atoms into the ceramic pipe 8 portion can be almost neglected.
A dimension of the material in which the rod and pipe after the baking are integrated is 3.9 mm and 50 mm in an outer diameter and a length, respectively. The material is processed into a diameter of 3 mm and a length of 30 mm so that a thickness of the ceramic pipe may be formed 0.5 mm as a covering layer in the periphery of the rod followed by polishing a side surface and end surfaces (step S 1 - 7 ), and thereby a composite laser rod 10 in which the laser rod 7 and a ceramic skin layer 9 are integrated as shown in the drawing can be formed.
In the next place, an embodiment of a laser oscillator that is shown in FIG. 3 and in which the composite laser rod 10 is used will be explained.
In a laser oscillator shown in the drawing, cooling water 12 is flowed along a side surface of the composite laser rod 10 that is held at both ends, and from the outside thereof a side surface excitation is applied with an exciting LD (laser diode) 11 . A pulse oscillation is effected with a Q-switch 13 and a pulse of pulse laser beam is outputted from an output mirror 15 .
A measurement monitored with an oscilloscope of an waveform of each pulse of the outputted pulse laser beam is compared with characteristics when an ordinary single crystal YAG laser rod that is not provided with a non-doped pipe and has a diameter of 2.0 mm, a length of 30 mm and an added Nd concentration of 1 atomic % is used.
FIGS. 4 and 5 are diagrams showing the pulse-to-pulse stability of the laser beam having a wavelength of 1.064 nm oscillated at 10 kHz.
As shown in FIG. 4 , in the case of an ordinary single crystal YAG laser rod, the output stability is ±7.5%, in contrast, as shown in FIG. 5 , in the case of the composite YAG laser rod 10 , the output stability thereof is ±2.5%. That is, the output dispersion becomes one third that of the ordinary rod, resulting in an improvement by three times in the output stability. The output modes are the single mode for both cases.
Furthermore, another actual measurement with the composite laser rod 10 will be explained with reference to FIG. 6 . In FIG. 6 , to the laser oscillator shown in FIG. 3 , a lens, a second harmonic generation element 16 and a third harmonic generation element 17 are added to an outputted laser beam.
In the illustrated laser oscillator, a laser beam is focused with a lens and inputted into the second harmonic generation element 16 and the third harmonic generation element 17 , and 355 nm that is of the generated third harmonic is oscillated. The positional stability of the beam according to the apparatus is studied by use of a beam profiler. In order to study the magnitude of the fluctuation while enlarging, a laser beam is allowed to propagate 2 meter from a third harmonic output surface into a space, and the beam is received by the beam profiler and studied.
As a result, as shown in FIG. 7 , while the fluctuation of the output beam of the ordinary 2 mm-diameter single crystal YAG laser rod is ±100 μm in the X-axis direction and ±75 μm in the Y-axis direction, that of the 3 mm-diameter composite YAG laser rod 10 is ±50 μm in the X-axis direction and ±50 μm in the Y-axis direction. That is, it is confirmed that the beam positional stability of the wavelength-converted light is improved by 50% in the X-axis direction and 66% in the Y-axis direction. From the results, it can be confirmed that not only the output positional stability of the beam is improved, but also the difference in X- and Y-axis directions of the positional stability is made smaller, and thereby the fluctuations are equalized. By the way, when the laser processing is performed with the laser beam, it is confirmed that the processing precision is improved with a ratio same as that of the improvement of the positional stability and an aspect ratio of a shape of a hole formed by the processing is improved from 4:3 to substantially 1:1.
Embodiment 2
Next, with reference to FIG. 8 , another composite laser rod 20 different from that described above will be explained.
The illustrated composite laser rod 20 is fabricated as follows. Firstly, in order to obtain a high quality single mode narrow laser beam, a single crystal YAG laser rod 21 that contains 0.7 atomic % of Nd and has a diameter of 1 mm and a length of 15 mm is prepared. In the next place, the YAG laser rod 21 is bonded to a ceramic YAG pipe 22 according to a method same as that of the above embodiment, and thereby the composite laser rod 20 having a diameter of 3 mm and a length of 15 mm is prepared. The composite laser rod 20 , as shown in the drawing, is disposed between an output mirror 25 and a rear mirror 24 . The composite laser rod 20 , similarly as shown in FIG. 3 , is excited from a side surface with a laser diode, and thereby, without disposing an aperture, an oscillation beam of a single mode having a beam diameter of 1 mm can be outputted. In the laser oscillator, the pulse-to-pulse output stability is ±2.5%, the positional stability of the laser beam is ±10 μm in both length and breadth directions at a position after the laser beam is propagated 1 meter in a space, and an aspect ratio of the positional stability is 1:1.
For comparison purpose, a single crystal YAG laser rod that has a diameter of 1 mm and a length of 15 mm and contains 0.7 atomic % of Nd is prepared, and an oscillation experiment is carried out according to a resonator configuration same as FIG. 8 . As a result, because of narrowness of the laser rod, the laser rod is fixed in the resonator with difficulty, and the laser rod is caused to vibrate owing to the vibration of the cooling water that flows in the periphery of the rod, though oscillated in the single mode, the pulse-to-pulse output stability resulting in ±10%.
Then, as shown in FIG. 9 , a single crystal YAG laser rod 31 that has a diameter of 3 mm and a length of 15 mm is prepared, an aperture 36 having a diameter of 1 mm is disposed before an output mirror 35 , and similarly to the above method, the laser rod 31 is oscillated. As a result, an oscillation beam of a single mode having a beam diameter of 1 mm can be outputted. However, the pulse-to-pulse output stability is ±7%, and the oscillation efficiency from the excitation light to the oscillation light, in comparison with the embodiment of FIG. 8 , decreases to two third. This is because there is a Nd doped portion that does not contributes to the oscillation in the rod, this absorbs the excitation light.
Embodiment 3
In the next place, a fabricating method of a still another composite laser rod 40 different from the above will be explained with reference to FIGS. 10A to 10C .
Firstly, a ceramic YAG laser rod 42 that has a diameter of 2 mm and a length of 30 mm and contains an active element, Nd, of 1.5 atomic % is prepared. The ceramic laser rod 42 , as shown in the drawing, is disposed at a center portion of a cylindrical slurry container 41 . In this state, slurry 4 for use in the formation of YAG ceramic that is prepared according to a process the same as mentioned above is discharged and filled in the container (step S 2 - 1 ). Thereafter, water in the slurry 4 is vaporized followed by pre-baking at 800 degree centigrade for 10 hour, and thereby pre-baked ceramic material 43 is formed. Subsequently, the slurry container 41 is removed (step S 2 - 2 ). Furthermore, the pre-baked ceramic material 43 , with the laser rod 42 inserted, is baked at 1700 degree centigrade for 10 hour (step S 2 - 3 ), and thereby the periphery of the Nd-doped ceramic YAG laser rod 42 is surrounded by a transparent ceramic YAG material 44 . The ceramic YAG material 44 is polished (step S 2 - 4 ) so as to form a ceramic pipe 45 having a thickness of 0.5 mm as a skin layer, and thereby the composite laser rod 40 having an outer diameter of 3 mm and a length of 30 mm is formed.
When an oscillation experiment of laser beam is performed with the composite laser rod 40 , the laser beam output stability of ±2.5% and the beam positional stability of the third harmonic of ±0.75 μm are obtained, respectively. That is, the same results as that of the composite laser rod in which the single crystal YAG laser rod 7 is used are obtained. Furthermore, since the Nd concentration is 1.5 atomic % higher by 0.5% than 1.0% of the single crystal YAG laser rod 7 , it is confirmed that at the same laser diode excitation power, the oscillation output is improved by substantially 20%.
Embodiment 4
Next, still another composite laser rod 50 different from the above ones and a laser oscillator therewith will be explained with reference to FIGS. 11A and 11B .
An experiment is carried out to fabricate a composite laser rod in which the refractive index of a laser rod is higher than that of a ceramic pipe. A ceramic YAG rod that contains 1 atomic % of Nd, 10 atomic % of Lu, and 20 atomic % of Ga, has a length of 5 mm and a diameter of 2 mm, and has a mirror-polished side surface is prepared. The ceramic YAG rod is inserted in a pre-baked ceramic YAG pipe that is fabricated according to a procedure the same as that described above and has a length of 10 mm, an inner diameter of 2.1 mm and an outer diameter of 5.1 mm followed by baking at 1700 degree centigrade for 10 hour. After the baking, the periphery thereof is processed, and thereby a composite laser rod 50 is formed such that the periphery of the Nd, Lu, Ga doped ceramic YAG laser rod 51 having a diameter of 5.0 mm and a length of 5 mm is bonded to the non-doped ceramic YAG pipe 52 .
In the composite laser rod 50 , the ceramic YAG laser rod 51 at a center thereof has the refractive index of 1.84 that is higher by 1.1%, 0.02 in the refractive index, than 1.82 of the ceramic YAG pipe 52 in the periphery thereof. Accordingly, as shown in the drawing, excitation light 57 in the composite laser rod 50 that is excited through a side surface with an exciting LD 56 is confined into the Nd, Lu, Ga-doped ceramic YAG laser rod 51 . As a result, the excitation light 57 is efficiently absorbed by the ceramic YAG laser rod 51 .
The oscillation efficiency is compared with that of the composite laser rod in which a single crystal YAG laser rod doped with 1 atomic % of Nd is used as the laser rod. As a result, it is confirmed that under the same excitation light intensity condition, the excitation efficiency when the Nd, Lu, Ga-doped ceramic YAG laser rod 51 is used is 1.2 times that of the 1 atomic % Nd-doped single crystal YAG laser rod.
Similarly, when a ceramic YAG rod that contains 1 atomic % of Nd and 70 atomic % of Lu and has the same dimension is used as the laser rod, the refractive index of the rod becomes 1.83, that is, higher by 0.5% in the refractive index than that of the ceramic YAG pipe. When the same experiment is carried out with the laser rod, the laser beam intensity is 1.1 times that of the 1 atomic % Nd-doped single crystal YAG laser rod. Furthermore, the refractive index of a ceramic laser rod in which 1 atomic % of Nd and 18 atomic % of Ga are doped is also 1.83, and when the characteristics of the laser rod to which a ceramic YAG pipe is bonded are compared by the same experiment, it is confirmed that the laser beam intensity becomes 1.1 times higher than that of the 1 atomic % Nd-doped single crystal YAG laser rod.
Embodiment 5
In the next place, with reference to FIG. 12 , a composite laser rod 60 different from ones described above will be explained.
Firstly, a single crystal gadolinium gallium garnet (Gd 3 Ga 5 O 12 ; GGG) laser rod 61 that is doped with 1 atomic % of Nd and has a diameter of 2 mm and a length of 35 mm is prepared and a side surface thereof is mirror-polished. With the laser rod 61 , in the periphery thereof, according to a process the same as that described above, a non-doped ceramic YAG pipe 62 is formed. As a result, the composite laser rod 60 having a diameter of 3 mm and a length of 35 mm is formed. Since the refractive index of GGG is 1.94 and that of YAG is 1.82, there is 6% of the refractive index difference therebetween. Accordingly, light excited from a side surface of the composite laser rod 60 can be confined into the GGG laser rod 61 at the center thereof.
The laser rod is oscillated by means of the side surface excitation and the results thereof are compared with that of a composite laser rod in which the GGG ceramic is used in the ceramic pipe so that there is no refractive index difference. As a result, under the same excitation light intensity condition, the oscillation efficiency can be improved by 10%. From the result, it is confirmed that when the refractive index of the laser rod that constitutes the composite laser rod is made higher than that of the ceramic pipe in the periphery thereof, the beam positional stability and output stability can be improved in comparison with an ordinary rod, and the oscillation efficiency is improved in comparison with that of the composite laser rod in which the refractive index difference is not disposed.
Embodiment 6
Next, a composite laser rod 70 different from ones described above will be explained with reference to FIGS. 13A and 13B .
First, in place of the above Nd-doped single crystal YAG laser rod, a ceramic Y 2 O 3 laser rod 71 that contains 5 atomic % of Yb and has a diameter of 2 mm and a length of 35 mm is prepared. A non-doped ceramic pipe in the periphery thereof is fabricated with slurry in which Y 2 O 3 powder is used. As illustrated in the drawing, after the Yb-doped ceramic Y 2 O 3 laser rod 71 is inserted into a pre-baked ceramic Y 2 O 3 pipe 72 , non-doped ceramic Y 2 O 3 rods 73 that are separately prepared and have a diameter of 2 mm and a length of 5 mm are inserted into a hollow portion of the ceramic Y 2 O 3 pipe 72 from both sides thereof. In order to promote the bonding between the ceramic Y 2 O 3 laser rod 71 and the non-doped ceramic Y 2 O 3 rods 73 , in a gap in the ceramic Y 2 O 3 pipe 72 , slurry of Y 2 O 3 is filled in. Thereafter, by baking at 1700 degree centigrade for 10 hour, the rods 71 and 73 in the ceramic Y 2 O 3 pipe 72 and the pipe 72 are integrated, and thereby a ceramic covered body 74 in which the non-doped ceramic completely covers the doped-ceramic Y 2 O 3 laser rod 71 is formed. From the sample after the baking, the composite laser rod 70 having a length of 45 mm and a diameter of 3 mm is fabricated.
The composite laser rod 70 forms a rod in which, at both ends thereof, the pipe 72 and the rods 73 all of which are made of non-doped ceramic Y 2 O 3 are completely integrated. When the oscillation characteristics of the composite laser rod are measured with a resonator in which laser diode excitation is applied from a side surface, it is found that output is improved by substantially 15% in comparison with that of a composite laser rod in which the non-doped portions are not disposed at both ends.
Embodiment 7
In the next place, with reference to FIG. 14 , a composite laser rod 80 different from ones described above will be explained.
As a laser rod, a single crystal YAG laser rod 81 that has a diameter of 2 mm and a length of 30 mm and contains 0.8 atomic % of Nd is prepared. As a non-doped ceramic pipe in the periphery thereof, one that is prepared with slurry of Y 2 O 3 is prepared. In a pre-baked Y 2 O 3 ceramic pipe, the single crystal YAG laser rod 81 is inserted followed by baking at 1700 degree centigrade for 10 hour and furthermore followed by processing, and thereby the composite laser rod 80 that has a diameter of 3 mm and a length of 30 mm and in which to the periphery of the single crystal YAG laser rod 81 the ceramic Y 2 O 3 pipe 82 is bonded is prepared. The rod is oscillated with the resonator similar to one described in FIG. 3 , and the thermal lens effect is compared with that of one in which a ceramic YAG pipe is bonded to a periphery. Since the thermal conductivity of the Y 2 O 3 pipe is such large as twice that of the YAG pipe, the laser rod can be more excellently cooled, resulting in a reduction of the thermal lens effect by 30% or more.
As explained above, according to the invention, a composite laser rod in which a laser rod and a non-doped ceramic pipe that becomes a skin layer in a periphery of the rod are baked and completely integrated is realized. The composite laser rod according to the invention can suppress the thermal fluctuation of the laser rod during the laser oscillation associated with the variation of the cooling capacity, and can reduce an influence of the vibration received from the cooling medium. Accordingly, the positional stability and the output stability of the laser beam oscillated from the laser rod can be improved. Furthermore, when a composite laser rod with a combination in which the refractive index of the laser rod is higher than that of the ceramic pipe is prepared, since the excitation light can be efficiently absorbed by the laser rod, the oscillation efficiency can be improved. Still furthermore, when the ceramic pipe is formed with a material higher in the thermal conductivity than that of the laser rod, since the rod can be efficiently cooled, the thermal lens effect can be lowered. When the laser rod according to the invention is applied to a laser processor, high precision and stable laser processing can be speedily and efficiently performed.
Accordingly, for instance, processing accuracy in boring a hole in a printed wiring board is improved, and energy for a pulse of a laser beam is also increased. As a result, the number of pulses is less needed for the same processing and the processing speed is also enhanced. Furthermore, in a trimming device that uses a laser beam, while measuring characteristics of an element to be trimmed, laser beam is irradiated onto the element. When the composite laser rod according to the invention is used, finer control of the element characteristics can be realized. Still furthermore, even in a repair device, a welder and a surface modifier that use laser beam, by improving the output stability and the positional stability of the laser beam, processing accuracy and processing speed can be appreciably improved. Thus, the invention contributes to the development of industries in which laser devices are applied. | As a composite laser rod capable of satisfying the positional stability and output stability of a laser beam, a laser rod in which a laser active element is doped is intimately inserted into a hollow portion of a non-doped ceramic pipe that has a crystal structure the same as the laser rod followed by baking so as to remove a gap and strain at an interface between the laser rod and the ceramic pipe after the baking further followed by polishing a surface of the ceramic pipe to form a ceramic skin layer, and thereby a composite laser rod is formed. In the composite laser rod, an influence due to fluctuation in the cooling capacity of cooling water or a heat sink is averaged by a non-doped skin layer, temperature fluctuation of the laser rod is suppressed, and an influence of vibration from the cooling water or a cooling fan can be suppressed. When the refractive index of the laser rod is made higher than that of the ceramic pipe, a high efficiency oscillation can be realized, and furthermore when the thermal conductivity of the ceramic pipe is made higher than that of the laser rod, the thermal lens effect can be alleviated. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a new an improved panel molding system and more particularly to a panel molding system which is adapted for use in decorating paneled walls of variable heights to provide decorative profiles along the floor or base, along an intermediate level such as the level of a chair rail and along the ceiling.
2. Description of the Prior Art
Prior art panel systems have employed matched moldings of relatively simple profiles, but for the most part, prior systems have not placed emphasis on the decorative aspects and the fact that paneled walls of different heights require moldings of different widths to provide a functional and decorative visual foundation for the wall decor. In this connection, prior art systems normally have provided only a single molding of relatively narrow width and these moldings often do not lock well on walls that are relatively high. Moreover, prior systems have not provided the needed variety of molding widths for more aesthetic treatment of paneled walls and the like.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a new and improved panel molding system.
More particularly, it is an object of the present invention to provide a new and improved panel molding system which is adapted to provide a wide variety of molding combinations for improved wall decor of paneled walls.
Another object of the present invention is to provide a new and improved panel molding system wherein a basic molding may be utilized alone or in combination with one or more additional molding members in an attractive and tongue and groove interlocked combination to provide a wide variety of molding profiles with a minimum number of standard profile sections.
Another object of the present invention is to provide a new and improved panel molding system of the character described wherein a pair of molding members may be in tongue and groove interconnected relationship when overlapped to provide a broader width molding for improved appearance.
Another object of the present invention is to provide a new and improved panel molding system wherein a basic molding member may be utilized in combination with one or more secondary molding members in a variety of combinations interlocked together.
Another object of the present invention is to provide a new and improved panel molding system which is easy to install, relatively low in cost, physically strong and which provides for a wide variety of appearances.
These and other objects and advantages of the present invention are accomplished in the several illustrative embodiments, one of which comprises a panel molding system having in combination a first or base corner molding member having an outer viewing face and an opposite back face adapted to confront a wall surface of the like. The base member includes a base portion along a lower edge of the face having a support surface adapted to rest or bear against the floor or the like and includes a rib extending away from the outer face. A secondary molding member having an outer viewing face and an opposite back face adapted to bear against the wall surface is provided and the secondary member includes groove means formed in the outer face spaced between the upper and lower edges and dimensioned to receive at least a portion of the rib of the base member when placed in partially over-lapping relation upon the second member. The base corner member may be utilized alone and/or the combination may be utilized to provide a more massive and decorative pleasing appearance. The combination may also be enlarged to include a third molding member having an outer viewing face and an opposite face adapted to confront a wall surface or the like. The third member is also provided with groove means in the outer surface intermediate the upper and lower edges and the secondary member has a rib extending away from the outer face adapted to seat in the groove means of the third member dimensioned to receive the rib when the secondary member is placed in partially overlapping relation on the third molding member.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the present invention reference should be had to the following detailed description taken in conjunction with the drawings in which:
FIG. 1 is an elevational view of a wall section treated with a panel molding system constructed in accordance with the features of the present invention;
FIG. 2 is an enlarged fragmentary sectional view taken substantially along lines 2--2 of FIG. 1;
FIG. 3 is an elevational view of a wall section treated with another combination encompassed by the panel molding system of the present invention;
FIG. 4 is an enlarged fragmentary sectional view taken substantially along lines 4--4;
FIG. 5 is an elevational view of a wall section treated with yet another combination encompassed by the panel molding system of the present invention;
FIG. 6 is an enlarged fragmentary sectional view taken substantially along lines 6--6 of FIG. 5; and
FIG. 7 is an elevational view illustrating how the molding members of the panel molding system of the present invention may be used individually and in combinations to provide a decorative architectural interest for wall surfaces, door, cabinet or picture frames, window treatment and the like in order to magnify and improve the visual interest.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2, therein is shown a paneled wall structure 10 trimmed with a composite base molding 12, an intermediate or chair rail level molding 14 and a ceiling molding 16 constructed in accordance with the panel molding system of the present invention. The wall structure 10 includes vertically grooved wall panels 18 extending between the base molding 12 the the intermediate level molding 14 and a plurality of windows 20 or other panels extending between the intermediate level molding 14 and the ceiling or top level molding 16. The panels 20 are separated by vertical mullions 22.
As shown in enlarged detail in FIG. 2, the wall structure 10 may include a two by four frame 24 or other type of structural system covered with wall boards 26 on one or both sides. The wall structure extends upwardly between floor structure 28 and a ceiling (not shown) and the base molding 12 of the present invention is adapted to beautify and trim the wall along the base or floor line.
The base molding 12 includes a base or primary elongated molding strip 30 formed of wood or other material having an upstanding leg 32 and a base or shoe 34 at right angles adapted to rest upon the floor structure 28. The base molding member includes an irregular outer viewing face 36 and an opposite or back face 38 adapted to confront the wall 10 or panel 18 when positioned in place as shown in FIG. 2. The outer viewing face of the base molding strip includes a lower face segment 36a, a sloping segment 36b extending upwardly thereof and a vertical segment 36c of relatively narrow width is formed adjacent the upper edge of the sloping segment. A narrow horizontal segment 36d extends at right angles along the upper edge of the narrow vertical segment 36c. A relatively wide vertical segment 36e extends upwardly from the narrow horizontal segment 36d and a narrow sloping segment 36f extends upwardly along the upper edge of the relatively vertical face segment 36e. The upper surface of the base molding strip comprises a horizontal top 36g forming the upper surface of a rearwardly extending rib 39 formed along the upper edge of the base molding strip. The outer viewing face 36 of the base molding thus includes a plurality of segments 38a-38g of different widths and slopes to provide extra visual interest and pleasing appearance for a wall trim because of the highlights, shadows and combinations thereof formed by the variety and orientation of the face segments. Along the base molding 30 may also be used for a framing member for mirrors, pictures, cabinets, doors, etc., in any number of different applications, for example as shown in FIG. 7.
The composite base molding 12 including the base 30 (with a profile as described) also includes a secondary molding or casing member 40 which may be used independently on the vertical mullions 22 between the window panels 20 and/or the upper or ceiling molding 16 as shown in FIG. 1. The secondary molding includes an outer viewing surface 42 and an opposite back face 44 adapted to confront and normally contact a wall surface such as the paneling 18 as shown in FIG. 2. The outer viewing face includes a relatively wide, centrally disposed face segment 42a flanked on opposite sides by a pair of relatively narrow inwardly offset, face segments 42b. The large center face segment 42a and the upper and lower narrower face segments 42b of the outer viewing face 42 are separated by a pair of indented grooves 46. These grooves provide shadows and contrast and are appropriately dimensioned to receive the rib 39 of the base molding 30 when the moldings 30 and 40 are interconnected in composite overlapping relation as shown in FIG. 2 to form the base molding 12. The rib 39 of the base molding and the grooves 46 of the secondary narrow casing molding form a tongue and groove joint for positively interlocking the moldings together to form the relatively wide composite base molding 12.
On the wall structure 10, the ceiling molding 16 and the vertical mullions 22 may be provided by applying segments of the secondary narrow casing 40. The intermediate level molding 14 may be formed by the base molding 30 in an inverted position with the base or shoe portion 34 providing a counter like top or cap. The panel molding system as described using base molding 30 alone or in combination with secondary casing members 40 which also may be used alone for some purposes as described provides a system with a wide variety of choices for a decorator. The system is rich in highlights, shadows, extra visual interest and is extremely pleasing to the eye.
Referring now to FIG. 3, therein is illustrated another embodiment of a wall structure 10A generally similar to the structure 10 as previously described but including a wider composite base molding 12A, the same intermediate level molding 14 (comprising a single base 30 in inverted position) and a relatively wide upper ceiling molding 16A comprising the composite base molding 12 of FIGS. 1 and 2 in inverted position. The modified wider base molding 12A as shown in FIGS. 3 and 4 includes in combination with the base molding 30 a secondary casing member 50 having both a width and thickness substantially greater than the relatively thin and narrow casing member 40 as previously described. The wide casing member 50 includes an outer viewing face 52 and an opposite or back face 54 adapted to bear against the surface of a wall such as the wall panel 18. The outer viewing face 52 is formed with a relatively narrow lower face segment 52a and a relatively wide intermediate face segment 52b separated from one another by a groove 56 dimensioned to receive the rib 39 of the base molding 30 when placed in overlapping relation to form a tongue and groove combination as shown. The outer viewing face of the wide molding 50 includes a narrow horizontal face segment 52c along the upper edge of the intermediate face segment 52b and a narrow vertical face segment 52d extends upwardly from the face segment 52c. A sloping face segment 52e is provided adjacent the upper edge of the vertical face segment 52d and the upper edge of the casing member 50 is formed by a horizontal face segment 52f, which segment forms the upper edge surface of a rearwardly extending rib 58 along the upper edge of the casing member. A similar rearwardly extending rib 60 is formed along the lower edge of the casing and an intermediate land 62 is provided at mid level on the casing member between the ribs on the back face 54. As shown in FIG. 4, the ribs 58 and 60 and the land 62 are adapted to bear against a wall surface such as the wall panel 18 when the wide casing member 50 is used in combination with the base molding 30 to form the modified composite relatively wide base molding section 12A.
Referring now to FIG. 5, therein is illustrated another embodiment of a wall structure indicated by the reference number 10B and generally similar to the wall structures 10 and 10A as previously described. The structure 10B includes a somewhat wider composite base molding 12B and an intermediate level molding 14A which comprises the same composite base molding 12A as in the prior embodiment of FIGS. 3 and 4. In addition, the wall structure 10B includes a ceiling molding 16A also like the composite base molding 12A in the prior embodiment. Accordingly, the intermediate level molding 14A an the ceiling molding 16A of the wall structure 10B will not be described in detail.
Referring to FIG. 6, the composite molding 12B includes in combination, the base molding 30 having its rib 39 in tongue and groove interlocking relation within the groove 56 of a secondary wide molding strip 50. The upper rib 58 of the wide molding strip 50 is in turn interlocked in tongue and groove relation within the lower groove 46 of a third member of the combination comprising the secondary casing or molding strip 40. The combination of three elements making up the composite molding 12B thus provides a massive appearance and is rich in shadows and detailed visual effect. As shown in FIG. 6, the lower rib of the wide secondary molding stip 50 is adapted to bear against a spacer or furring strip 64 and this strip along with the vertical wall panels 18 are preferably applied to the wall structure over underlayment backing board 66 attached to the structural framing members.
Referring to FIG. 7, it will be seen that the molding strips 30, 40 and 50 may be used in a variety of combinations to provide frames suitable for pictures, mirrors, cabinets, windows, doors and the like and the novel interlocking tongue and groove arrangement between the several molding strips when assembled together in composite moldings of various combinations as described, provides a means for giving a decorator a wide variety of choices for an aesthetic design but an economical basis.
Although the present invention has been described with reference to the illustrative embodiments thereof, it should be understood that numerous other modifications and embodiments can be devised by those skilled in the art that will fall within the spirit and scope of the principles of this invention. | A panel molding system comprising in combination a first corner member having an outer viewing face and an opposite back face adapted to confront a wall surface or the like, said first member having a base portion along the lower edge of said faces and having a support surface adapted to rest on a floor or the like and including a rib extending away from the outer face and a second member having an outer viewing face and an opposite back face adapted to bear against a wall surface, said second member having groove means defined in the outer face spaced between upper and lower edges and dimensioned to receive at least a portion of the rib of the first member placed in partially overlapping relation on the second member. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 205,254 filed Nov. 10, 1980, now abandoned, which is a divisional application of the application Ser. No. 934,612 filed Aug. 17, 1978, now U.S. Pat. No. 4,261,187 issued Apr. 14, 1981.
BACKGROUND OF THE INVENTION
Generally, conventional circular knitting machines employ a driving pinion to engage with a ring gear integrally formed with or mounted onto a latch needle cylinder having thereon latch needles to perform the knitting operation. Due to the clearance between the teeth of the pinion and those of the ring gear, an oscillation will certainly occur at the point the ring gear and pinion are engaged. Each time any of the latch needles rotates to the position where it is relatively close to the point of engagement i.e., the oscillation source, the oscillation will grow, while each time any of the latch needles rotates to the position where it is relatively far from the oscillation source, the oscillation decreases. This uneven oscillation leads to the occurrence of undesirable horizontal lines on the knitted fabric. Aside from such an uneven oscillation, there are of course still other causes, such as the uneven quality of yarns, mis-adjustment of cams, etc., which will also create the undesirable horizontal lines. Nevertheless, these other causes may be more easily controlled than the uneven oscillation and have been controlled in actual practice. To prove that the undesirable horizontal lines arise from the uneven oscillation, the inventor has made an experiment with a circular knitting machine of 38 gauge. In the experiment dye was smeared on the yarn entrance of the transmission assembly which was closest to the oscillation source, i.e., the engagement point between a gear wheel and a pinion so that when yarn entered, the dye marked the yarn. The resulting knitted fabric revealed a dyed track on thick horizontal lines thereof. The same experiment was repeated at another transmission assembly opposite the first transmission assembly, and the dyed track was again seen on thin horizontal lines thereof. To obtain further proof thereof, the inventor removed the second mentioned transmission assembly and found that the thin horizontal lines disappeared. Therefore, it has been concluded that the greater the source of oscillation of the latch needles the denser will be the undesirable horizontal lines.
SUMMARY OF THE INVENTION
This invention discloses a circular knitting machine comprising a machine truss, a machine plate fixedly mounted onto the machine truss, and a latch needle holder rotatably supported by the machine plate, the latch needle holder having thereon a plurality of latch needles to perform the knitting operation. The latch needle holder is driven for rotation by a driving device including a gear wheel in mesh with a pinion driven by an electric motor, in which the gear wheel is separated from the portion of the latch needle holder where latch needles are provided so that the oscillation created by the gear wheel and pinion is dispersed before reaching the latch needles.
The circular knitting machine of this invention may be of a single knitting type having one group of latch needles on one latch needle holder that may be in the form of a cylinder or a circular plate, or of a double knitting type having another group of latch needles on another latch needle plate disposed above the first latch needle holder to cooperate with the first group of latch needles on the first latch needle holder.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinal cross-sectional view of first and second embodiments of the invention wherein the former is the portion under the phantom line, while the later includes the portions under and above the phantom line;
FIG. 2A is a top view of the bearing transmission device of the invention;
FIG. 2B is a front view of the bearing transmission device of the invention;
FIG. 3 is a longitudinal cross-sectional view of a third embodiment of the invention;
FIG. 4 is a top view depicting the distance adjusting steel rings of the third embodiment of the invention;
FIG. 5 is a longitudinal cross-sectional view of fourth and fifth embodiments of the invention, wherein the former is the portion under the phantom line, while the latter includes the portions under and above the phantom line;
FIG. 6 is a longitudinal cross-sectional view of sixth and seventh embodiments of the invention, wherein the former is the portion under the phantom line, while the latter includes the portions under and above the phantom line, and wherein the base portion is omitted from the drawing;
FIG. 7 is a top view of an oscillation damping plate provided in the sixth and seventh embodiments of the invention showing a cross sectional view taken along the section line VII--VII of FIG. 6;
FIG. 8 is a longitudinal cross-sectional view of an eighth embodiment of the invention, with the base portion omitted from the drawing;
FIG. 9 is a longitudinal cross-sectional view of a ninth embodiment of the invention;
FIG. 10 is a longitudinal cross-sectional view of a tenth embodiment of the invention; and
FIG. 11 is a longitudinal cross-sectional view of eleventh embodiment of the invention, with non-essential portions omitted.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, the portion under the phantom line is a single circular knitting machine with a single shaft, being a first embodiment of the invention. Upon base 11 of machine truss 10, gear wheel 13 is rotatably mounted with bearing 12. The gear wheel 13 is in mesh with pinion 14 so that when driven by motor M, the pinion 14 will drive the gear wheel 13 to rotate. Upon gear wheel 13, these are provided an upper driving bracket 15 and a lower driving bracket 16, both being connected together by means of movable pins 19. Also as shown in FIG. 1, the upper driving bracket 15 is fixed beneath transmission ring 18, while the lower driving bracket 16 is fixed onto gear wheel 13. Cloth take-up roll 5 is rotatably mounted on lower driving bracket 16. When gear wheel 13 is driven, transmission ring 18 will rotate by means of the transmission of the upper and lower driving brackets whereby central hollow shaft 20 fixed onto the transmission ring 18 will rotate on the heels thereof. The shaft 20 thus forms an active central hollow shaft. Horizontally upon central hollow shaft 20 is secured a latch needle holder or a circular latch needle plate 22 having a rim and a lower hub, and the outer circumference thereof is provided with a plurality of latch needles 23. Between the rim and the lower hub of circular latch needle plate 22, there is further provided an inspection space 29. The central hollow shaft 20 is rotatably supported by circular machine plate 25 by means of bearing 24, the circular machine plate 25 being fixed onto the machine truss 10. In abutment with the rim of circular machine plate 25, cams 26 are provided. Between cams 26 and latch needle plate 22, inspection space 29 is provided. It is noted in FIG. 1 that one inspection space 29 is defined between the lower hub and the rim of the circular latch needle plate 22 and other spaces between the cams 26 and cam seats 27. Therefore, taking advantage of a plurality of inspection spaces 29 which are formed in pairs, the operator can check the status of cloth inside the knitting machine. When circular latch needle plate 22 is driven to rotate, cams 26 will coordinate therewith to perform the knitting. From above, it is easily seen that gear wheel 13 and pinion 14 are located at the bottom of the machine and that the oscillation occurring between gear wheel 13 and pinion 14 travels a long distance successively through lower driving bracket 16, upper driving bracket 15, central hollow shaft 20, and further circular latch needle plate 22 to the tips of latch needles 23 where the magnitude of oscillation is reduced to the smallest. Besides, when the oscillation reaches central hollow shaft 20, it can be radially and evenly distributed latch needles whereby the equal magnitude of oscillation thereupon can obviate the occurrence of the undesirable horizontal lines.
The fabric is drawn through latch needles 23 and 23B whereby the fabric is being knitted into a cloth of cylindrical shape, which is gathered and drawn through the hollow space around a rod in shaft 20 to the take up roll 5 below, the rod being fixed to the lower, central portion of latch needle plate 22B and provided with a fabric stretcher 6 at its lower end, and with stretcher 6 the cloth drawn through the central hollow space in shaft 20 is stretched for winding by take-up roll 5. The size of the central hollow shaft 20 depends upon the thickness of the cloth to be knitted so that there is ample space between the inner surface of the shaft 20 and the outer surface of the rod in the shaft.
The portion under the phantom line of FIG. 1 has been described above as the first embodiment of the invention, this portion may be operated as a single knitting machine without the portion shown above the phantom line, or with the portion shown above the phantom line to become a two needle bed knitting machine, which will be described below as the second embodiment. In this second embodiment, the upper part of the machine comprises an upper machine plate 25B fixedly mounted onto machine truss 10, an upper central hollow shaft 20B, a passive shaft, rotatably supported by upper machine plate 25B, an upper latch needle plate 22B fixed onto the lower end of upper central hollow shaft 20B, a plurality of upper latch needles 23B on the circumference of upper latch needle plate 22B, the upper latch needles 23B being adapted to cooperate with latch needles 23 on the latch needle holder or lower needle plate 22. Cams 26B are provided to enable latch needles 23B to perform the knitting operation. Upper latch needle plate 22B and lower latch needle plate 22 and adapted to rotate synchronously by means of bearing transmission device 30 as shown in FIG. 1, (also in FIGS. 2A and 2B) so that the upper central hollow shaft 20B rotates as a passive revolving shaft with central hollow shaft 20 as an active revolving shaft.
As shown in FIGS. 2A and 2B, the bearing transmission device 30 comprises two transmission bearings 32 and 33 respectively rotatably supported by two stationary eccentric axes 31--31 which are integrally formed and are fixed onto upper supporting plate 30A secured onto the bottom surface of upper latch needle plate 22B. Also as shown, the bearing transmission device 30 further comprises a driving bearing 34 and a braking bearing 35 respectively disposed at both sides of the two transmission bearings 32 and 33, the driving bearing 34 and braking bearing 35 being fixed onto lower supporting plate 30B respectively by means of two axes 36--36. The two axes 36--36 are fixed onto lower supporting plate 30B which is secured onto the surface of circular latch needle plate 22. There is the provision of a small clearance between the transmission bearing 33 and the driving bearing 34 and likewise a small clearance is provided between the transmission bearing 32 and the braking bearing 35. Since the two transmission bearings 32 and 33 are respectively provided on eccentrical axes 31--31, the knitted fabric may pass through the clearances and then go thereunder, during which the two transmission bearings 32-33 are transmitted to rotate thereby (as shown by arrows A and B in FIGS. 2A and 2B). Therefore, in addition to a function for the upper circular latch needle plate 22B and the circular latch needle plate 22 to have synchronous rotation, the transmission bearing device 30 has another function for knitted fabric to pass therethrough. Since the conventional bearing transmission device thereof comprises four sets of driving bearings and one set of braking bearings, five undesirable vertical lines will consequently be brought about. Since two friction forces are generated between the clearances respectively and are exerted on the knitting fabric, only two undesirable vertical lines will occur on the knitted fabric because of the present bearing transmission device, but as the distance between them is small, it requires to insure the beauty of the knitted fabric only that the knitted fabric be cut along the central line between the two vertical lines without losing its beauty because these undesirable vertical lines are near the outer border of the knitted fabric.
FIGS. 3 and 4 show a third embodiment of the invention. In this embodiment the circular knitting machine comprises a machine truss 10, a base 11 on which the machine truss 10 is fixedly mounted, an upper machine plate 25B fixedly mounted onto an upper part of machine truss 10, lower machine plate 25 fixedly mounted to lower a generally middle portion of machine truss 10, a central hollow shaft 20A having an upper portion rotatably supported by upper machine plate 25B with bearing 24B and a lower portion rotatably supported by lower machine plate 25 with bearing 24, a latch needle holder or a lower latch needle plate 22A integrally formed with central hollow shaft 20A, an upper latch needle plate 22C fixedly mounted on central hollow shaft 20A and disposed above lower latch needle plate 22A, a plurality of latch needles 23B on the circumference of upper latch needle plate 22C, a plurality of latch needles 23 on the circumference of lower latch needle plate 22A, a plurality of cams 26 and 26B adapted to enable latch needles 23 and 23B, respectively, to perform the knitting operation, and cam seats 27. Central hollow shaft 20A is provided with a lower extension on which a transmssion ring 18 is fixedly mounted. The transmission ring 18 is provided with an upper driving bracket 15 fixedly mounted onto a lower side thereof, the upper driving bracket 15 being operatively connected to a lower driving bracket 16 which is fixedly mounted onto gear wheel 13, the gear wheel 13 being rotatably mounted onto base 11 with bearing 12 and in mesh with pinion 14 driven by an electric motor M. Pins 19 are adapted to operatively connect upper driving bracket 15 and lower driving bracket 16, the pins 19 having one end fixed to upper driving bracket 15 and another end loosely inserted into a slot 19A formed in lower driving bracket 16 so as to allow self-alignment of the upper and lower driving brackets.
Furthermore, between upper latch needle plate 22C and lower latch needle plate 22A a plurality of supporting bars 42 are secured onto central hollow shaft 20A; at the ends of which lower adjusting steel ring 44 is horizontally secured. Upon the lower latch needle plate 22A a plurality of supporting bars 41 are secured, at the ends of which an upper distance adjusting steel ring 43 is horizontally fixed. The upper distance adjusting steel ring 43, which is a regular circle, and central hollow shaft 20A are concentric, while the lower distance adjusting steel ring 44, is an irregular circle but symmetrical to the supporting bars 41, and eccentric to the hollow shaft. As seen in FIGS. 3 and 4, knife 40 for cutting the knitted fabric is provided between upper circular latch needle plate 22C and lower circular latch needle plate 22A whereby knitted cylinderlike fabric is cut into a flat one. Opposite to knife 40, fabric outlet 45 is provided upon central hollow shaft 20A. In operation, the fabric flows from a knitting position, and afterwards passes along knife 40, to the inner rim of upper ring 43 to the outer rim of lower ring 44, and finally to fabric outlet 45. In order to equalize the strain force on every vertical line of the fabric, namely, the vertical lines between every needle position and fabric outlet which vertical lines are equal in the time of fabric flowing, the lower distance adjusting steel ring 44 is thus constructed with supporting bars 41 in cooperation with upper distance adjusting steel ring 43.
To further clarify, as the arrows show in FIGS. 3 and 4, when the knitted fabric is cut by means of knife 40, it will pass forward at equal distances from whatever tangential point of the circumference of the upper distance adjusting steel ring 43 to the fabric outlet 45 from which it exists. Since the third embodiment hereof has the provision of the upper and lower latch needle plates secured on one central shaft, they rotate synchronously.
The third embodiment shares the same effect with the first and second embodiments in the damping and counterpoising of oscillation, having the special features that the power transmission distance is lengthened for the purpose of reducing the violent oscillation occurring from the power source, and the oscillation transmitted from any oscillation starting point to the central hollow shaft is radially distributed to each latch needle whereby the occurrence of the undesirable horizontal lines in the knitted fabric is obviated.
The portion under the phantom line in FIG. 5 shows a fourth embodiment, which is operable without the portion shown above the phantom line in the drawing as a single circular knitting machine. In the drawing, 22D is latch needle holder or lower latch needle cylinder having a plurality of latch needles 23, and being rotatably supported by lower machine plate 25. A plurality of cams 26 are provided around latch needles 23 to enable the latch needles to perform the knitting operation when lower latch needle cylinder 22D is rotated. The lower latch needle cylinder 22D is provided with upper driving bracket 15A having an upper end fixedly connected thereto, and a lower end operatively connected to lower driving bracket 16 fixedly mounted on gear wheel 13 which is rotatably mounted on base 11 with bearing 12 and in mesh with pinion 14 driven by electric motor M. Upper driving bracket 15A is opperatively connected to lower driving bracket 16 with pins 19 having one end fixed to the upper driving bracket and another end loosely inserted into a slot 19A formed in lower driving bracket 16 so as to allow self-alignment of the upper and lower driving brackets. In this arrangement the oscillation derived by pinion 14 and gear wheel 13 travels a long path to reach the latch needles, and thus the oscillation can be dispersed evenly by the upper and lower driving brackets before it reaches the latch needles and thereby the undesirable horizontal lines may be prevented.
FIG. 5 inclusively of portions under and above the phantom line indicates a fifth embodiment of this invention, which is a two needle bed knitting machine having the arrangement of the fourth embodiment and an upper latch needle plate 22B provided with a plurality of latch needles 23B to cooperate with latch needles 23 of lower latch needle cylinder 22D. Upper latch needle plate 22B is fixedly mounted onto upper central hollow shaft 20B which is rotatably supported by upper machine plate 25B. A bearing transmission device 30, having the same construction and arrangement as that of the second embodiment described above, is provided between the lower latch needle cylinder and the upper latch needle plate whereby lower latch needle cylinder 22D and upper latch needle plate 22B rotate synchronously.
The portion under the phantom line in FIG. 6 shows a sixth embodiment which is operable as a single knitting machine without the portion shown above the phantom line. The circular knitting machine of this embodiment comprises machine trusses 10 and 10', a base not shown, a lower machine plate 25A fixedly mounted onto machine truss 10a, latch needle holder or lower latch needle plate 22 having a lower central hollow shaft 20 integrally formed therewith, the lower central hollow shaft 20 being rotatably supported by lower machine plate 25A with bearing 24 and a, lower latch needle plate 22 being provided with a plurality of latch needles 23 on the circumference thereof. A plurality of cams 26 mounted on cam seats 27 are provided around latch needles 23 to enable latch needles 23 to perform the knitting operation when latch needle plate 22 is rotated. A gear wheel 13A is fixedly mounted to a lower end of central hollow shaft 20 to be driven by pinion 14A fixedly mounted on shaft 50 which is driven by an electric motor, not shown. Lower machine plate 25A is provided with a lower damping plate 52 having one end fixed to a hub formed on the lower machine plate 25A, and another end fixed on machine truss 10', and shaft 50 is rotatably supported by lower damping plate 52 by bearing 51.
In this arrangement the rotational driving power is introduced to gear wheel 13A by pinion 14A which is fixedly mounted on shaft 50 driven by a motor, not shown, and thus central hollow shaft 20 and consequently lower latch needle plate 22 are rotated. The oscillation derived from pinion 14A and gear wheel 13A is damped by the oscillation damping plate 52 and evenly dispersed on each latch needle, therefore, the undesirable horizontal lines will not occur on the knitted fabric.
The portion under the phantom line in FIG. 6 as described above as a sixth embodiment may be equipped with the portion shown above the phantom line to become a two needle bed knitting machine, to be referred to as a seventh embodiment of the invention. In addition to the arrangement of the sixth embodiment as described above, the seventh embodiment comprises upper machine plate 25C, an upper central hollow shaft 20C rotatably supported by the upper machine plate 25C, the upper central hollow shaft 20C being provided with a gear wheel 13B fixedly mounted onto its upper end and an upper latch needle plate 22B fixedly mounted onto its lower end, an upper latch needle plate 22B having a plurality of latch needles 23B on the circumference thereof to cooperate with latch needles 23 on the lower latch needle plate 22, and a plurality of cams 26B to enable latch needles 23B to perform the knitting operation. Gear wheel 13B is identical with gear wheel 13A and is driven by pinion 14B which is identical with pinion 14A. Pinion 14B is fixedly mounted on extension shaft 50A extending from shaft 50, the extension shaft 50A freely passing through hole 28 formed in lower machine plate 25A, a hole 28B formed in upper machine plate 25C, and being rotatably supported by bearing 51B in an upper damping plate 52B having one end fixed to a hub formed on upper machine plate 25C and another end fixed to machine truss 10'. In this arrangement, upper latch needle plate 22B rotates with the upper central hollow shaft which is driven by gear wheel 13B, and gear wheel 13B is driven by pinion 14B which is identical with pinion 14A which drives gear wheel 13A, therefore upper latch needle plate 22B and lower latch needle plate 22 rotate synchronously with each other.
A schematic top view of the sixth and seventh embodiments is shown in FIG. 7.
FIG. 8 shows an eighth embodiment of the invention. In this embodiment the general construction is the same as the seventh embodiment except that gear wheel 13B and pinion 14B of the seventh embodiment are deleted and the transmission bearing device 30 of the first embodiment is employed instead.
FIG. 9 shows a ninth embodiment of the invention. The circular knitting machine of the embodiment is similar to the third embodiment as shown in FIG. 3, having those members of the third embodiment such as machine truss 10, base 11, upper machine plate 25C, lower machine plate 25A a, central hollow shaft 20A, an upper latch needle plate 22C provided with latch needles 23B, cams 26B, latch needle holder or lower latch needle plate 22A provided with latch needles 23, cams 26, cam seat 27, knife 40, supporting bars 41, 42, upper adjusting ring 43 and lower adjusting ring 44. In addition, this embodiment further comprises gear wheel 13A fixedly mounted onto the lower end of central hollow shaft 20A, pinion 14A in mesh with gear wheel 13A, shaft 50 on which pinion 14A is fixedly mounted, extension shaft 50A extending from shaft 50, upper damping plate 52B having one end fixed to a hub formed on upper machine plate 25C and another end fixed machine truss 10', and lower damping plate 52 having one end fixed on a hub formed on lower machine plate 25A and another end fixed to machine truss 10'. Shaft 50 is driven by an electric motor, not shown, and rotatably supported by lower damping plate 52 with bearing 51. Extension shaft 50A passes through hole 28 formed in lower machine plate 25 and hole 28B formed in upper machine plate 25B and is rotatably supported by damping plate 52B with bearing 51B.
In this arrangement the rotational power is transmitted to central hollow shaft 20A through shaft 50, pinion 14A and gear wheel 13A, and upper and lower latch needle plates 22C and 22A are driven to rotate synchronously. The oscillation derived by gear wheel 13A and pinion 14A is dispersed upon upper and lower damping plates and consequently no horizontal lines will occur on the knitted fabric.
FIG. 10 shows a tenth embodiment of the invention. The circular knitting machine of this embodiment is similar to the first embodiment shown in the lower portion under the phantom line shown in FIG. 1, having those members such as machine truss 10, base 11a, lower machine plate 25A a, latch needle holder or lower latch needle plate 22 provided with central hollow shaft 20 and rotatably supported by lower machine plate 25A, latch needles 23 on lower latch needle plate 22, cams 26, cam seats 27, a tramsmission ring 18 and an upper driving bracket 15B. This embodiment further comprises an interim driving bracket 45 operatively connected to upper driving bracket 15B with pins 19 having one end fixed to upper driving bracket 15B and another end loosely inserted in slot 44 formed on the upper end of interim driving bracket 45 so as to allow self-alignment of upper and interim driving brackets. Interim driving bracket 45 is provided with ring gear 40 rotatably supported by third machine plate 12 fixedly mounted to machine truss 10, ring gear 40 being in mesh with pinion 41 fixedly mounted on transmission shaft 43 driven by electric motor M. Transmission shaft 43 is rotatably supported with bearing 51 on oscillation damping plate 52 having one end fixed on a hub formed with lower machine plate 25A and another end fixedly mounted on another machine truss 10', and also journaled with bearings 62 on third machine plate 61. In FIG. 10, 16 is a lower bracket operatively connected to interim bracket 45 with pins 46 and rotatably supported by base 11, and 5 is a take up roll rotatably mounted on the lower bracket 16.
In this arrangement the oscillation created by ring gear 40 and pinion 41 at the point of engagement 42 is dispersed and damped by transmission ring 18, third machine plate 61, and also by oscillation damping plate 52, therefore no horizontal lines will occur in the knitted fabric.
FIG. 11 shows the essential portion of an eleventh embodiment of the invention. The circular knitting machine of this embodiment is similar to the fourth embodiment as shown in FIG. 5, having those members of the fourth embodiment such as latch needle holder or latch needle cylinder 22D having a plurality of latch needles 23, cams 26, lower machine plate 25D on which said latch needle cylinder 22D is rotatably supported, and upper driving bracket 15C having an upper end fixedly connected to latch needle cylinder 22D. In addition, this embodiment further comprises an interim driving bracket 45 operatively connected to upper driving bracket 15C with pins 19 having an upper end fixed to upper driving bracket 15C and a lower end loosely inserted into a slot 44 formed on interim driving bracket 45 so as to allow self-alignment of upper driving bracket and interim driving bracket. Interim driving bracket 45 is provided with ring gear 40 fixedly connected thereto, the ring gear 40 being rotatably supported by third machine plate 61 which is fixedly mounted on machine truss 10. Ring gear 40 is in mesh with pinion 41 fixedly mounted onto a transmission shaft 43 rotatably supported by third machine plate 61 with bearings 62 and driven by an electric motor, not shown. In FIG. 11, 16 is a lower bracket operatively connected to interim driving bracket. In this arrangement, the oscillation created by ring gear 40 and pinion 41 is dispersed by third machine plate 61 and upper driving bracket 15C, and therefore the undesirable horizontal lines will not occur on the knitted fabric.
The inventor has made a series of experiments upon embodiments six, seven, eight and nine. Taking a circular latch needle plate of 30 inches in diameter as an example, the results of the experiments indicate that the distance from the starting point of oscillation upon the teeth of the pinion, through the gear wheel 13A, the central hollow shaft 20, the lower circular latch needle plate 22 to the tip of any latch needle is about 1,000 mm, and that the distance extending from the lower bearing 51, through the lower oscillation damping plate 52, the lower cam seat 27, the lower cams 26, to the tip of any latch needle is about 1,000 mm. Since the oscillation damping distance of the embodiments six to nine is about 3-5 times of that of the conventional art, it is obvious that the oscillation can be greatly decreased and meantime equally dispersed upon any latch needle whereby the undesired horizontal line is effectively prevented.
The oscillation damping distance of the embodiments one, two, three, four, five, ten and eleven is longer than that of the embodiments 6, 7, 8 and nine. Therefore, the embodiments one-five, ten and eleven have greater effect in oscillation damping and oscillation counterpoising effect.
Although a transmission ring having no gear teeth on its circumference has been illustrated in FIGS. 1, 3 and 10, however, it is to be understood that the transmission ring may be provided with gear teeth on its circumferences to engage with a pinion for driving other equipment. | A knitting machine having a plurality of latch needles on a latch needle holder rotatably supported on a machine plate on a machine truss, the latch needles being capable of performing a knitting operation when the latch needle holder is rotated by a driving device. The driving device has a gear member, wherein the gear member is disposed away from the latch needle holder so that the distance oscillation created by the gear member must travel for reaching the latch needles is lengthened, and/or an oscillation damping structure is further provided whereby the oscillation which would create undesirable horizontal lines upon the knitted fabric is counterpoised and thereby greatly reduced.
The oscillation damping structure includes an oscillation damping plate having one end fixedly mounted on a hub formed on a first machine plate and another end fixedly supported by another machine truss. A second central hollow shaft is rotatably supported by a second machine plate. An upper latch needle plate is fixedly mounted to the second central hollow shaft and has a plurality of upper latch needles to cooperate with the latch needles on the latch needle holder. A plurality of cams are adapted to enable the upper latch needles to perform a knitting operation when the upper latch needle plate is rotated, and an upper damping plate has one end fixedly mounted on a hub formed on said second machine plate and another end fixedly supported by another machine truss. A synchronous driving means is provided for causing the upper latch needle plate to rotate synchronously with the latch needle holder, and a knife is provided in between the upper latch needle plate and the latch needle holder for cutting the knitted fabric. The combined central hollow shaft is provided with an opening formed between the upper latch needle plate and the latch needle holder, with the opening being adapted to allow the knitted fabric cut by the knife to flow into the hollow interior of the integrally combined central hollow shaft. | 3 |
BACKGROUND OF THE INVENTION
The invention relates to a method for the treatment of wood using a wood preservative in liquid or paste-like form. Such a method for the treatment of wood using a biocide in a liquid medium is already known. One difficulty of this known method is that the penetrating capacity of the composition containing the biocide into the wood is extremely low. Attempts had been made to improve this by executing treatment under pressure and some small improvements has been achieved, but even so this is inadequate to provide a treated wood which, when exposed to weather conditions, will remain unattacked by fungi and other micro-organisms.
One further difficulty of the known methods is that the personnel who have to carry out the treatment are directly exposed to the effects of the composition, so that if this contains toxic fungicidal substances, special precautions have to be taken.
One further difficulty of the known methods is that under the influence of weathering, the fungicidal substances can be leached out of the wood very quickly, so that the wood is again exposed to the unimpeded action of fungi, with all the associated disadvantages. The treated wood can be sealed off by a covering layer, but particularly at the angle joints of window frames, where two frame sections are connected with each other, even a short period after application of the paint layer a seam forms as a result of expansion and contraction due to high or low external temperatures.
As a result of the latter-mentioned phenomenon, in spite of good maintenance of many buildings, wood rot is observed in window frames and door frames at the angle points on these frames. Repairs to these attacked locations incur high costs and cannot be undertaken immediately.
The present invention relates to a method for the treatment of wood using a liquid wood preservative whereby all the abovementioned difficulties are avoided.
SUMMARY OF THE INVENTION
The aim of the present invention is achieved in that a wood preservative is incorporated in a recess made in the wood and subsequently the recess is sealed.
By initially providing a recess in the wood, for example by drilling, and subsequently inserting a wood preservative in this recess, followed by the sealing of this recess, a reservoir is provided for a wood preservative in the wood which can subsequently continually supply the said preserving agent. The wood preservative penetrates extremely gradually into the wood located adjacent to the recess. In this way, considerable savings are obtained as compared with the known methods. For example, large quantities of solvent which are used with the known methods and which are lost, can be saved, whilst furthermore after this treatment the wood material can be painted directly.
After the known method of impregnation of wood using salts it is necessary to wait 6 to 10 weeks before a paint coating can be applied. When using organic solvents, the waiting time is 1 to 3 days. Furthermore, using the method in accordance with the present invention, it is also possible to treat types of wood (such as meranti) into which, normally, wood preservatives cannot penetrate from outside.
Finally the fire resistance of the wood is increased because, as compared with known methods, much less solvent is present in the wood than is the case with vacuum-pressure impregnation methods.
Furthermore, the method in accordance with the invention offers the advantage that the treatment can be restricted to the portions of the wood prone to attack, such as those adjacent to the angle connections of frames. Finally the method is not affected by the season of the year.
Preferably the agent containing the wood preservative consists of a water-expelling liquid medium, especially an organic solvent together with an organosilicon compound or a solid paraffin as water repellent agents.
In this way the water present in the wood is displaced by the water-expelling medium, so that the moisture content of the wood drops below 21%, a value at which no fungal growth can occur. Furthermore, this prevents corrosion of corrodible metals such as nails in the wood.
When using an organo-silicon compound which on curing transforms into a non-adhesive hard polysiloxane, we furthermore obtain an action which tends to reinforce the wood skeleton, so that wood which has been already attacked can be preserved once more without it being replaced by new wood material.
It is especially advantageous to insert a biocide into the recess, particularly a fungicidal agent. We then obtain wood having a biocide impregnant which penetrates slowly into the wood and which can never be completely leached out under the effect of weathering. In those cases where some leaching occurs, this is made up directly by new biocide from the recess.
In this way, it is possible to prevent the growth in wet wood of wood-attacking fungi (Basidiomycetes) and fungi which discolor wood (Ascomycetes) when using fungicidal biocides, also of algae (Pleurococcus) possibly using appropriate agents.
On the other hand, it is possible in this way to counteract attack on wood having low moisture content by insects such as the house beetle (Hylotrupus bajulus) and woodworm (Anobium punctatum or Luctunus brunius), or by bacteria which attack wood.
It is particularly suitable to insert into the recess a composition consisting of a biocide with an evaporative water-expellent solvent. This evaporative solvent is preferably used in an amount of at least 5% and consists of e.g. tetraline, aliphatic or aromatic hydrocarbons whether or not substituted and/or halogenated, ketones, esters, alcohols and ethers. As a result of evaporation of the solvent, the biocide is entrained into the wood and consequently the biocide penetrates very deeply into the wood.
It is extremely suitable to employ a solvent which evaporates slowly, so that very gradual impregnation of the wood around the recess is obtained, thus giving extremely good penetration of the biocide into the wood.
Concerning fungicides, it is recommended that a fungicide be employed with low volatility, combined with a fungicide of high volatility, thus giving an optimum action on the part of the fungicide after a very short period. The most volatile fungicide will penetrate extremely rapidly into the wood, but can admittedly easily evaporate from this, after which the less volatile fungicide will replace any quantity of the more volatile fungicide which has disappeared.
The method in accordance with the invention is particularly suitable for treatment of timber in existing structures, such as door and window frames, which under the effect of weathering are extremely prone to attack by fungi.
In such a case, a considerable amount of moisture is present in the wood, more than 21% wood moisture content, whereby difficulties can be encountered in connection with the penetration of the fungicide in and around the attacked locations in the wood, particularly the angle points of frames.
With particular advantage, one can then use a composition consisting of a biocide such as tributyl tin oxide or a chlorinated hydrocarbon as a water-expelling solvent. This water-expelling solvent can comprise the said organo-silicon compound as water repelling agent, especially a siloxane compound which transforms into a non-adhesive polysiloxane. In such a case, the water-expelling solvent together with the organosilicon compound whilst penetrating into the wood displaces the moisture present there and at the same time entrains the biocide present in the composition. After a fairly short period, the moisture at the attacked locations will have been expelled and the residual wooden skeleton will have been intimately impregnated by a biocidal agent, originating from the composition, while on curing, the water-repelling organo silicon compound contributes toward increasing the rigidity of the structure. The presence of a topping-up reservoir of water-expelling and/or biocidal agent accomodated in a recess in the wood furthermore offers the major advantage that even in the event of leaching from the surface of the wood, new supplies of preservative can be made available immediately, so that there is practically no possibility of attack by wood fungi in the event of damage to a paint coating on the wood.
On the other hand, by inserting a suitable biocide, it is possible to counteract attack on dry wood by woodworm in buildings, whereby in comparison with known methods of preservation, species such as pigeons suffer no disadvantage from this. With these known methods an agent which attacks woodworm is injected by needle under pressure into a joist, whereby the toxic agent can easily emerge from the wood with serious consequences for pigeons and the like; frequently these animals die as a result of poisoning by such agents.
To facilitate the insertion of the agent containing the wood preserving substance into the recess, it is recomended that the composition be incorporated in absorbent material.
It is very appropriate if the composition is incorporated in a capsule having an aperture, which can be opened when the seal is placed on the recess. This embodiment is particularly advantageous because in such a case, the persons who undertake the treatment are working with a composition to which they are not exposed because the toxic substances possibly present in the composition are only released at the moment when the recess in the wood is sealed off from the outside, such as by a plastic cover. This cover material can be subsequently painted over in the normal manner, so that, for example in the case of a frame, it is not possible even from the outside to perceive that the relevant treatment has been carried out.
When using a capsule, it is most appropriate if this is surrounded by a layer of absorbent material, so that extremely gradual release of the composition to the wood from the absorbent material is possible.
By including a stiffening substance in the absorbent material, whose action is obtained mainly after evaporation of the solvent and disappearance of the fungicidal products, we achieve extremely good sealing and filling out of the recess. Furthermore, it is easy to later insert a new quantity of wood preservative agent into the recess, after removal of the plug or capsule inserted previously.
The invention similarly relates to wood impregnated by a wood preservative agent, wherein the wood possesses a recess in which a wood preservative agent is incorporated, the said recess being terminated by a covering material, and where preferably a biocide is present together with a solvent, particularly a water-expelling solvent, in the recess. More than 5% of a water-expelling solvent such as tetraline, aliphatic hydrocarbons and aromatic hydrocarbons whether or not substituted and/or halogenated ketones, esters, alcohols, glycols, ethers is used.
It is advisable that the biocide in the recess should be a biocide of low volatility or a biocide of high volatility, preferably a mixture of both. The biocide should advisably be a fungicide.
The wood should preferably be impregnated with a biocide, advisably a fungicidal substance, in the vicinity of the recess.
In the recess, the wood preservative agent is advisably in the form of an opened capsule, advisably surrounded by an absorbent material.
The invention similarly relates to a cartridge with absorbent material, with water-expelling agent or wood preservative biocide perhaps incorporated in a separate holder.
SHORT SURVEY OF THE DRAWINGS
FIG. 1 denotes a section through a wooden object provided with a drilled recess in which there is an absorbent material with a fungicidal or water-expelling agent;
FIG. 2 shows the same recess in which there is a capsule surrounded by absorbent material, and
FIG. 3 shows a capsule in which the water-expelling or biocidal agent is under pressure in the capsule.
DESCRIPTION OF PREFERRED EMBODIMENTS
EXAMPLE I
In a wet timber joist having a thickness of 5 cm, a recess 2 is drilled which is capable of being sealed at the top 3. The recess 2 does not need to be cylindrical but can also be tapered in shape. An absorbent plug 4 (see FIG. 1) consisting for example of cotton, wool or fiber material in which a liquid composition is absorbed consisting of a polysiloxane compound which can form a non-adhesive polysiloxane in the dry state is inserted in the recess 3. The composition contains 2% of polysiloxane, 5% of tributyltin oxide and for the remaining part, tetraline.
After insertion of the plug 4, the top side 3 of the recess 2 is sealed off by means of a plastic cover, e.g. a polythene cap 4a.
After roughly 14 days, significant penetration of the water-repellent silicon compound into the timber is observable, in the direction toward the arrows 5.
It will be obvious that particularly when locating such a recess in the vicinity of the transition between two portions of wood in a frame, the water-repellent silicon compound can move easily toward the top surface of the associated timber portions.
As a result of expulsion of the water, the moisture content of the wood will drop below 21%, thus precluding fungal growth. The curing of the silicon compound occurring during this period will furthermore considerably stiffen the structure of the wood.
The plug 4 should preferably be incorporated in a sealing covering 11 made of aluminium foil, which covering 11 is stripped off from the plug during the application of the cover 12, which is provided with pins 13 which strip off the covering.
EXAMPLE II
Insert a plug 4 (FIG. 1) containing a 2% siloxane compound and 10% tributyl tin oxide together with 88% tetraline as fungicide. The siloxane compound together with tetraline expels the water whilst entraining the fungicide and penetrates up to the top surface of the wood.
In the event of leaching out as a result of penetrating rain, new supplies of fungicide will be provided immediately from the fungicide reservoir in the form of the plug 4 which is located in the recess 2.
After application of the polythene covering cap 12, the entire wooden surface can normally be covered by a coloured paint coating.
EXAMPLE III
In the recess 2 (see FIG. 2) insert a polythene capsule 6 which is filled with the composition of a polysiloxane compound (2%) and 10% tributyl tin oxide as well as tetraline. At its end 7, this capsule is provided with a hole 8 which opens up to a certain extent when pressure is exerted on the polythene capsule 6. A layer of cellulose wadding 9 is placed around the polythene capsule.
After inserting the capsule 6 in the recess 2, install a cover 12 which penetrates into the recess 2 to such an extent that pressure is exerted on the polythene capsule 6, and consequently the aperture 8 at the end of the capsule opens. By this means the liquid composition consisting of 2% polysiloxane together with 5% tributyl tin oxide and 93% tetraline in the absorbent layer 9 (e.g. cotton wool) can pass through and from this point penetrate into the wood material located around the recess 2.
In the liquid composition which is located in the capsule 6, there is a tributyl tin oxide of high volatility and a tributyl tin oxide of low volatility so as to ensure optimum action on the part of the fungicide.
Above we have always mentioned a polysiloxane compound together with an organic solvent as the water-expelling solvent, but it should be made clear that other water-expelling products together with organic solvents can also be employed; preferably organic solvents which exhibit low volatility and thus ensure optimum penetration of solvent with fungicide into the wood around the recess should be used. One major advantage in this respect is that the persons who are treating the wood in accordance with the method in this invention do not come into contact with toxic substances such a tributyl tin chloride.
EXAMPLE IV
In a recess 2, insert a capsule 6 surrounded by an absorbent layer 9, this layer 9 again being surrounded by a perforated plastic cylinder 10. The capsule 6 is provided with an impact pin 14 which can be pressed through the capsule so that the contents of the capsule, solid paraffin m.p. 40° C. (2%) with 10% tributyl tin oxide and tetraline 88% can penetrate into the porous layer. The contents of the capsule 6 are under pressure, but this is not essential. For checking purposes, tracers can be included in the composition so as to monitor penetration.
EXAMPLE V
A porous material impregnated with silane compound and tributyl tin oxide is placed between a tongued and grooved joint. The effective compounds penetrate into the wood. | A method for the treatment of wood by a wood preserving agent in a liquid or paste-like form, to be positioned (inserted) in a recess in the wood, which recess is subsequently sealed off.
The wood preserving agent contains a water-expelling agent, a water-repellent agent and a biocide. | 8 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. patent application Ser. No. 12/882,202, filed on Sep. 15, 2010, which is incorporated herein by reference in its entirety.
FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
None.
TECHNICAL FIELD
The present invention relates to nutritionally enhanced nutraceutical hydrophilic and lipophilic fractions from rice bran and a method of using the same to reduce Insulin Resistance in animals, especially humans with pre-diabetes and Type 2 diabetes or others with symptoms of Metabolic Syndrome. More particularly, the present invention relates to the mixture of elevated levels of nutraceutical compounds, including but not limited to gamma-oryzanol, inositol, ferulic acid, tocotrienols and phytosterols and pharmaceutical and nutritional compositions thereof, and a method of using the same to reduce insulin resistance.
BACKGROUND
Insulin resistance is a physiological condition where the natural hormone insulin becomes less effective at lowering blood sugars. Depending on physical activity and dietary conditions, blood glucose levels may rise outside the normal range and cause adverse health effects. Fat and muscle cells require insulin to absorb glucose. In a dietary state of energy overabundance, cells internally create a cascading process in which insulin receptors on the cell membrane no longer properly interact with insulin. When these cells fail to respond adequately to circulating insulin, glucose is not adequately absorbed, consequently blood glucose levels rise. For many, long periods of insulin resistance precede clinical Type 2 diabetes. During this latent period of insulin resistance blood glucose may be maintained at near normal levels by overcompensation of insulin. It is widely accepted that the diabetic state greatly increases the risk for cardiovascular disease. This process is a continuum and the prediabetic subject also has increased cardiovascular disease risks and inflammation that is primarily associated with insulin resistance.
Convincing evidence has established that insulin resistance is a pre-diabetic state that can predict incident Type 2 diabetes relatively far into the future. Of the diabetic population in the U.S., 90 to 95% suffer from Type 2 diabetes. According to the American Association of Clinical Endocrinologists, up to 80% of Type 2 diabetics are insulin resistant. Numerous studies have documented the development of insulin resistance as a result of increased intake of dietary fats. In both animals and humans, there is an inverse relationship between fasting plasma triglyceride concentration and insulin sensitivity. This medical research associating triglycerides and insulin resistance has practical applications. A multifaceted diabetic medical nutrition therapy program that simultaneously addresses lipids, triglycerides, and insulin resistance can greatly increase the efficacy of a diabetic management program. Recent clinical studies have shown excellent sensitivity at measuring insulin resistance with a triglyceride/glucose index. Others have observed the connections between oxidative stress indicators and lower antioxidant levels.
Elevated Body Mass Index (BMI) is well associated with and the primary contributor to insulin resistance but the initial events triggering the development of insulin resistance and its causal relations with deregulation of glucose and fatty acids metabolism remain unclear. There is clear evidence that insulin resistance is associated with increased oxidative stress and that oxidative stress is the causal agent for insulin resistance. Oxidative stress also disrupts internal antioxidant mechanisms.
Numerous studies have linked increased oxidative stress to insulin resistance. In diabetics, oxidative stress increased and antioxidant defenses are diminished. In both normal individuals and Type 2 diabetic patients, reduction of oxidative stress improved insulin sensitivity as well as improved Beta-cell function. Most Type 2 diabetics are significantly influenced by insulin resistance. A number of researchers have demonstrated that the activities of pathways for reactive oxygen species (ROS) production and oxidative stress increase in liver, muscle and fat tissue in animals and humans before the onset of insulin resistance. Reducing insulin resistance also offers a protective effect on beta-cells. This is very important for the long-term preservation of insulin secretion. Clinical trials have demonstrated improvement of insulin sensitivity in insulin resistance and diabetic patients treated with antioxidants.
Recent landmark research from M.I.T. and the Harvard Medical School indicates that increased oxidative stress levels are an important trigger and causal agent for insulin resistance in numerous physiological settings and that antioxidants were able to decrease insulin resistance caused by oxidative stress. Other researchers have also found that glycemic control and oxidative stress are seen to be tightly related, and improving glycemic control is associated with a lowering of oxidative stress. Reducing oxidative stress can also improve glycemic control. Antioxidants have been shown to reduce oxidative stress and in turn improve insulin secretion and decrease insulin resistance in diabetics. Accordingly, medical nutrition therapy for humans concerned with diabetes should include decreasing fatty acids and increasing intake of effective antioxidants.
Antioxidants should be administered in an effective manner. Many antioxidants work only in specific chemical reactions within the body. Thus, single antioxidant dosages may overload the body with one antioxidant, and saturate that one chemical reaction, but not address the more complex and holistic oxidative stress problem. Some oxidative stress occurs within the cell with over-production of mitochondrial NADH. Many antioxidants are not able to provide intracellular relief of oxidative stress. Antioxidants have demonstrated the ability to decrease oxidative stress, thus preserving Beta-cell function, increasing insulin sensitivity, protecting vascular cell integrity, and repairing nerves in diabetes damaged organs. Additionally, oxidative stress has been documented to inversely affect mitochondrial activity and oxidative stress has been found to be a relevant negative regulator of insulin secretion. Because of the negative effects of oxidative stress, nutrition experts suggest that daily intake should be at least 3,000 to 5,000 Oxygen Radical Absorbance Capacity (“ORAC”) units to have a significant impact on plasma and tissue antioxidant capacity. According to estimates however, the average American consumes only 1,000 to 2,000 ORAC units per day. What is needed therefore is a nutritional supplement that makes up for this deficiency in daily antioxidant intake of ORAC units.
SUMMARY
The present inventors have discovered that the enhanced enzymatic extraction processing of enhanced rice bran hydrophilic and lipophilic fractions yields elevated levels of nutraceutical components that can be administered in such a way as to reduce insulin resistance. These compounds are more bioavailable to humans due to enhanced enzymatic processing.
Rice bran is a nutrient-dense composition derived from the milling of rice. Rice bran is a rich source of protein, fat, carbohydrate and a number of micronutrients such as vitamins, minerals, antioxidants, phytochemicals and phytosterols. The nutritional value of rice bran has been well recognized. Use of rice bran in treatment of a number of human ailments, such as diabetes, coronary diseases, arthritis, and cancer, have been described in the following U.S. Patents and published patent applications including: U.S. Pat. No. 5,985,344, issued Nov. 16, 1999, entitled, “Process for Obtaining Micronutrient Enriched Rice Bran Oil;” U.S. Pat. No. 6,126,943, issued Oct. 3, 2000, and entitled, “Method for Treating Hypercholesterolemia, Hyperlipidemia, and Atherosclerosis;” U.S. Pat. No. 6,303,586 issued Oct. 16, 2001, and entitled “Supportive Therapy for Diabetes, Hyperglycemia and Hypoglycemia;” U.S. Pat. No. 6,350,473, issued Feb. 26, 2002 and entitled “Method for Treating Hypercholesterolemia, Hyperlipidemia, and Atherosclerosis;” U.S. Pat. No. 6,558,714, issued May 6, 2003, and entitled “Method for Treating Hypercholesterolemia, Hyperlipidemia, and Atherosclerosis;” U.S. Pat. No. 6,733,799 issued May 11, 2004, and entitled “Method for Treating Hypercholesterolemia, Hyperlipidemia, and Atherosclerosis;” and U.S. Pat. No. 6,902,739, issued Jun. 7, 2005, and entitled “Method for Treating Joint Inflammation, Pain, and Loss of Mobility,” and U.S. Patent Application Publication US 2008/0038385 entitled “Therapeutic uses of an anti-cancer composition derived from rice bran.” Additional utilizations of rice bran have been described in U.S. Patent Application Publication US 2009/0285919 entitled “Rice Bran Extracts for Inflammation and Methods of Use Thereof;” U.S. Patent Application Publication US 2009/0220666 entitled “Utilization of Stabilized Bran in High Protein Products;” U.S. Patent Application Publication US 2009/0191308 entitled “Method of Preparing Emulsified Cereal Bran Derivatives;” and U.S. Patent Application Publication US 2009/0162514 entitled “Production of Pasta Using Rice Bran and Rice Flour.” Each and every one of the foregoing patents and published patent applications are hereby incorporated herein by reference in their entireties for all that they teach and describe.
The present invention relates to the use of end-products of the process of producing nutritionally enhanced nutraceutical hydrophilic and lipophilic fractions from rice bran, which process is described in U.S. patent application Ser. No. 12/882,202, filed on Sep. 15, 2010, which is incorporated herein by reference in its entirety. Such end-products are available from Diabco Life Sciences LLC under the brand name Nutra-Iso™. It has been discovered that these end-products may be used in a method as described herein to reduce Insulin Resistance in animals, especially humans with pre-diabetes and Type 2 diabetes or others with symptoms of Metabolic Syndrome.
More generally, the inventors have discovered that the mixture of elevated levels of nutraceutical compounds including but not limited to any of gamma-oryzanol, inositol, ferulic acid, tocotrienols and phytosterols and pharmaceutical and nutritional compositions thereof, may be used in a method as described herein to supplement medical nutrition therapy and reduce insulin resistance. These nutraceutical levels may be obtained by a series of enzymatic extractions that have been found to yield significantly more bioavailable levels of these compounds. For example, the inventors have discovered that the Nutra-Iso™ brand nutraceutical hydrophilic and lipophilic fractions have significantly increased bioavailability and increased nutraceutical content that may be used to successfully reduce insulin resistance.
Accordingly, what is described herein is a nutraceutical antioxidant complex specially adapted for the treatment, management, and/or prevention of insulin resistance and other conditions in animals, especially humans. Provided is a composition and method for treating, managing or preventing insulin resistance in animals, especially humans, that employs a safe and effective nutraceutical antioxidant complex, without pro-oxidation activity, while providing a beneficial effect to the blood profile. Also provided is an orally delivered composition useful for treating, managing or preventing insulin resistance in animals, especially humans. Further provided is a nutraceutical antioxidant complex for treating animals, especially humans with insulin resistance.
Also provided are compositions of a nutraceutical antioxidant complex with nutritional fortification to enhance antioxidant synergisms. These compositions may be comprised of dosage units effective to reduce insulin resistance levels, such as about 5-50 mg gamma-oryzanol, 10-200 mg of inositol, 5-50 mg ferulic acid, 2-25 mg tocotrienols, and 20-50 mg phytosterols of these nutraceutical antioxidants per day and a complete complex dosage of 5 to 60 gram per day administered once or twice a day.
In various example embodiments, provided is a unique formulation of antioxidants in combination with hydrophilic and lipophilic fractions that provides approximately two to four times the minimum recommended daily antioxidant intake of ORAC units per day.
In various example embodiments the composition may include a nutraceutical antioxidant complex of plant origin having no pro-oxidation activity, wherein antioxidants include soluble and insoluble polyphenols and phytosterols which can be obtained from the genus Oryza sativa or Oryza glaberrima.
In various example embodiments the composition may comprise any of gamma-oryzanols, inositol, ferulic acid, tocotrienols or their conjugates, including dimers and oligomers, which are suitable for the treatment, management, or prevention of insulin resistance in animals, especially humans.
The nutraceutical antioxidant complex may be prepared through multiple enzymatic processes that may comprise of the steps of: adding at least three enzymes to the slurry separately and heating the slurry sufficiently to activate the given enzymes. These separate enzymatic processes enhance the nutritional content of rice bran by further extracting soluble and insoluble vitamins, minerals, phytosterols and polyphenols bound to the fiber component in the rice bran.
The present improvements are achieved by utilizing additional enzymes under a range of conditions to convert protein and fiber in the rice bran to less complex fractions that can be isolated from insoluble fractions by screening and centrifuging. This process is described in U.S. patent application Ser. No. 12/882,202, filed on Sep. 15, 2010, which is incorporated herein by reference in its entirety, and that process is referred to herein as the “Enhanced Enzyme Treatment” and includes treating rice bran slurries with certain enzymes in single or multiple process steps to facilitate isolation and inclusion of protein and fiber into the hydrophilic and lipophilic fraction from rice bran. With the inclusion of the protein, fat, and fiber fractions, the yield of the finished product is significantly increased in quantity and improved in nutritional quality. The finished products resulting from the Enhanced Enzyme Treatment process are referred to herein as “the Hydrophilic and Lipophilic Rice Bran Fractions.” Examples of the Hydrophilic and Lipophilic Rice Bran Fractions include Nutra-Iso™ brand products available from Diabco Life Sciences LLC. Other aspects of the invention are disclosed herein as discussed in this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
Various aspects of the invention can be better understood with reference to the following figures. In the figures, like reference numerals designate corresponding parts throughout the different views. It will be understood that certain components and details may not appear in the figures to assist in more clearly describing the invention.
FIG. 1 is a chart showing typical analytical data of a complex of The Hydrophilic and Lipophilic Rice Bran Fraction resulting from The Enhanced Enzyme Treatment, according to various example embodiments of the invention.
FIG. 2 is flow chart showing example steps of therapeutic processes according to various example embodiments of the invention.
DETAILED DESCRIPTION
1. Rice Bran Hydrophilic Fraction
A. Source of Rice Bran Hydrophilic Fraction
The Enhanced Enzyme Treatment process, as defined above, may be completed with at least three potential end-products or fractions. The enzymatic slurry may be designed to extract additional nutrients normally bound too tightly to the bran fiber to become nutritionally available to animals. The rice bran slurry can be separated into hydrophilic and lipophilic fractions. The soluble fraction may be pumped from the slurry and air dried to specific moisture specifications. The resulting Hydrophilic and Lipophilic Rice Bran Fraction is high in niacin and B 6 vitamins and also provides significant nutraceutical levels of gamma-oryzanol, ferulic acid and at least four phytosterols. When tested using the ORAC antioxidant analysis method, the Hydrophilic and Lipophilic Rice Bran Fraction has the highest overall ORAC Total level when compared to other rice bran fractions.
2. Rice Bran Fraction of Hydrophilic and Lipophilic Components
A. Source of Rice Bran Fraction of Hydrophilic and Lipophilic components.
When rice bran is subjected to the Enhanced Enzyme Treatment process, as defined above, the end-products can be formulated to create solutions with targeted levels of hydrophilic and lipophilic components. This formulated slurry is not only designed to extract additional nutrients normally bound too tightly to the bran fiber to become nutritionally available to animals, but further to isolate desired hydrophilic and lipophilic components that have been tested for nutraceutical value. This isolated slurry is then air dried to specific moisture specifications. This Hydrophilic and Lipophilic Rice Bran Fraction is more nutritionally robust than the soluble fraction. It is high in niacin, B6, biotin, Choline, copper, magnesium, phosphorus and zinc. This Hydrophilic and Lipophilic Rice Bran Fraction also provides significant nutraceutical levels of inositol and gamma-oryzanol with lesser levels of ferulic acid and phytosterols. When tested using the ORAC antioxidant analysis method, the Hydrophilic and Lipophilic Rice Bran Fraction had significant antioxidant levels.
The analytical method used to analyze the antioxidant composition of the Hydrophilic and Lipophilic Rice Bran Fractions was developed by USDA personnel and further validated, using the methods set forth in Opara E C., Oxidative Stress, Micronutrients, Diabetes Mellitus and its Complications, The Journal of the Royal Society for the Promotion of Health, 122:28-34; and Krauss S, et al., Superoxide-mediated activation of uncoupling protein 2 causes pancreatic β cell dysfunction, Journal of Clinical Investigation, 2003, 112:1831-1843. The analysis of antioxidant capacity of the Hydrophilic and Lipophilic Rice Bran Fractions shown in FIG. 1 was conducted by Brunswick Laboratories, Norton, Mass., utilizing the published methodology noted above. The test was conducted by Y. Kou and supervised and approved by Boxin Ou, PhD.
B. Nutraceutical Significance of Hydrophilic and Lipophilic Components of Interest
Scientific research, in both animal and human subjects, generally concludes that there are multiple enzymatic and metabolic actions that play interactive roles in reducing insulin resistance, thereby helping improve blood glucose metabolism, reducing blood glucose and serum insulin levels and reducing the health risks associated with diabetes. Preliminary research concludes that this is also the case with the Hydrophilic and Lipophilic Rice Bran Fractions. The present Hydrophilic and Lipophilic Rice Bran Fractions are thought to interact in several ways to reduce insulin resistance, as described below.
First, the Hydrophilic and Lipophilic Rice Bran Fractions contain very high levels of a number of polyphenols. These polyphenols have significantly higher antioxidant capacity than traditional supplemental vitamins (Vitamin E, C, etc.) In particular, the complex of the invention is high in natural tocotrienols, ferulic acid, gamma-oryzanols, inositol and several phytosterols. These antioxidants, in combination with over 80 additional natural antioxidants provide a nutraceutical foundation for decreasing insulin resistance.
Second, independent laboratory analyses have documented the high natural antioxidant levels found in the Hydrophilic and Lipophilic Rice Bran Fractions, as noted in Brunswick Lab ORAC Test Values, 2012, shown in FIG. 1 . Vitamin E is known to have eight homologues that are active in glucose metabolism, four each of tocopherols and tocotrienols. The primary bioactive function of the tocotrienol complex is its capacity as an antioxidant in improved cellular function and protection of the lipid cell membrane, thereby promoting healthy cellular function and more balanced blood glucose metabolism. Results indicate that α-tocotrienol, which is contained in the Hydrophilic and Lipophilic Rice Bran Fractions, may be at least 3-fold more efficient as a scavenger of peroxyl radicals than conventional vitamin E (α-tocopherol). The Hydrophilic and Lipophilic Rice Bran Fractions contain significant levels of tocotrienols. In addition, these tocotrienols have been scientifically documented to lower total cholesterol and LDL cholesterol in blood plasma. Studies suggest that this may be accomplished by inhibiting the activity of the enzyme HMG-CoA which is responsible for cholesterol synthesis in the liver. Micromolar amounts of tocotrienol, but not tocopherol, have been shown to suppress the activity of HMG-CoA. These findings provide insight into how lipid metabolism modification associated with the Hydrophilic and Lipophilic Rice Bran Fractions affect blood glucose metabolism.
Third, the Hydrophilic and Lipophilic Rice Bran Fractions contain very high levels of natural gamma-oryzanols. Scientific studies have confirmed that oryzanol is a natural antioxidant superior to tocopherols. The biologically active portion of gamma-oryzanol is ferulic acid. Just recently in animal studies, ferulic acid significantly decreased the levels of glycogen in the liver and skeletal muscle along with diminishing the activities of hepatic glucose-6-phosphate dehydrogenase, catalase and peroxidase in when compared with controls. In addition, gamma-oryzanol has been shown to affect bile acid secretion and fecal excretion of cholesterol.
3. Nutritional and Nutraceutical Complex of the Hydrophilic and Lipophilic Rice Bran Fractions
A. Preparation of the Complex
The complex of the Hydrophilic and Lipophilic Rice Bran Fractions can be prepared by dry blending a fine powder of the Fractions in specific ratios in a suitable blender as described below and as described in U.S. patent application Ser. No. 12/882,202, filed on Sep. 15, 2010, which is incorporated herein by reference in its entirety.
4. Pharmaceutical and Nutraceutical Formulation of the Complex of the Hydrophilic and Lipophilic Rice Bran Fractions
A. Preparation of Formulations
Pharmaceutical and nutritional formulations of the Hydrophilic and Lipophilic Rice Bran Fractions may include suitable pharmaceutical and/or nutritional excipient(s) that are suitable for oral administration. Generally, these oral formulations of the invention fall into one of five categories:
1. A solution, suspension or syrup that is ready for oral administration; 2. A dry powder composition that can be combined with water just prior to use, i.e., a reconstitutable composition; 3. A liquid concentrate ready for dilution prior to administration; 4. A tablet ready for oral administration; or 5. A capsule ready for oral administration.
The orally administered vehicle in these formulations normally has no therapeutic activity and is nontoxic, but presents the active constituent to the body tissues in a form appropriate for absorption. Suitable absorption of the complex normally will occur most rapidly and completely when the composition is presented as an aqueous solution. In preparing formulations which are suitable for oral administration, one can use aqueous vehicles, water-miscible vehicles, or non-aqueous vehicles. Water-miscible vehicles are also useful in the formulation of the composition of the Hydrophilic and Lipophilic Rice Bran Fractions. Another useful formulation is a reconstitutable composition that may be a sterile solid packaged in a dry form. Additional substances may be included in the compositions of the Hydrophilic and Lipophilic Rice Bran Fractions to improve or safeguard the quality of the composition. An added substance may affect solubility, provide for patient comfort, enhance the chemical stability, or protect preparation against the growth of microorganisms. The composition may also include an appropriate solubilizer, or substances that act as antioxidants, and a preservative to prevent the growth of microorganisms. These substances may be present in an amount appropriate for their function, and should not adversely affect the action of the composition.
Preferred pharmaceutical or nutritional formulations are typically those suitable for oral administration to warm-blooded animals. The compositions herein may contain the complex ingredient alone, or in combination with a pharmaceutically or nutritionally acceptable excipient, in dosage unit forms such as dry powder, tablets, coated tablets, hard or soft gelatin capsules or syrups. These administratable forms can be prepared using known procedures, for example, by conventional mixing, granulating, tablet coating, dissolving or lyophilisation processes. Thus, pharmaceutical or nutritional compositions for oral administration can be obtained by combining the active ingredient with solid carriers, optionally granulating the resulting mixture, and processing the mixture by granulation, if desired or necessary, after the addition of suitable excipients, to give tablets or coated tablet cores. Dyes or pigments can be added to the tablets or coated tablets, for example, to identify or indicate different doses of the active complex ingredient.
Other pharmaceutical or nutritional preparations suitable for oral administration are hard gelatin capsules and also soft gelatin capsules made, for example, from gelatin and a plasticizer such as glycerol or sorbitol. Hard capsules may include the complex containing the Hydrophilic and Lipophilic Rice Bran Fractions in admixture with fillers such as lactose, binders such as starches, and/or lubricants such as talc or magnesium stearate, and if desired, stabilizers. In soft capsules, the Hydrophilic and Lipophilic Rice Bran Fractions are preferably dissolved or suspended in a suitable liquid, such as fatty oil, paraffin oil or a liquid polyethylene glycol, to which a stabilizer can be added.
The Hydrophilic and Lipophilic Rice Bran Fraction complex, when obtained by dry blending process, converts into true complex when formulated in aqueous or alcoholic systems. Alternately, this dry blended material can get converted into an effective complex when administered to primates, especially human.
B. Other Active Ingredients
The formulations of the invention may include added active ingredients other than the Hydrophilic and Lipophilic Rice Bran Fraction complex itself, including by way of example and not limitation:
1. Antioxidants: e.g., Alpha lipoic acid, Coenzyme Q; 2. Minerals and Vitamins synergistic to the antioxidant found in the Hydrophilic and Lipophilic Rice Bran Fractions in their effect on the oxidative stress complex: e.g., Vitamin C, Vitamin E, Selenium, Chromium, and Zinc; 3. Minerals, Vitamins, or other compounds with laboratory or clinical evidence of reducing insulin resistance: e.g., Chromium, Boron, Carnitine; 4. Other Minerals, Vitamins, or other compounds with laboratory or clinical evidence in decreasing cardiovascular disease risk: e.g., Vitamin B3, Vitamin B12, Biotin, Folate, B6; 5. Other Minerals and Vitamins needed for optimum health: e.g., Vitamin B5, Vitamin D, Vitamin K, Calcium, Potassium, and Magnesium; 6. Plant extracts: e.g., American ginseng, Bilberry, Ginkgo biloba , Garlic and Onions; and 7. Any other suitable ingredients.
5. Therapeutic Uses
A user, including an animal or person, can use the Hydrophilic and Lipophilic Rice Bran Fractions to reduce insulin resistance as described herein. FIG. 2 shows example steps of therapeutic processes according to various example embodiments of the invention.
Step 1 , monitor and evaluate, includes measuring health and insulin resistance parameters. Currently there is no clinically efficient method of effectively and directly measuring insulin resistance. Instead, clinicians look at measurable symptoms relating to insulin resistance to manage and reduce the risks associated with insulin resistance. The American Association of Clinical Endocrinology (AACE) has created a position statement on insulin resistance syndrome that summarizes the effective clinical symptoms associated with insulin resistance. The diagnosis of the insulin resistance syndrome according to AACE is based on clinical judgment in view of various factors and symptoms. For example, following are clinical symptoms endocrinologists use to measure and manage insulin resistance:
1. Triglycerides above 1.7 mmol/l (150 mg/dl); 2. HDL-cholesterol for men less than 1.03 mmol/l (40 mg/dl) and for women less than 1.29 mmol/l (50 mg/dl); 3. Blood pressure above 130/85 mmHg; and 4. Plasma glucose, either fasting of 6.1-6.9 mmol/l (110-125 mg/dl) or 2-hour post-glucose challenge of 7.8-11.1 mmol/l (140-200 mg/dl).
Other factors to be considered in the diagnosis in Step 1 are overweight/obesity (body mass index over 25 kg/m 2 ), a family history of Type 2 diabetes, polycystic ovary syndrome, sedentary lifestyle, advancing age, and ethnic groups particularly susceptible to Type 2 diabetes.
The present therapies may be indicated for humans with pre-diabetic condition fasting glucose levels of 100 to 120 mg/dL along with elevated LDL cholesterol or elevated triglycerides and blood pressure at or above 130/85 mmHg. For the diabetic human, the most serious symptom of elevated blood sugar has already been diagnosed. If the human also has elevated blood pressure (exceeding 130/85 mmHg) and elevated LDL cholesterol or elevated triglycerides, then the human should begin therapy as described below with respect to Step 2 shown in FIG. 2 .
Step 2 comprises initiating therapy by using or providing the user with a therapeutic amount of the Hydrophilic and Lipophilic Rice Bran Fractions. In various example embodiments, a dosage range of 5 grams to 30 grams of a combination of the Hydrophilic and Lipophilic Rice Bran Fractions may be administered once, twice or three times daily. Dosage range and frequency may be determined by estimated duration of experiencing insulin resistance, severity of fasting glucose levels, triglyceride levels, overall physical activity and obesity. For pre-diabetic humans, a typical therapy may begin with a 10 to 20 gram dosage of the Hydrophilic and Lipophilic Rice Bran Fractions, twice daily for 90 days. For Type 2 diabetic humans, estimated duration of the diabetic condition, blood sugar, lipid and triglyceride levels may be considered in developing a therapeutic program. When A1c levels exceed 7.2% with elevated lipids and triglycerides, a diabetic human may begin therapy with a 20 to 30 gram dose taken two to three times daily.
As mentioned in the American Association of Clinical Endocrinology (AACE) position statement, ethnicity can also play a role in the aggressiveness of initiating therapy and therapeutic dosage and frequency. African-Americans, Hispanics, Pacific Islanders, and Native American Indians are more susceptible than Caucasians to Type 2 diabetes and thus should begin therapy earlier in symptom progression and with more aggressive overall therapy, i.e., higher dosage and/or greater frequency.
Delivery of the Hydrophilic and Lipophilic Rice Bran Fractions could be in the form of a dry powder, tablets, coated tablets, hard or soft gelatin capsules, syrups, or any other suitable delivery means.
It may also be helpful to prescribe or obtain nutrition and physical activity coaching as part of the therapy or to complement the therapy.
In Step 3 compliance with the therapy is managed. The patient or user may be contacted periodically or regularly, for instance at least every 30 days in certain embodiments. When contacted, the patient or user may be coached to help them continue with the therapy, including encouraging the user to consume the Hydrophilic and Lipophilic Rice Bran Fractions at prescribed intervals and to comply with any nutrition and physical activity programs.
Turning to Step 4 , the therapy may be periodically monitored and reevaluated. For instance, at the end of the 90-day or other designated period blood may be drawn for glucose and lipid profile analysis. Blood pressure may also be recorded. If blood glucose and lipid profiles have improved measurably, for instance after A1c levels decreased to 5.7%, then a revised therapy may be initiated. A revised therapy may comprise a preventative or maintenance therapy, such as a single 10 to 20 gram dosage of the Hydrophilic and Lipophilic Rice Bran Fractions taken daily with a meal (preferably breakfast). Such a preventative or maintenance therapy may continue until BMI decreases below 24 and blood sugar and lipid profiles remain within healthy ranges for a long period of time, especially when the human has been in the diabetic state for an extensive period of time. If there is a change in the monitored parameters requiring a different or new therapy, then the process returns to Step 1 and repeats.
In various embodiments, any or all of Steps 1 , 2 , 3 or 4 might be omitted. For example, while it is not advised, in practice a user might simply obtain some of the Hydrophilic and Lipophilic Rice Bran Fractions and self-administer a therapeutic amount, for instance based on instructions on a product container or in advertising material or even in this patent, and thereby obtain some or all of the benefits described herein.
Based on clinical results applying the methods described herein, the likelihood of measurable decreases in insulin resistance parameters is in the range of 80 to 90 percent.
As will be apparent to persons skilled in the art, modifications and adaptations to the above-described example embodiments of the invention can be made without departing from the spirit and scope of the invention, which is defined only by the following claims. | Nutritionally enhanced nutraceutical Hydrophilic and Lipophilic Rice Bran Fractions from rice bran are provided, as well as a method of using the same to reduce Insulin Resistance in animals, especially humans with pre-diabetes and Type 2 diabetes or others with symptoms of Metabolic Syndrome. Provided in various example embodiments are mixtures of elevated levels of nutraceutical compounds, including but not limited to gamma-oryzanol, inositol, ferulic acid, tocotrienols and phytosterols and pharmaceutical and nutritional compositions thereof. Steps are provided including evaluating insulin resistance parameters, initiating therapy including providing therapeutic amounts of Hydrophilic and Lipophilic Rice Bran Fractions from rice bran to treat pre-diabetes and Type 2 diabetes or others with symptoms of Metabolic Syndrome, managing compliance with the therapy, and monitoring and reevaluating the therapy. | 0 |
RELATED APPLICATION DATA
This application claims priority of U.S. Provisional Application No. 60/882,750 filed on Dec. 29, 2006, which is incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to a multi-band tracking, calibration and/or registration system for calibrating, detecting and/or registering an object such as an instrument (e.g., a medical instrument), implant, patient and/or structure.
BACKGROUND OF THE INVENTION
In order to use a medical instrument in image-guided surgery, the instrument has to be calibrated, verified and/or validated, i.e., the dimensions, configuration and/or arrangement of the instrument are made known to a navigation system or the like. Otherwise, for example, if the instrument is damaged (e.g., bent), healthy tissue that lies next to tissue to be treated may be impinged by the instrument.
A device and method for calibrating a bent element are known from EP 1 413 258 A1, wherein the bent element is connected to a navigation element, placed onto a calibrating device, and moved while resting on said calibrating device until the element is calibrated.
The navigational calibration of medical instruments or implants is known from EP 1 369 090 A1. A spatial position of the instrument or implant is ascertained by means of a medical navigation system. This enables the relative position of the instrument or implant to be ascertained with respect to anatomical data, wherein the spatial orientation of a multi-dimensionally configured, functional section of the instrument or implant can be ascertained.
U.S. Pat. No. 6,428,547 B1 describes detecting the shape of a treatment device, wherein the treatment device is referenced in a computer-controlled, camera-assisted navigation system by means of a marker array attached to the treatment device. Projections of the treatment device can be detected by means of radiographic images, and, in the navigation system, the shape of the treatment device can be assigned to the projections via the position of the marker array in/on the projections.
A verification method for positions in camera images is known from U.S. Pat. No. 6,724,922 B1.
DE 199 44 516 A1 describes a method for detecting a shape of an object, wherein a camera image of the object is produced and an outline of the object is detected in a first plane by an evaluation unit (which is connected to the camera). The focusing distance of the camera is changed and an outline of the object is detected in a second plane by the evaluation unit. These steps are repeated until a sufficient number of outlines have been detected, such that the spatial shape of the object can be determined.
EP 1 667 067 A1 discloses a method for calibrating an instrument or implant to which at least one marker is attached. The position of the instrument or implant in space can be determined using the at least one marker. Outlines, a view and/or a geometry of the instrument or implant can be optically captured from at least one side and compared with corresponding outlines, views and/or geometries of stored pre-calibration data of the instrument or implant. A determination then can be made whether or not the instrument or implant is calibrated. A device for calibrating an instrument or implant includes a computational unit connected to a memory in which pre-calibration data of the instrument are stored; at least one camera, using which markers attached to the instrument can be captured; and at least one video camera, wherein the at least one camera and the video camera are connected to the computational unit and exhibit a defined positional relationship to each other. The positional relationship can be determined by the computational unit, and the image data of the instrument as captured by the video camera can be evaluated using the instrument position information as captured by the camera, such that said data can be compared with the pre-calibration data.
A system for determining the spatial position of a body is known from WO 99/17133 and WO 99/30182.
SUMMARY OF THE INVENTION
A camera system in accordance with the invention comprises at least two optical detection systems or cameras arranged, for example, within a casing and being separated from one another by a predetermined distance (e.g., 10 to 1000 mm). At least one and advantageously each optical detection system can be designed such that light may be simultaneously or sequentially detected in a different spectral or wavelength range. These ranges can include, for example, infrared, visible light (for example in the range of about 380 to about 780 nm) and light having a wavelength in the ultraviolet range. On the one hand, this enables a tracking method to be performed using the camera system in conjunction with a navigation system such as is known in its own right, wherein, for example, the cameras or detection system detect light in the infrared range. On the other hand, the detection system or cameras, for example, also can be used to detect light in the visible range. This enables calibration, verification and/or validation of an instrument. By integrating at least two detection devices for detecting light, such as visible light, into the cameras for detecting other types of light (e.g., infrared light) of a known stereoscopic camera system, it is possible (without significantly increasing the weight of the camera system as a whole and without set-up or synchronization problems) to easily provide a device that can not only be used to track markers that reflect, for example, infrared light, but also enables the evaluation of optical information, for example in the visible wavelength range.
The camera system in accordance with the invention also can be used in place of known camera systems that, for example, only detect infrared light, wherein this functionality is retained and broadened to include optical detection in another wavelength range. This additional capability can be used, for example, to perform calibration by means of stereoscopic recordings.
Where wavelength or spectral ranges are mentioned herein, this is intended to encompass light of a constant wavelength.
A camera can be modified to detect light of another, different wavelength range, for example, by providing a beam splitter. Such beam splitter may be a prism or semi-transparent mirror, for example, which can lie in the beam path of light entering a lens or lens system. The incident light split by the beam splitter, after the beam has been split, can strike (e.g., impinge on) a detection element such as a first sensor. The sensor, for example, can be a known CCD array for detecting light of a first wavelength range. The split beam also can impinge on a second sensor for detecting light of a second, different wavelength range. A system for separating incident light is for example described in WO 96/41481 and, in particular, in the example embodiment shown in FIG. 7 of WO 96/41481. The content of WO 96/41481 is hereby incorporated by reference in its entirety.
The term “detection element” or “CCD element” includes any detection element for detecting an optical signal and, for example, converted into an electrical signal, such as for example a separate camera, a CCD chip, CMOS sensor or the like.
It is noted that it is also possible to provide more than two detection elements or CCD elements in an individual camera to enable detection of more than two spectral ranges. Additional semi-transparent mirrors and/or prisms and optionally also additional filter elements, for example, can be used in the cameras to simultaneously or sequentially detect ultraviolet light, visible light and infrared light.
It is also possible to use one or more optical filters positioned in front of one or more detection elements, for example a CCD array, or positioned in the beam path of the light reaching the respective detection element. This can enable light of different wavelengths to be detected by different sensors of the same or different constructions. It is also possible to use sensors that are respectively formed to specifically detect a particular wavelength range. If, for example, only one detection element (e.g., a CCD array) is provided for each camera of the camera system, then it may be made possible to detect light of different wavelength ranges. For example an optical filter that only passes light of a first wavelength range can be arranged in front of the detection element or in the beam path of the light that impinges on the detection element. As a result, only light of the first wavelength range can be detected by the detection element. After a predetermined period of time, in which the light of the first wavelength range has been detected, the filter can be removed or replaced by another filter at the same location or also for example at a different location, in order to detect light of a second wavelength range.
A filter such as a passive filter element can be used wherein the filter characteristics are fixed (e.g., a color filter). Alternatively, an active filter whose filter characteristics can be controlled may be used (e.g., a polarization filter).
It is also possible to provide a camera system, for example, wherein the system includes a movable mirror that in a first position deflects light onto a first detection element, and in a second, for example folded-away or rotated position, deflects light onto a second detection element. The movable mirror can be constructed, for example, as in a single lens reflex (SLR) camera such as is known in its own right. Further, depending on the desired wavelength range to be detected, the mirror can be moved by a mechanism such as is known from an SLR camera so as to deflect light impinging on the mirror and then onto the respective sensor.
The frame rate at which a camera detects light of different wavelengths (e.g., sequential detection), for example, can lie in the range of 50 ms per frame. Thus, in one second ten frames are detected in a first wavelength range and ten frames are detected in a second, different wavelength range.
Since the same lens system, through which light enters the camera, can be used in all of the embodiments of the camera system as described herein, it is possible to determine the corresponding pixels, e.g., a pixel-to-pixel relationship, between the two imaging modalities. The transformation protocol for mapping a pixel in a first image, e.g., an infrared image, onto a corresponding second image, e.g., an image in the visible range, can be known or determined such that it is possible to determine a location on the medical instrument (which is clearly identifiable in the visible range) that the markers (which are clearly visible in the infrared range) are arranged, so as to be able to track and simultaneously also calibrate the instrument. Ideally, the respective pixels of an image recorded in a first wavelength range, for example, can be directly mapped onto the corresponding pixel of an image recorded in a second, different wavelength range. Then, the images in two different wavelength ranges, detected by the same detection element or by two different detection elements, can be superimposed to provide the combined information from detecting both wavelength ranges in one image.
As opposed to the use of external image sources, a synchronization method does not have to be performed for the camera system in accordance with the invention. Since synchronizing the individual sub-assemblies or partial elements of the camera, such as for example the movable mirror or filters or different detection elements, has already been solved by hardware, firmware, software settings and/or adjustments during or after manufacture of the camera system, subsequent synchronization is not required. Thus, when using the camera system for navigation, corresponding stereo video images can be provided, fully synchronized, in addition to tracking the infrared markers. To this end, the camera system merely needs to be calibrated, which, for example, can be performed before it is used for the first time, e.g., by detecting two test images and then comparing the two test images to determine the aforementioned transformation protocol.
Using the camera system in accordance with the invention, it is thus possible for example to verify an instrument in a non-contact process, wherein as opposed to known methods, the use of a calibrating instrument, such as for example an instrument calibration matrix (ICM), can be omitted.
A model of the three-dimensional surface of an object also can be reconstructed from the at least two recordings of the object, as for example described in the article “Shape from Stereo Using Fine Correlation: Method and Error Analysis” by Frédéric Devernay and Olivier Faugeras, which is hereby incorporated by reference in its entirety.
One or more light sources, such as for example LEDs, lasers or lamps, can advantageously be arranged on one or more cameras, for example around an incident light opening or lens of the cameras. The light sources on the cameras can be advantageously designed such that light is emitted in at least one of the wavelength ranges detectable by the camera system, such as for example infrared light, and this emitted light, for example, is reflected from reflective surfaces (e.g., a marker) and transmitted back to the camera. It is also possible to provide light sources of different types on one camera, such as for example lamps for emitting visible light, LEDs or lasers. If a laser or video projector, for example, is used as a light-emitting or projection element, then reconstructing three-dimensional surfaces can be simplified by using so-called “structured light”, as described in the article “3-D Computer Vision Using Structured Light: Design, Calibration and Implementation Issues” by Fred W. DePiero and Mohan M. Trivedi, in: Advances in Computers, Volume 43, pages 243 to 278, depiero96computer, 1996.
A lens system lying in front of the respective detection elements of the camera can be provided as a variable lens system, in order to perform setting procedures such as for example zooming or focusing, as also known from photography. The variable lens system, for example, can be set manually or electronically, in order to configure the camera system to optimally detect an object at a predetermined distance from the camera system.
A computational unit is preferably connected to both cameras and can contain the images recorded by the respective cameras. The computational unit also can process and/or evaluate the images as stereo images, for example, to perform a calibration after performing a 3D reconstruction method.
It is also optionally possible to use three or more cameras that preferably are designed such that light can be detected in at least two different wavelength ranges.
In accordance with another aspect of the invention, there is provided a navigation system comprising a camera system as described herein.
A device for calibrating an instrument that preferably can be used medically and to which at least one marker or reference star is attached, includes a computational unit and a memory connected to the device, wherein pre-calibration data of at least one medical instrument are stored in the memory. At least one camera, as described herein, is also provided for detecting markers attached to the instrument (e.g., by means of reflected infrared light). The camera can be connected to the computational unit, which can ascertain the spatial position of the instrument on the basis of the detected marker image data and optionally on the basis of the pre-calibration data. The device also can include a second camera or image detecting device that is integrated into the above-described camera and can detect light of another wavelength range, which cannot for example be detected by the above-described camera. Using the second camera, the instrument itself or the geometry or dimensions of partial regions of the instrument can be detected, wherein the second camera is also connected to the computational unit. A comparison then can be made in the computational unit between the instrument data optically detected by the camera and the pre-calibration data stored in the memory, wherein the camera for detecting the marker positions is identical to the camera for optically detecting the instrument. It is also possible to detect the position of the markers using the same camera and so as to track the instrument connected to the markers, and to detect the instrument itself or its dimensions.
The invention also relates to a system comprising a device as described above and an instrument to which at least one marker is attached.
In a method in accordance with the invention for calibrating, verifying or validating an instrument or implant (also referred to below as the instrument) which can preferably be used medically and to which at least one marker (and preferably three markers, for example in the form of a so-called reference star, or a number of markers having a geometry which is known, fixed or for example variable depending on the configuration of the instrument) is attached. The position of the instrument in space can be ascertained in a known way by means of a navigation system, for example, using an infrared stereo camera. and markers, which can be formed as reflective surfaces or spheres. For detecting the position of the instrument, a camera can be provided that is integrated into at least one infrared camera and, for example, can detect visible light emitted or reflected by the instrument. The camera is preferably calibrated and the position of the camera in space is also known or defined. The geometry, e.g., one or more views, images or outlines of the instrument from one direction or from different directions, also can be optically detected by means of at least one camera. The camera can be the same camera used to detect the position of the markers, or can also be a second camera, different from said camera, so as to record images in the visible wavelength range, for example.
The geometry or calibration data of the instrument can be stored in software or a computer, such that the three-dimensional representation of the instrument, for example, is stored in a database. These stored, so-called pre-calibration data can be compared with the geometry of the instrument as detected by the camera. This comparison can be used with the optical detection data to determine whether the optically detected data representing the actual geometry or configuration of the instrument match the pre-calibration data. So-called tracking data, detected for example in the infrared range, and a camera image detected in the visible range are thus assigned, wherein if the camera image data match the pre-calibration data, the instrument is said to be in calibration, verified and/or validated. If a difference or deviation from the pre-calibration data is determined, an error prompt, for example, can be output such that the instrument has to be calibrated or the pre-calibration data used for subsequent navigation have to be adjusted to the optical detection data. Preferably, those views or outlines of the instrument model that correspond to the orientation or relative position between the actual instrument and the camera as measured by means of the markers are respectively calculated from a three-dimensional data or software model of the instrument.
If it is assumed that the image calculated by the computer on the basis of the detected position in space of the instrument (which is known as a three-dimensional model) and on the basis of the knowledge of the calibration of the video camera (which is the representation, view, model of the world, or of an instrument by the computer or a software), and that the video input data detected by the camera show the situation in the real world (e.g., an actual available instrument), then if the video camera is properly calibrated (the camera has a known position and orientation and detection range) and the medical instrument is registered or calibrated, the image calculated by the computer would coincide, for a pre-calibrated instrument, with the image which is seen in the video input. If this is not the case, then either the calibration or adjustment of the camera is faulty or the instrument does not correspond to the pre-calibration data, for example, because it is bent. If it is assumed that the calibration of the camera is correct throughout the method, then instruments for which pre-calibration data are available can be reliably verified using the calibrated volume which can be detected by the camera.
The data stored for example in a computer, which define the geometry and optionally also possible degrees of freedom of the instrument, can be stored in a database or the like as pre-calibration data (e.g., as a description of the three-dimensional object) for a navigation system. The data can represent a three-dimensional model that describes the exact shape of an object or instrument and the position of each marker or reference array on the object. The navigation system or a computer can display the three-dimensional model that corresponds to the instrument the surgeon is using. The description of the pre-calibrated instrument, for example, can include information as to which regions, functional locations or areas of the instrument have to be verified. It is also possible to store, as pre-calibration data, information that defines possible shapes that the instrument can assume, such as for example information regarding joints that the instrument may have and ways in which such joints can move, or in general information regarding ways in which the instrument may change or its degrees of freedom.
A calibrated video signal is an input that, for example, can be received from a standard video camera. The properties or parameters of the signal, such as for example the position and/or detection function of the camera, can be determined and calculated for a so-called “virtual” camera. This virtual camera can be used by the computer to calculate images based on three-dimensional objects. This can be accomplished, for example, by projecting in the detection direction of the actual camera, which match the views or objects actually available or detected, such that when the video camera is pointed at a cube-shaped object of known dimensions, the position of the cube-shaped object in three-dimensional space, once the camera volume has been calibrated, can be determined on the basis of the image information. Additional information then can be superimposed onto the video image recorded by the camera, for example, such that this additional information (e.g., a virtual representation of the instrument to be verified) looks like a part of the scene recorded by the camera.
The calibrated video signal can be used to verify and validate pre-calibrated instruments, wherein it is not necessary to use any other object, such as for example a contact area, such that the surgeon's working range is not restricted by an additional object or instrument. Verification, which can be a non-contact process, merely requires a surgeon to hold the instrument to be calibrated such that the video camera can detect at least a partial outline or record a partial view of the object from at least one side. A subsequent software application, such as for example navigation software of the navigation system, can automatically determine whether the detected shape is correct by comparing it with the pre-calibration data.
If an instrument having a more complex shape is to be calibrated, the instrument may be moved or rotated so as to record a number of views of the instrument via the camera, wherein the software, for example, can output a corresponding instruction to move the instrument. Optionally or additionally, other cameras can also be provided to enable detection of the instrument from different directions.
Using the method in accordance with the invention, it is possible to ensure that only calibrated instruments or implants are used for surgical methods. More specifically, if, for example, the shape of an instrument to be used deviates from the pre-calibration data, an error prompt can be output, or the navigation system may not enable the instrument, which has been identified as faulty, to be navigated.
Since it is no longer necessary, in accordance with the invention, to place an instrument to be calibrated onto a reference area, the handling of instruments which are to be kept sterile is simplified.
Preferably, not only one but at least two or more lateral views of the instrument are detected in the visible range of light by an optical camera, wherein the instrument can also be rotated or shifted within the visual range of the camera. Preferably, the visibility of particular points, such as for example the tip of an instrument, can be tested. To this end, it is for example possible to test whether specific points defined in the pre-calibration data, such as for example corner points, edges or tips of the instrument, are also visible or are obscured in the optically detected recording. If obscured, a signal can be output in order to indicate to a user that he should hold and/or reposition the instrument, unobstructed, in the line of sight of the camera.
It is also possible for only particular regions, such as for example corner points, edges, a tip or functional areas, of the instrument which are characteristic of or relevant to the function of the instrument to be tested relative to the pre-calibration data. Information in this respect can be stored in software and, for example, in the pre-calibration data.
In general, the pre-calibration data can include information on the geometry, dimensions, the spatial arrangement of combinable elements (e.g., an instrument and exchangeable tips or an instrument for positioning implants in conjunction with the selected implant) and/or on possible degrees of freedom (e.g., joints or ways of deforming the instrument). By using the pre-calibration data, the configuration or the current state of an instrument, which may be adjusted or deformed, can be identified so as to subsequently use this information on the actual configuration of the instrument, e.g., within the framework of treatment assistance or for a surgical incision by means of image-guided surgery.
Comparing the image data detected by the camera with the pre-calibration data can also be used to test whether an instrument is within a predetermined specification. This predetermined specification, for example, can be specified in the pre-calibration data as a tolerance regarding the dimensions of the instrument. If it is determined that an instrument exceeds a tolerance limit, a corresponding prompt, for example, can be output.
The data, recorded by the camera, regarding the actual state or configuration of the instrument can also be used to adapt or modify the pre-calibration data, such that the data regarding the actual configuration of an instrument, as ascertained by means of the camera, can for example be provided to a navigation system, in order to precisely navigate said instrument.
An instrument corresponding to the pre-calibration data and/or an instrument actually detected by the camera, for example, can be indicated on a screen. It is also possible for both instruments, e.g., the actual and the virtual instrument, to be simultaneously indicated adjacent to one another or superimposed on one another, for example as a so-called overlap image. Characteristic points such as corners and/or edges then can be compared to determine whether the actual instrument matches the virtual instrument in accordance with the pre-calibration data or deviates from it.
The camera for optically detecting the instrument in the visible range is preferably calibrated. To this end, an optical pattern such as for example a chessboard or an object having known dimensions can be held in front of a camera, for example, such that on the basis of the image data detected by the camera, the dimensions of an object situated within the visual range of the camera can be ascertained, optionally using navigation data.
In accordance with another aspect of the invention, there is provided a computer program which, when it is loaded onto a computer or is running on a computer, performs one or more of the method steps described herein. The program can include, for example, program sections for evaluating image data detected by an optical camera such that dimensions or the geometry of a visible region of the instrument can be determined, optionally using navigation data, wherein the optically detected data can be compared with pre-calibration data. The computer program may be provided on a program storage medium or as a computer program product.
BRIEF DESCRIPTION OF THE DRAWINGS
The forgoing and other features of the invention are hereinafter discussed with reference to the drawings.
FIG. 1 illustrates an exemplary device in accordance with the invention.
FIG. 2 illustrates another exemplary device in accordance with the invention.
FIG. 3 is a schematic cross-sectional view of an exemplary camera of a camera system in accordance with the invention, said camera system used in accordance with the device of FIG. 1 .
FIG. 4 is a schematic cross-sectional view of another exemplary camera of a camera system in accordance with the invention, said camera system used in accordance with the device of FIG. 2 .
FIG. 5 is a perspective view of an exemplary stereoscopic camera in accordance with the invention.
DETAILED DESCRIPTION
FIG. 1 shows a first exemplary navigation system 1 in accordance with the invention, wherein the navigation system 1 is coupled to an optical camera comprising two individual cameras 4 a and 4 b , which are part of an optical tracking system 2 and are describe din more detail below. The navigation system 1 can be connected to the optical tracking system 2 by means of a data line, such as for example a cable 3 , or via radio. The cameras 4 a and 4 b can detect infrared light signals emitted or reflected by markers (e.g., the three markers of the reference star 6 ) so as to detect a position of the medical instrument 5 (shown as a pair of scissors) connected to the reference star 6 . Each of the cameras 4 a and 4 b also can be used as a video camera, wherein visible light is detected. The data of the reference star 6 , detected by the optical tracking system 2 in the infrared mode of the cameras 4 a and 4 b , can be transmitted to the computational unit 1 , together with the data of the instrument 5 detected in the video camera mode, and for example evaluated as described in EP 1 667 067 A1 by referring to FIG. 3 and 4 in EP 1 667 067 A1.
By integrating the video camera function into the optical infrared tracking system, the step of calculating the current position of the video cameras in space is omitted. Thus, an instrument 5 , which, for example, may be pre-calibrated, can be tested or verified by correlating the images recorded by the cameras 4 a and 4 b in the infrared range for detecting the markers and in the visible range for detecting the shape or geometry of the instrument 5 . This data can be used to determine if there is a deviation of the instrument from a predetermined shape of the instrument. Calibrating the video cameras, for example when manufacturing the system, provides the information for a “virtual camera”. This information remains valid, since the position of the video camera relative to the tracking system is not changed after calibration. If another, detached video camera 4 c is provided, as shown in FIG. 2 , then the current position of the camera 4 c also can be determined so as to relate the position of the tracked instrument 5 to the “virtual camera”.
FIG. 2 shows a second embodiment, wherein another camera 4 c is detached from the optical tracking system 2 (which includes the cameras 4 a and 4 b ). The camera 4 c can be connected to the computational unit 1 via a separate data connection, such as for example a cable 3 a . Such an arrangement enables detection of the instrument 5 to be more flexibly configured using the additional camera 4 c , since the latter can be positioned independent of the tracking system 2 . This can enable easy detection of the instrument 5 from a number of directions. To this end, the distance, starting from the coordinate system of the additional camera 4 c , between the instrument 5 and the camera 4 c can be ascertained. This enables evaluation of the image data detected by the camera 4 c such that dimensions or the geometry of the instrument 5 can be ascertained from the data. A spatial location of the camera 4 c , via its connection reference star 6 a (which is detectable by the tracking system 2 ) can be calculated. From the spatial position of the additional camera 4 c , the relative position between the camera 4 c and the instrument 5 also can be calculated. Thus, the distance between the instrument 5 and the video cameras can be determined. It is thus for example possible to calibrate an instrument by means of three cameras 4 a , 4 b and 4 c , which can respectively detect infrared and visible light.
FIG. 3 shows a perspective cross-sectional view of a camera 4 , wherein in the incident light region of the camera 4 , a lens 8 is shown as an example of a lens system and is surrounded by LEDs 9 a and 9 b . The LEDs 9 a and 9 b , for example, can be arranged annularly around the lens 8 as shown in FIG. 5 . A beam of light entering through the lens system or lens 8 impinges on a semi-transparent mirror 7 , which lets through a portion of the beam of light so as to strike both the filter 5 b lying directly in the beam path and the detection element or CCD element 6 b lying behind it. By means of the CCD element 6 b , light can be detected in the wavelength range which the filter 5 b lets through. A portion of the light entering through the lens 8 also may be reflected by the semi-transparent mirror 7 in the direction of the second filter 5 a , which lets through light in a different wavelength range relative to the filter 5 b . The light of said other wavelength range strikes the second CCD element 6 a lying behind the filter 5 a in the direction of the beam of light reflected by the semi-transparent mirror 7 , wherein said CCD element 6 a can detect in said other wavelength range. The wavelength range that is detected, sequentially or also simultaneously, by the CCD elements 6 a and/or 6 b can be set, depending on the type of filters 5 a and 5 b that are used.
It may be noted that one of the filters 5 a and 5 b can be omitted in the example embodiment shown in FIG. 3 . This can be done, for example, to detect visible light by means of the CCD element not shielded by a filter, wherein an infrared filter, for example, can be placed in front of the other CCD element.
The region in front of the camera 4 , for example, can be illuminated with infrared light by means of a light source 9 a . This can improve the detection of reflective markers. The second light source 9 b , for example, can emit light in another wavelength range, such as for example visible light or also ultraviolet light, so as to improve the detection of objects using light in the visible range. However, depending on the application, it is also possible to omit one or all of the illuminating elements 9 .
It may be noted that the position of the CCD elements 6 a and 6 b in relation to the semi-transparent mirror 7 can be different. For example, the CCD elements 6 a and 6 b can be at different distances from the mirror 7 , since light of different wavelengths does not focus onto exactly the same point. The optical element 8 can also be configured to be variable, in a similar way for example to a photographic or video camera such as is known in its own right, in order to focus the light on the respective sensor 6 a or 6 b , depending on the desired light detection range.
FIG. 4 shows a second embodiment of a camera 4 in accordance with the invention, wherein a beam splitting prism 10 is provided instead of the semi-transparent mirror 7 shown in FIG. 3 . Light 11 entering the prism 10 is split into light of a first wavelength range 12 b , which passes through the prism 10 and strikes the first CCD element 6 b . Light of a second wavelength range can be refracted by the prism 10 and deflected onto the second CCD element 6 a as diverted light 12 a . It is thus also possible to omit filters and simultaneously, for example continuously, detect an object using the two CCD elements 6 a and 6 b.
FIG. 5 shows an exemplary stereoscopic camera, wherein two individual cameras 4 a and 4 b are separated from one another, for example as described above, are arranged in a casing 13 . The respective lenses 8 and the illuminating elements or LEDs 9 can be seen in the perspective shown in FIG. 5 . A CPU 14 can be arranged in the casing 13 and connected to each of the cameras 4 a and 4 b and, in particular, to the respective CCD elements 6 a and 6 b . Via a connection 3 , stereoscopic images detected by the cameras 4 a and 4 b can be transmitted in two different wavelength ranges to the computational unit 1 shown in FIGS. 1 and 2 .
Recording the images using the cameras 4 a and 4 b , setting the lens system 8 or setting or positioning a filter 5 a and 5 b , such as for example shifting a filter in front of one or more of the CCD elements 6 a and 6 b in order to detect a different wavelength range, can be controlled by means of the computational unit or CPU 14 . The CPU 14 also can synchronize the CCD elements 6 a and 6 b of a camera and the illuminating elements 9 a and 9 b respectively assigned to the respective CCD elements 6 a and 6 b . The evaluation result or also the optical signals, which for example may not be directly evaluated by the CPU 14 , can be transmitted to another system via the connection 3 .
Although the invention has been shown and described with respect to a certain preferred embodiment or embodiments, it is obvious that equivalent alterations and modifications will occur to others skilled in the art upon the reading and understanding of this specification and the annexed drawings. In particular regard to the various functions performed by the above described elements (components, assemblies, devices, compositions, etc.), the terms (including a reference to a “means”) used to describe such elements are intended to correspond, unless otherwise indicated, to any element which performs the specified function of the described element (i.e., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the herein illustrated exemplary embodiment or embodiments of the invention. In addition, while a particular feature of the invention may have been described above with respect to only one or more of several illustrated embodiments, such feature may be combined with one or more other features of the other embodiments, as may be desired and advantageous for any given or particular application. | A camera system includes at least two camera units, wherein each camera unit comprises at least one detection element for detecting an optical signal. At least one of the at least two camera units includes at least one element operative to enable detection of light in at least two different spectral ranges. | 0 |
BACKGROUND OF THE INVENTION
This invention relates to an apparatus and method for protecting computer code placed in internal circuitry within a computer, sometimes known as firmware. This invention accomplishes this by "scrambling" or altering data placed on the data bus from circuit firmware according to a given encoding word and a predetermined circuit matrix.
The unauthorized copying of data placed in firmware poses a threat to the integrity of the computer industry. Typically, the quantity of data placed in firmware is not great, but it is often extremely crucial to the operation of a particular machine (e.g. computer bootstraps, video games, computer operating systems and the like). For factory programmed read-only memories (ROMs) or for field programmable read-only memories (PROMs) the stored data may reveal crucial information about the operation of the system. One approach to protecting such data is to provide a fusible link in the array so that the data, once programmed, simply cannot be externally accessed. See, e.g., R. Birkner, et al., U.S. Pat. No. 4,124,899, "Programmable Read-Only Memory", which is hereby incorporated by reference. This approach has the disadvantage that, once the fuse is opened, the PROM may not be altered and the use of diagnostic routines is thereby inhibited.
Copy protection schemes fall into four broad categories: hardware dependent approaches, load format alteration, software that checks the environment as it executes, and software that executes through a "filter". In each case the protection schemes involve an interaction of software and hardware. Where software is used, a microprocessor is usually involved so that one convenient technique of copying is to intercept the instructions and data supplied to the microprocessor. This invention makes interception of that data more difficult. The various approaches that have been used to protect software are discussed in J. Commander, et al., "How Safe is Your Software?", Microcomputing, July 1982 p. 60 which is hereby incorporated by reference.
It is desirable for data protection circuitry to be composed of as few components as possible. This yields two benefits. First, the amount of area utilized in a particular integrated circuit chip for the purposes of data protection circuitry is held to a minimum. Second, each component in a particular data path slows the propagation of data by a specific amount determined by the characteristics of the device in the data path; the fewer components in the data path the faster the circuit can operate.
It is an object of this invention to encode data carried on data lines running between integrated circuits in a certain predetermined manner in order to protect the data carried upon those data lines. Further, it is an object of this invention to do this with a minimum number of components.
SUMMARY
An encoding Exclusive-OR gate is provided for each data transmission lead. One input lead of each encoding Exclusive-OR gate is connected to the corresponding incoming data transmission lead in order to receive data to be transmitted on accessible data lines. The other input lead of each encoding Exclusive-OR gate is connected via a code matrix to a source of a random M-bit binary number. The output signal provided by each Exclusive-OR gate is the encoded data bit which is applied to one of the accessible data lines.
The encoded data is decoded by a circuit similar to the encoding circuit. In the decoding circuit a decoding Exclusive-OR gate is provided for each data transmission lead. One input lead of each decoding Exclusive-OR gate is connected to an incoming encoded data transmission lead. The other input lead to the decoding Exclusive-OR gate is connected via a code matrix which is similar to the code matrix provided in the encoding circuit, to a source of a random M-bit binary number, where the M-bit binary number is the same M-bit binary number provided in the encoding circuit. The output leads of the decoding Exclusive-OR gates are the transmission lines which carry the decoded data.
The encoding matrix and the random M-bit word are the same in the encoding and decoding circuit, so the data on the output leads of the Exclusive-OR gates is properly decoded.
However, the data on bus lines running between integrated circuits, and which therefore may be intercepted through the use of logic probes, is in encoded form, thereby substantially increasing the effort required to illicitly determine the data stored in firmware.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of structure including a processor capable of addressing a read-only memory, together with one embodiment of the present invention used to both encode and decode the data being accessed from the read-only memory;
FIGS. 2a and 2b are schematic diagrams showing one embodiment of the encoder and decoder, respectively, of the present invention suitable for use in the structure of FIG. 1;
FIGS. 3a and 3b are logic diagrams showing one embodiment of counters 21 and 31 in FIGS. 2a and 2b, respectively;
FIG. 4 is a block diagram of a microprocessor accessing data from a read-only memory, where the decoding circuitry is contained in the microprocessor chip;
FIGS. 5a and 5b are schematic diagrams showing one embodiment of the encoder and decoder, respectively, of the present invention suitable for use in the structure of FIGS. 3a and 3b;
FIG. 6a shows an integrated circuit electrical conductor pattern which is one method of implementing the matrix of the described embodiment of invention;
FIG. 6b shows a cross-sectional view of the integrated circuit electrical conductor pattern shown in FIG. 6a;
Table 1 shows the status of a particular bit in the data word as it is encoded and subsequently decoded by the embodiment of the present invention shown in FIGS. 2a, 2b, 4a and 4b; and
Table 2 is a truth table for an Exclusive-OR gate.
DETAILED DESCRIPTION
FIG. 1 shows a block diagram of a circuit constructed in accordance with one embodiment of the present invention. Read Only Memory (ROM) 1 is controlled by central processing unit (CPU) 5 via address bus 10 and ROM enable circuit 4. Address bus 10 contains a plurality of data lines 10-1 through 10-k where k is a selected integer. When CPU 5 addresses a memory word contained in ROM 1 (via address bus 10), ROM enable circuit 4 provides a logical 1 enable signal to ROM 1. ROM 1 then places the selected data word (i.e., the data word stored within ROM 1 which corresponds to the address provided by CPU 5 on address bus 10) on data bus 7. Circuit 2 encodes the data placed on data bus 7, and places the encoded data on bus 8. Circuit 3 decodes the data placed on data bus 8, and places the decoded data on data bus 9. In a preferred embodiment, only data bus 8 runs between integrated circuits 6 and 12 and therefore only data bus 8 can be accessed without dismantling integrated circuits 6 or 12.
FIGS. 2a and 2b are schematic diagrams of one embodiment of encoder 2 and decoder 3, respectively, of FIG. 1. Input data is applied to circuit 2 of FIG. 2a via data bus 7, which in the embodiment of FIG. 2a includes a plurality of N data leads 7-1 through 7-N, and which is capable of receiving an N bit data word. Exclusive-OR gate bank 23 contains a plurality of N Exclusive-OR gates 23-1 through 23-N, each uniquely associated with a single one of data leads 7-1 through 7-N, respectively. Each data lead 7-1 through 7-N in data bus 7 is connected to one input lead of its corresponding Exclusive-OR gate 23-1 through 23-N, respectively, in Exclusive-OR gate bank 23. The other input leads of Exclusive-OR gates 23-1 through 23-N are connected to M-bit counter 21 by coding matrix 22. M-bit counter 21 as shown of FIG. 2a is connected to the output lead 11 of ROM enable circuit 4 of FIG. 1. M-bit counter 21 is a means for providing an M-bit encoding/decoding word. NAND gate 24 is provided to cause M-bit counter 21 to function as a so-called "pseudo-random" word generator.
Counters are well known in the art. A counter provides a logical M-bit number in a predictable and well known manner. An M-bit pseudo-random counter provides an M-bit number in a predictable manner. How a particular pseudo-random counter will behave is difficult for a potential unauthorized software copier to ascertain. Gate 24 alters the bit connected to the output lead of gate 24 in response to the input signals applied to gate 24 by counter 21. Because gate 24 changes the manner in which counter 21 operates, the combination of counter 21 and gate 24 is referred to as a pseudo-random counter. A pseudo-random counter behaves predictably, if one knows how a pseudo-random counter is designed. The specific connections of the input and output leads of NAND gate 24 are provided as an example only. Other connections of input and output leads and the use of other types of logical gates, including logic gates of other than two input leads or one output lead, will become obvious to one skilled in the art in light of the teachings of this invention. Gate 24 alters the bit connected to the output lead of gate 24 in response to the input signals applied to gate 24 by counter 21.
Of importance, the M-bit encoding word is used in encoder circuit 2 of FIG. 1 and the M-bit decoding word used in decoder circuit 3 of FIG. 1 must be identical in order for the encoded data placed on bus 8 to be properly decoded and set onto bus 9. FIGS. 3a and 3b are logic diagrams of embodiments of counters 21 and 31 in FIGS. 2a and 2b, respectively. The operation of counters in general and these counters specifically are well known in the prior art by the terms "shift counters" or "shift registers". The counters shown in FIGS. 3a and 3b are provided by way of example only. The use of other types of counters will become obvious to those of ordinary skill in the art in light of the teachings of this invention. In U.S. Pat. No. 4,176,247 for "SIGNALS SCRAMBLER-UNSCRAMBLER FOR BINARY CODED TRANSMISSION SYSTEM", R. M. Englund, operations of shift registers in association with a signal scrambler-unscrambler system, are detailed. At each clock pulse, a M-bit binary word from the M stages of such register is generated. In like manner, in FIGS. 3a and 3b, the input signal to be counted is placed on input leads 211 and 311 in counters 21 and 31, respectively. Of importance is the fact that input leads 211 and 311 connect to the clock input leads of D-type flip-flops 21-1 through 21-M, and 31-1 through 31-M, respectively. As is well known to those in the art, in typical systems, there are several sources available to pulse such clock input leads. In the embodiments shown, both input leads 211 and 311 are connected to ROM enable lead 11 of FIG. 1, although it is to be understood that any other desired signal may serve the purpose of causing counters 21 and 31 to count. Output leads 210-1 through 210-M and 310-1 through 310-M carry output signals 212-1 through 212-M and 312-1 through 312-M, respectively. Output signals 212-1 and 312-1 are the least significant bits of the counter. Of importance, however, is the inclusion of input leads 213 and 313 which are connected to all of the clear input leads of D-type flip-flops 21-1 through 21-M and 31-1 through 31-M, respectively. Leads 213 and 313 are provided to ensure that the M-bit word carried by output leads 212-1 through 212-M and 312-1 through 312-M are identical. Periodically, a logical 1 input signal is applied simultaneously to input leads 213 and 313, thus setting flip-flops 21-1 through 21-M and 31-1 through 31-M to a logical 0 output state. The input signal applied to input leads 213 and 313 may be provided by a number of sources. For example, a specific address applied to address bus 10 may also trigger a pulse on input leads 213 and 313 derived from the internal circuitry (not shown) of ROM 1. Alternatively, an external reset clock (not shown) may be used which provides a logical 1 pulse periodically, provided the speed at which the reset clock operates is much slower than the operation speed of counters 21 and 31. FIGS. 3a and 3b show the specific connections of gates 24 and 34 in FIGS. 2a and 2b. In the example shown in FIGS. 3a and 3b the output leads of gates 24 and 34, respectively, are connected to the input leads of flip-flops 21-3 and 31-3, respectively. As shown in the embodiments of FIGS. 3a and 3b, the output leads of Exclusive-OR gates 201-2 and 301-2 are disconnected from input leads to flip-flops 21-3 and 31-3, respectively. Alternatively, the output leads of gate 201-2 and 24 (FIG. 3a) and 301-2 and 34 (FIG. 3b) may be connected together in a "wired AND" configuration. The input leads to gates 24 and 34 may be connected to any output lead of flip-flops 21-1 through 21-M and 31-1 through 31-M, respectively, and the output leads of gates 24 and 34 may be connected to the input leads of any of flip-flops 21-1 through 21-M and 31-1 through 31-M, respectively, provided that the connections of gate 24 are identical to the connections of gate 34.
The encoded output signals of encoding circuit 2 of FIG. 2a are carried by data bus 8, which includes a plurality of N data leads 8-1 through 8-N suitable for transmitting an N-bit encoded data word.
In FIG. 2b, the encoded data is applied to decoding circuit 3 via data bus 8. Exclusive-OR gate bank 33 contains a plurality of N Exclusive-OR gates 33-1 through 33-N, each uniquely associated with a single one of data leads 8-1 through 8-N, respectively. Each data lead 8-1 through 8-N in data bus 8 is connected to one input lead of its corresponding Exclusive-OR gate 33-1 through 33-N respectively, in Exclusive-OR gate bank 33. The other input leads of Exclusive-OR gates 33-1 through 33-N are connected to M-bit counter 31 by coding matrix 32. M-bit counter 31 is a means for generating an M-bit decoding word. M-bit counter 31 is constructed in the same manner as M-bit counter 21. The decoded output signal is provided on the output leads of Exclusive-OR gates 33-1 through 33-N. The decoded output word of circuit 3 is carried by data bus 9 which includes a plurality of N data transmission leads 9-1 through 9-N suitable for transmitting an N-bit decoded data word. Each transmission lead 9-1 through 9-N is uniquely connected to one of the output leads of Exclusive-OR gates 33-1 through 33-N.
The M-bit word provided by M-bit counter 21 need not be provided by a counter. FIG. 4 and FIGS. 5a and b show one embodiment of the present invention. FIG. 4 is the block diagram of a microprocessor accessing data from a read-only memory (ROM) where the decoding circuitry is contained in the microprocessor chip. FIGS. 5a and 5b are schematic diagrams showing one embodiment of the encoder and decoder of the present invention. It is thus seen by these figures that the logical word on address bus 10 of FIG. 4 is used in FIGS. 5a and 5b for encoding and decoding purposes, viz, as the M-bit encoding word in FIG. 5a and the M-bit decoding word in FIG. 5b. The M-bit word received by coding matrix 22 may be any M-bit word, provided means are used to ensure that the M-bit logical word provided to decoding matrix 32 is the same as the M-bit logical word provided to encoding matrix 22.
Similarly, coding matrix 22 may connect the second input lead of any of the Exclusive-OR gates in Exclusive-OR gate bank 23 with any bit in the M-bit word contained in M-bit counter 21 provided the connections in coding matrix 22 are exactly the same in the encoding circuit 2 in FIG. 2a as in coding matrix 32 in decoding circuit 3 in FIG. 2b. If N is the number of data lines, where N is a positive integer, and M is the number of bits in the M-bit encoding/decoding word, then the number of possible coding matrices is M!/N!. If M is less than N, the second input leads of selected Exclusive-OR gates may be left unconnected or if M is greater than N, two second input leads may be connected to one bit of the M-bit encoding/decoding word.
The effect of the encoding/decoding circuitry on a particulaar bit of the N bit data word is shown in Table 1. For example, if the data bit is a logical 0 and, also for example, the code bit provided by the N-bit encoding word and coding matrix 22 is a logical 0, the output signal on data lead 8-x, where x is a positive integer between 1 and N, for that particular bit in encoded data output bus 8 is a logical 0. The M-bit decoding word in decoding circuit 3 of FIG. 2b is the same M-bit word as in encoding circuit 2 of FIG. 2a. The coding matrix 32 in decoding circuit 3 must connect the second input leads of Exclusive-OR gate bank 33 to predetermined stages of the M-counter 31 in the same manner as the connections made by coding matrix 22 in encoding circuit 2. Therefore, the code bit provided by the decoder 3 in Table 1 is the same as the code bit provided by the encoder 2 in Table 1, in this example a logical 0. The Exclusive-OR gate in decoding circuit 3 for this particular bit combines the logical 0 on encoded data bus 8 and the logical 0 code bit to provide an output signal of 0, the same as the input bit on input bus 7. Alternatively, if the data bit provided by data input bus 7 is a logical 1 and the code bit provided by the M-bit counter 21 and coding matrix 22 is also a logical 1, the output signal on encoded data bus 8 for that particular data bit is a logical 0. That logical 0 bit on encoded data bus 8 is combined in circuit 3 with the logical 1 decoding bit provided by the decoding word. Therefore, the output signal will be a logical 1, the same as the input data bit. Table 1 shows that for any combination of data bit and code bit the output signal on data bus 9 is exactly the same as the input data bit on data bus 7.
Coding matrix 22 may be constructed in a number of ways. One method which can be used when the invention is implemented in an integrated circuit is to construct the metal conductor pattern of the integrated circuit corresponding to the desired combination of connections between the M-bit word contained in M-bit counter 21 and the Exclusive-OR gates in Exclusive-OR gate bank 23. This is an efficient method of construction of the matrix. Many ROMs are programmed by altering the metalization mask used to make the conductor on the ROM chip. The matrix can simply be developed during this step. Another method of constructing coding matrices 22 and 32 is shown in FIGS. 6a and 6b. The conductors of the matrix are laid out in a square cross-hatch pattern as shown in FIG. 6a, where N is the number of leads in data buses 7, 8 and 9, and M is number of bits in M-bit counters 22 and 32. If the X-bit, where X is a number between 1 and M of M-bit word is to be connected to Exclusive-OR gate 23-Z, where Z is a number between 1 and N, then a hole in oxide insulator 42 is made and conductors 43-Z and 41-1 are thereby connected. If bit X of the M-bit word and Exclusive-OR gate Z are not to be connected then the oxide insulator 42 in between the two conductors is left intact. These examples are only particular embodiments of the coding matrix 22 in the present invention. The invention is by no means limited to these examples.
While this specification illustrates specific embodiments of this invention, it s not to be interpreted as limiting the scope of the invention. Many embodiments of this invention will become evident to those of ordinary skill in the art in light of the teachings of this specification.
TABLE 1______________________________________ Encoder Decoder Code Output Encoder/ Code OutputData Bit(7) Bit(2) Input Decoder(8) Bit(3) Decoder(9)______________________________________0 0 0 0 00 1 1 1 01 0 1 0 11 1 0 1 1______________________________________
TABLE 2______________________________________Exclusive ORInput 1 Input 2 Output______________________________________0 0 00 1 11 0 11 1 0______________________________________ | The present apparatus provides for the encoding of data carried on bus lines running between integrated circuits in order to protect the data carried upon those bus lines, with encoding and decoding circuits included for providing those functions in regard to the data on the bus lines. | 6 |
CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the priority of German Patent Application Serial No. 101,33,653. 5, filed Jul. 11, 2001, the subject matter of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates, in general, to an arrangement of electric machines.
[0003] Electric machines typically include a stationary stator having slots for receiving windings. A rotor, which represents the moving part of the electric machine, generates the excitation. Stator as well as rotor are arranged point-symmetric with respect to the axis of the electric machine. The shaft of the electric machine extends in alignment with the axis and operates essentially power machines, for example, machine tools, pumps etc.
[0004] There are applications that require several electric machines to be disposed in a narrow space such that their axes extend substantially in parallel relationship. This is the case in particular when multiple spindle machines of machine tools are involved. Hereby, the individual spindles are each operated by an electric machine. Each electric machine has its own stack of stator laminations and stack of rotor laminations, which are spatially separated from one another. Assembly of, for example, a multiple spindle machine thus requires sufficient geometric dimensions in order to accommodate the required electric machines while still effecting a sufficient cooling action.
[0005] It would therefore be desirable and advantageous to provide an improved arrangement of electric machine, which is so configured as to further reduce the need for space while still improving thermal exploitation of the overall arrangement in comparison to conventional arrangements.
SUMMARY OF THE INVENTION
[0006] According to one aspect of the present invention, in an arrangement of a plurality of electric machines, the electric machines are defined by axes in parallel relationship, wherein the electric machines have a common stator which incorporates a plurality of stator portions that cooperate with rotors insertable in the stator portions, wherein the number of rotors corresponds to the number of the axes of the electric machines.
[0007] The present invention resolves prior art problems by providing a common stator for all electric machines, thereby reducing the outer dimensions so that the arrangement can be installed in even tight spaces. A common, single-piece configuration of the stator saves also additional assembly steps for fabricating the arrangement according to the present invention.
[0008] The common stator may have a laminated configuration, whereby the stator is formed by stacking single piece metal sheets in axial direction. As an alternative, the common stator may also be made of composite materials or by a combination of laminated parts and composite materials.
[0009] The arrangement of such electric machines may have any suitable geometric configuration, e.g. a polygonal shape, a round shape or a linear shape of side-by-side disposition of the electric machines. The arrangement according to the present invention is in particular suitable for multiple spindle machines having six motors disposed in a circle, because such a disposition results in an arrangement of electric machines in which each electric machine occupies a segment of about 60°.
[0010] According to another feature of the present invention, the arrangement includes a cooling unit. Examples of such a cooling unit include the provision of an outer cooling jacket and/or a cooling in mid-section of the arrangement. A central cooling is appropriate for circular arrangement of the electric machines in order to further reduce the outer installation dimensions. In the event of a side-by-side disposition of the electric machines in a substantially linear alignment, the cooling unit is suitable placed between two neighboring electric machines. Of course, combinations of cooling systems are also conceivable without departing from the spirit of the present invention. For example, some areas may have an outer cooling jacket as well as an inner cooling jacket. Examples of a coolant medium include air or liquid coolants.
[0011] According to another feature of the present invention, each stator portion of the common stator has circumferentially spaced slots, whereby the slots disposed in the area of the overlap zones between immediately neighboring stacks of laminations have a geometry which is so configured as to optimize the magnetic field in the area of immediately neighboring stacks of laminations. Suitably, the width an the depth of these slots are selected to realize an optimal magnetic field.
[0012] According to another feature of the present invention, flux barriers may be provided between individual stator portions of immediately neighboring electric lamination stacks. Flux barriers may be implemented through provision of slots in the respective metal sheet or by using non-magnetic materials in these locations.
BRIEF DESCRIPTION OF THE DRAWING
[0013] Other features and advantages of the present invention will be more readily apparent upon reading the following description of currently preferred exemplified embodiments of the invention with reference to the accompanying drawing, in which:
[0014] [0014]FIG. 1 is a sectional illustration of an exemplified multiple spindle machine having incorporated six electric machines in an arrangement according to the present invention;
[0015] [0015]FIG. 2 is a sectional illustration of a side-by-side arrangement of electric machines in accordance with the present invention; and
[0016] [0016]FIG. 3 is an enlarged detailed view of an area encircled in FIG. 1 showing the zone between neighboring electric machines in accordance with a modified embodiment of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0017] Throughout all the Figures, same or corresponding elements are generally indicated by same reference numerals.
[0018] Turning now to the drawing, and in particular to FIG. 1, there is shown a sectional illustration of a machine tool in the form of an exemplified multiple spindle machine having incorporated six electric machines in an arrangement according to the present invention. For the sake of simplicity, the electric machines will be described hereinafter only in connection with those parts that are necessary for the understanding of the present invention. It will be appreciated by persons skilled in the art that the electric machines must contain much mechanical apparatus which does not appear in the foregoing Figures. However, this apparatus, like much other necessary apparatus, is not part of the invention, and has been omitted from the Figures for the sake of simplicity.
[0019] The electric machines have a common stator 10 in the form of a stack of single-piece laminations 1 . Although not shown in the drawing, the stator 10 may also be made of composite materials or by a combination of laminated parts and composite material. Examples of composite materials include materials based on iron and capable to guide the magnetic field without encountering excessive eddy current losses. Metal powder being useable here include ferrous alloys, copper, nickel etc.
[0020] The laminations I are formed with punchings or cutouts, here six and generally designated by reference numeral 11 , for defining stator portions and accommodating rotors 2 at formation of respective air gaps between the rotors 2 and the stator lamination stack that includes the stator portions. The electric machines are defined by respective axes 8 which are disposed in parallel relationship. The laminations 1 are further formed with punchings for providing possible cooling channels 4 and slits for providing flux barriers 6 . The stator portions of the stator 10 have slots 9 for placement of coils and windings, not shown. An arrangement in this way is optimized as far as space demands are concerned and thus is applicable also in smaller casings for power classes that were previously jot considered. The rotors 2 may suitably be permanently excited rotors.
[0021] The flux barriers 6 in overlap zones 7 between immediately neighboring electric machines properly route the magnetic flux between the individual electric machines and are implemented by slits in the laminations 1 . Alternatively, instead of slits in the metal sheets, the flux barriers 6 may also be implemented through use of suitable non-magnetic material that is known to a persons skilled in the art. Examples of non-magnetic material include plastics or light metals, e.g. aluminum. The cooling channels 4 may be formed at a peripheral area of the laminations 1 and radially inwards in a mid-section, as shown in the embodiment of FIG. 1, which depicts the electric machines in a circular disposition. The central cooling channel 4 may have a star-shaped configuration, as shown. Of course, other configurations are equally conceivable, e.g., a circular shape. The star-shaped configuration is presently preferred because of the enhanced cooling action at the center-proximal side of the individual electric machines.
[0022] The cooling action can be further enhanced in the outer areas that are radially outside of the stator portions of the electric machines by providing a cooling jacket 5 which circumscribes the entire stator 10 of the arrangement, i.e., the stack of laminations 1 . The cooling jacket has incorporated therein cooling channels, not shown, which contain a coolant, e.g., air or a suitable liquid. Thus, the cooling channels 4 and the cooling jacket 5 should be configured for circulation of air of liquids to ensure the operational safety of the electric machines. In particular, when a liquid-based cooling action is involved, care should be taken to provide proper sealing measures.
[0023] In addition to the flux barriers 6 , the magnetic flux in the overlap zones 7 can also be controlled by suitably configuring the width and depth of the slots 9 of the stator portions of the common stator 10 so as to conduct and configure the magnetic field in this overlap zone 7 .
[0024] Turning now to FIG. 2, there is shown a sectional illustration of a side-by-side arrangement of electric machines in accordance with the present invention. Parts corresponding with those in FIG. 1 are denoted by identical reference numerals and not explained again. In this embodiment, provision is made for a linear disposition of the electric machines, instead of the circular disposition in FIG. 1. The laminations 1 of the stator stack is formed here by way of example with three cutouts 11 for placement of the rotors 2 . The axes 8 of the rotors 2 and thus the electric machines are also disposed in parallel relationship. Also in this embodiment, any type of coil or winding can be placed in the slots 9 of the stator portions of the common stator 10 . Formed in the overlap zones between neighboring electric machines are the slotted flux barriers 6 , and punchings are provided to provide the cooling channels 4 . The stator 10 is embraced by a cooling jacket 5 .
[0025] [0025]FIG. 3 shows an enlarged detailed view of an area encircled in FIG. 1, to illustrate a modified embodiment of the electric machines in the overlap zone 7 between neighboring electric machines, involving a variation of the configuration of the slots 9 of the stator 10 . In accordance with the present invention, the stator portions of the stator 10 has in the area of the overlap zones 7 slots 9 a which have a reduced slot depth and/or slot width compared to the remaining slots 9 so as to optimize the magnetic field in the overlap zones 7 .
[0026] While the invention has been illustrated and described as embodied in an arrangement of electric machines, it is not intended to be limited to the details shown since various modifications and structural changes may be made without departing in any way from the spirit of the present invention. The embodiments were chosen and described in order to best explain the principles of the invention and practical application to thereby enable a person skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated.
[0027] What is claimed as new and desired to be protected by Letters Patent is set forth in the appended claims and their equivalents: | In an arrangement of a plurality of electric machines, the electric machines are defined by axes in parallel relationship, wherein the electric machines include a common stator which incorporates a plurality of stator portions. The stator portions of the stator cooperate with rotors which are insertable in the stator portions, whereby the number of rotors corresponds to the number of the axes of the electric machines. | 7 |
BACKGROUND OF THE INVENTION
The present invention relates to a downhole packer for use in a well bore. More particularly, the present invention relates to a packer which can be used for downhole testing.
During well completions it is desirable to check the integrity of the production bore and any packers used to isolate portions of the well. A known technique for this is to perform an in-flow or negative test. One or more packers are inserted into the well bore to seal off a portion of the well. Low density fluid is introduced to the work string reducing hydrostatic pressure within the pipe. As a consequence of the drop in hydrostatic pressure, well bore fluid flows through any cracks or irregularities into the bore resulting in an increase in pressure which can be monitored and used to indicate where repairs are necessary.
Typically, a separate trip is required to be made into the well to perform an in-flow or negative pressure test. This is because the conventional packer tools used are set by a relative rotation within the well bore. As many other tools are activated by rotation and indeed as the drill string itself would normally be rotated during this type of operation, it is likely that the packer would prematurely set. This problem has been overcome by the introduction of a weight set packer. Such a weight set packer, referred to as a compression set packer, is disclosed in the Applicant's International Patent Application, publication no. WO/0183938. The packer is set by a sleeve moveable on a body of the packer being set down on a formation in the well bore. Movement of the sleeve compresses one or more packing elements to provide a seal.
This compression set packer is particularly suitable for integrity testing of a liner when a permanent packer, or ‘tieback’ packer, with a Polished Bore Receptacle (PBR) has been used. Once the permanent packer with the PBR has been set, a single trip can be made into the well to operate clean-up tools and perform an in-flow or negative test. The clean-up tools may be operated by relative rotation of the work string in the well-bore and further the work string can be slackened off so that the sleeve of the compression set packer lands out-on the PBR. This sets the compression set packer above the PBR and seals the bore between the packers. An in-flow or negative test can then be performed.
A significant disadvantage of this compression set packer is that of loading on the PBR. When an in-flow test is carried out large pressure differentials are created across the packing element and thus a substantial force is applied to the packer from above. In a compression set packer much of this force is transferred to the PBR. As a result, both the packer element and the PBR are at risk of failure if the load bearing capacity is exceeded. This is a particular problem in deep wells were the differential pressures will be greater. For example, if a packer has an annulus surface area, in use, of 10 square inches and a pressure differential applied across it of 30,000 pounds, this provides a force of up to 250,000 pounds at the compression set packer.
The problem of excessive loading and the additional forces on the liner by the hydraulic test pressure differentials has been considered for a liner top test packer as described in WO 03/067027. This discloses an arrangement where the slips are set below a compression set packer and the packer is set against the slips. The additional loading and forces are all then transferred to the casing in which the packer is set via the slips. Thus the slips prevent loading onto any liner or liner hanger located below the slips.
This packer tool, however, has a number of disadvantages. As with all weight-set tools there is a risk that the tool will set in the wrong location if it meets an obstruction in the well bore. As this tool is set by shearing pins and then engaging slips before the packer elements expand, it is difficult to release the tool for repositioning once it has set. Additionally, as the slips move transversely in response to a longitudinally applied force, under excessive longitudinal loading, which can be experienced at high pressure differentials, the slips can loose grip and thus there is a risk of the full force landing on the liner top.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a compression set packer which includes a mechanism to take up excess force created by the pressure differential during an in-flow test.
It is an object of at least one embodiment of the present invention to provide a compression set packer which prevents force from the pressure differential being applied to a liner top.
According to a first aspect of the present invention there is provided a packer tool for mounting on a work string to provide a seal against a tubular, the packer tool comprising a body with one or more packer elements and a sleeve, the packer tool being set by movement of the sleeve relative to the tool body compressing the one or more packer elements, wherein the tool has a plurality of bypass channels to provide a fluid path past the packer elements and wherein the sleeve includes at least one anchoring member, the at least one anchoring member being actuable to contact the tubular by fluid pressure from the bypass channels when the packer is set.
Thus a flow path exists in the tool past the packer elements at all times. When the elements are set, the fluid pressure is used to actuate anchoring means against a wall of the well bore to prevent excess loading below. Increased flow pressure caused by a pressure differential at the elements is used to further secure the anchoring means. Further the existence of a flow path around the packer elements reduces surging and swabing when the tool is run-in and pulled out of the well bore.
Preferably the at least one anchoring member is a moveable pad. Preferably there are three pads equidistantly arranged around the sleeve. Preferably the pads are arranged to move radially with respect to a longitudinal axis of the tool. Preferably each pad includes a gripping surface to engage the tubular. Advantageously each pad is part cylindrical, with the curved face being the gripping surface. Preferably a radius of curvature of the gripping surface matches a radius of curvature of the tubular. Preferably also each pad includes a rear surface against which fluid pressure can act to move the pad.
The tool may include restraining means. The restraining means may be one or more springs which bias the/each pad toward the sleeve. The springs may be a pair of leaf springs arranged longitudinally on either side of each pad. The restraining means prevents the pads from engaging the tubular wall when the tool is run-in the tubular.
Preferably the sleeve includes a plurality of ports, each port being arranged between an inner and an outer surface of the sleeve. Preferably, when the packer is not set, the ports align with a base of the bypass channels so that fluid bypassing the packer elements passes to the outer surface of the sleeve. Preferably also, when the packer is set, the ports are closed by virtue of their movement away from the bypass channels.
Preferably, closure of the ports directs the fluid bypassing the packer elements and transfers the fluid pressure to the anchoring means. More preferably the directed fluid flows through one or more channels in the sleeve to exert the fluid pressure upon the rear surface of the pads.
Preferably the sleeve includes one or more recesses arranged longitudinally on the outer surface. The recesses provide fluid flow past the sleeve as the tool is run in a well bore.
The packer may include a shoulder on an outer surface. More preferably the shoulder is located on the outer surface of the sleeve. The shoulder provides an abutment surface for a liner top if located at the packer tool. Preferably the liner top is a polished bore receptacle.
Preferably the one or more packer elements are made from a moulded rubber material.
The sleeve may be mechanically linked to the body of the tool by a shear means, wherein the shear means is adapted to shear under the influence of setting down weight on the tool when the shoulder co-operates with the formation.
The sleeve may be mechanically linked to the sleeve by a safety trip button which prevents the sleeve from disengaging from the body until the tool has reached the liner top. Such safety trip buttons are as disclosed in WO 03/040516.
Preferably the sleeve is biased away from the packer element. Preferably the biasing is achieved by a spring. More preferably the spring is located in the channels to the pads.
Preferably the packer tool further includes one or more scrapers and/or brushes mounted below the sleeve. The scrapers and/or brushes clean ahead of the packer elements and prepare the area that the tool is to be set in.
Preferably the work string is a drill string. The drill string may also include dedicated well clean up tools.
According to a second aspect of the present invention there is provided a method for setting the packer tool of the first aspect in a well bore, the method comprising the steps of:
a) running the packer tool mounted on a work string into a well bore while allowing fluid to bypass the packer elements via bypass channels in the tool; b) landing the tool upon a liner top within the well bore; c) setting down weight on the packer tool to move the sleeve relative to the tool body in order to compress and set the packer elements; d) diverting the fluid pressure through the bypass channels to actuate anchoring means on the sleeve; and e) anchoring the tool against a wall of the well bore to limit the load on the liner top.
Preferably the method also comprises the step of performing an inflow or negative test to test the integrity of the well bore.
Preferably the packer elements can be set repeatedly.
Preferably the method further comprises the step of brushing and/or scraping the well bore ahead of packer when running the packer.
Preferably also the method includes the step of inserting the tool within the liner top to engage a safety trip button before retracting the tool to release the safety trip button and allow the sleeve to separate from the body.
According to a third aspect of the present invention there is provided a method of performing an inflow test within a tubular, the method comprising the steps of:
a) setting a compression set packer on a liner top within the tubular; b) creating a differential pressure between a bore of the liner and an annulus over which the packer element is set; c) diverting fluid pressure in the annulus through bypass channels around the packer element; d) using the fluid pressure to actuate anchoring means to secure the compression set packer against the tubular below the packer element to limit loading on the liner top; and e) monitoring fluid pressure at surface to detect leaks within the liner.
BRIEF DESCRIPTION OF THE DRAWINGS
Example embodiments of the invention will now be illustrated with reference to the following Figures in which:
FIG. 1 is a cross-sectional schematic view of a packer tool according to the present invention;
FIG. 2 is a sectional view through the line 2 - 2 of FIG. 1 ; and
FIG. 3 illustrates a further embodiment of a packer tool according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference is initially made to FIG. 1 of the drawings which illustrates a packer tool, generally indicated by reference numeral 10 , according to the present invention. Packer tool 10 is a compression set packer.
The packer tool 10 comprises a body 12 upon which is arranged a packing element 18 and a sleeve 14 . Packing element 18 is in the form of an annular band of rubber which when compressed longitudinally will expand radially, increasing the overall diameter of the tool 10 to provide a seal between the outer surface 20 of the body 12 and a surface 19 within a well bore. Packer tool 10 further includes bypass channels 16 behind the packer element 18 and an anchoring means, generally indicated by reference numeral 22 , below the packer element 18 .
Tool body 12 is a cylindrical mandrel including a throughbore 21 . At an upper end 24 , there is located a box section 26 to allow the body 12 to be connected to a work string (not shown). At a lower end of the body 12 there is located a corresponding pin section (not shown) so that the tool 10 can be mounted within the work string. The sleeve 14 includes a shoulder 28 on an outer surface 30 thereof. The shoulder is designed to match and locate on a top 34 of a tubular 32 which may be referred to as a liner top. In the preferred embodiment tubular 32 is a polished bore receptacle and is held in position by a tieback packer as is known in the art. The tieback packer provides a permanent seal below the top 34 .
The body 12 further includes a series of ports 36 providing a fluid passageway from the bypass channels 16 to the outer surface 20 of the body 12 . The ports 36 are equidistantly arranged around the circumference of the body 12 . The sleeve 14 is arranged to cover the ports 36 and has a series of matching ports 38 arranged around its circumference. The ports 38 extend through the sleeve 14 . In this way, when ports 38 are aligned with ports 36 fluid travelling through the channels 16 can pass from the channels 16 through the ports 36 , 38 into the well bore. Equally fluid pressure can be transferred through fluid within the channels 16 .
Sleeve 14 is initially held to the body 12 by a shear pin 48 . Shear pin 48 provides a mechanical link between the sleeve 14 and the body 12 . The shear line for the pin is on the outer surface 20 of the body and when split the pin is retained within the sleeve 14 . With the shear pin 48 in place, the ports 36 , 38 are aligned and fluid bypasses the packer element 18 and is returned to the well bore.
In an alternative embodiment the sleeve 14 is held to the body 12 by a safety trip button. Such a safety trip button is that disclosed in WO 03/040516 which is incorporated herein by reference. The button operates between the tool body 12 and a sleeve 14 of the tool, locking them initially together. When the tool reaches a liner top in a well bore, the button engages the liner which unlocks the body and sleeve. The button is kept in the unlocked position by virtue of the liner while the tool is set. The button prevents premature setting of the tool.
The sleeve 14 is moved by virtue of the shoulder 28 contacting the liner top 34 , and weight being set down on the work string. Sleeve 14 is biased away from the packer element 18 via a spring 40 located in a channel 42 , thus the spring 40 is compressed as the sleeve 14 is moved. Channel 42 is longitudinally arranged between the sleeve 14 and the body 12 . Channel 42 has a lower lip 44 against which spring 40 is biased and an upper opening 46 which aligns with the port 36 in the body 12 . In the embodiment shown there are three channels 42 . However, any number of channels or reservoirs may be incorporated. Fluid pressure in the bypass channel 16 will be directed through the opening 46 to travel through the channels 42 if the ports 38 are closed by virtue of being misaligned with the ports 36 .
Channels 42 extend into the anchoring section 22 and end behind three pads 50 located on the sleeve 14 . Thus fluid pressure guided through each channel 42 can impinge on a rear surface 58 of each pad. Each pad 50 lies in a recess 52 on the outer surface 30 of the sleeve 14 . Each recess 52 is shaped to provide a lip 54 to prevent the pad from moving into the body 12 . Recess 52 includes seals 56 so the fluid behind each pad 50 will not travel between the pad 50 and the recess 52 to escape from the tool 10 . Each pad 50 can therefore be moved radially outward from the sleeve 14 by virtue of fluid pressure reaching the rear surface 58 .
On actuation of the pads 50 , by increased fluid pressure through the channels 42 , each pad 50 moves as a piston, radially outwards and contacts the surface 19 in the well bore. Each surface 60 with moving pads 50 is serrated to provide a gripping surface such as would be found on slips and the like so that pads 50 adhere to the surface 19 .
Further, restraining means, generally indicated by reference numeral 62 , are attached to each pad also. In the embodiment shown the restraining means comprises two leaf springs 64 a,b arranged longitudinally on either side of each pad 50 . Each spring 64 is bolted 66 at one end to the pad 50 and is located under the surface 68 of each pad 50 at the other end. The springs 64 a,b bias the pad 50 into the recess 52 .
There are three pads 50 arranged equidistantly on the outer surface 30 of the sleeve 14 . It will be appreciated by those skilled in the art that the pads could be staggered upon the surface 30 and various numbers of pads could be used. Each pad 50 has an outer surface 38 which is part cylindrical, as seen with the aid of FIG. 2 . The curvature of the outer surface 68 matches the radius of curvature of the surface 19 to which it adheres.
On the outer surface 30 of the sleeve 14 at the anchoring means 62 there are arranged longitudinal recesses 70 between the pads 50 . The recesses reduce the diameter of the sleeve so that fluid can always flow past the sleeve 14 at the anchoring means 62 .
In use, tool 10 is located in a work string using the box section 26 and the pin section (not shown). The work string is then run into casing 17 until the tool 10 reaches a liner top 34 . During run in the ports 36 , 38 are aligned and fluid can pass around the packer elements 18 in an upward direction to achieve a faster run-in rate as the surge effect is reduced. This also allows the tool to have a diameter closer to the tubular diameter. On reaching the liner top 34 , shoulder 28 of the tool 10 contacts the liner top 34 . Weight set down on the work string causes the sleeve 14 to be arrested at the liner top 34 while the body 12 moves downwards relative to the sleeve 14 . This relative movement causes sufficient force to break the shear pin 48 so that the sleeve 14 and body 12 are released from each other. With the sleeve arrested, the downward movement of the body causes a shoulder 74 of the body 12 to move against the packer element 18 . Packer element 18 will expand radially under the compression caused from the shoulder 74 moving towards a shoulder 76 on the sleeve 14 at the opposite side of the element 18 . Continued compression will result in the packer element expanding until it meets the surface 19 of the casing 17 . At this point the element 18 provides a seal within the well bore in the annulus between the tool 10 and the casing 17 .
This movement of the sleeve 14 misaligns the port 36 , 38 and therefore blocks the exit of port 36 into the well bore and instead opens into the channels 42 which end at the rear surface 58 of the pads 50 . As a result, fluid pressure in the annulus above the packer 18 will cause the pads 50 to move radially outwards to contact surface 19 of the casing 17 . This anchors the sleeve 14 within the well bore. Such fluid pressure is created as the pressure differential is induced to perform an in-flow test.
In particular, as the sleeve is now fixed, the shoulder 28 is held at the liner top 34 . The fluid pressure at the packer 18 now directed to the pads 50 . Thus, any load transmitted through the packer element 18 to the sleeve 14 will be borne by the pads 50 and thus the liner top 34 is prevented from any additional pressure. Thus all load is now tied back to the tubular. Further, as the pressure is applied radially to the pads 50 , by virtue of pressure applied to their rear surfaces 42 , the pads cannot slip as there is no longitudinal loading applied.
With the ports 36 , 38 misaligned, the well bore within the casing 17 is now sealed by the packer element 18 . An in-flow or negative test can be performed. The pressure differential created in the annulus will be used to secure the pads 50 to the tubular.
Reference is now made to FIG. 3 of the drawings which illustrates a packer tool, generally indicated by reference numeral 74 , in accordance with an embodiment of the present invention. Like parts of FIG. 3 to those of FIGS. 1 and 2 have been given the same reference numeral but are now suffixed “a”.
Packer tool 74 comprises a one piece full length drill pipe mandrel 76 comprising a body 12 a with a longitudinal bore 21 a therethrough. A box section 26 a is located at the top end 24 a of the mandrel 76 and a corresponding pin section 78 is located at the lower end 80 of the mandrel 76 . Sections 24 a , 78 provide for connection of the packer tool 74 to upper and lower sections of a drill pipe or work string (not shown).
Mounted on the body 12 a of the mandrel 76 is a packer tool 10 a , described hereinbefore with reference to FIGS. 1 and 2 . Below the packer tool 10 a is located a stabilizer sleeve 82 . Sleeve 82 is rotatable in respect to the mandrel 76 . Raised portions or blades 84 on the sleeve 82 provide a “stand off” for the tool 74 from the walls of the well bore and reduce friction between the two during insertion into the well bore.
Located below the stabilizer sleeve 82 is a Razor Back (Trade Mark) lantern 86 . This Razor Back lantern (Trade Mark) provides a set of scrapers for cleaning the well bore prior to setting the packer 18 a . Though scrapers are shown, brushing tools such as a Bristle Back (Trade Mark) could be used instead of or in addition to the scrapers.
The shoulder 28 a for operating the sleeve 14 a of the packer 10 a is located on a top dress mill 88 at the lower end of the tool 74 . The shoulder 28 a , via abutting surfaces through the intermediary sections 88 , 86 , 82 acts on the sleeve 14 a operation of the tool 74 is achieved through landing the shoulder 28 a on a formation, such as a polished bore receptacle, to move the sleeve 14 a relative to the body 12 a as described hereinbefore. The presence of the top dress mill 88 allows the polished bore receptacle to be dressed prior to setting a packer.
The principal advantage of the present invention is that it provides a compression set packer tool to seal by a liner top within a well bore which prevents excess weight or force being placed on the liner top 34 .
Advantageously, fluid pressure in the well bore is used to energize and maintain an anchoring device which holds the tool at the liner top once the compression set packer has set.
Additionally by anchoring the tool below the packer element after the packer has been set the anchoring means of the present invention can be released so that the anchor is retracted, the packer elements are released from the well bore surface and the tool and work string can be easily removed from the well bore.
Additionally, the use of bypass channels around the packer element allows the tool to be dimensioned close to the inner diameter of the tubular without experiencing problems of surging and swabbing.
Various modifications may be made to the invention herein disclosed without departing from the scope thereof. In particular, the number, position and shape of the anchoring pads used can be varied. Additionally while longitudinal channels are described to connect the bypass channels to the rear surfaces of the pads, a single channel in the form of a reservoir could alternatively be used so that the pressure on the pads is equalized for use.
Where the packer tool comprises a one piece full length drill pipe mandrel, with items such as a stabilizer sleeve, razorback lantern and a mill, the packer tool may alternatively be actuated through a shoulder on the tool being set down on a liner (or other tubular) top. The other items may therefore be dimensioned to pass into the liner; in this situation, the mill may be provided as a stabilizer sleeve mill. | There is disclosed a downhole packer for use in a well bore, and in particular, a packer which can be used for downhole testing. In an embodiment of the invention, a packer tool ( 10 ) for mounting on a work string to provide a seal against a tubular ( 32 ) is disclosed, the packer tool comprising a body ( 12 ) with one or more packer elements ( 18 ) and a sleeve ( 14 ), the packer tool being set by movement of the sleeve relative to the tool body compressing the one or more packer elements, wherein the tool has a plurality of bypass channels ( 16 ) to provide a fluid path past the packer elements, the sleeve including at least owe anchoring member ( 22, 50 ), the at least one anchoring member being actuate to contact the tubular by fluid pressure from the bypass channels when the packer is set. | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. application Ser. No. 11/207,006, filed Aug. 19, 2005, now allowed, which is a continuation of U.S. application Ser. No. 10/661,570, filed Sep. 15, 2003, now U.S. Pat. No. 6,997,188, which is a continuation of U.S. application Ser. No. 10/230,169, filed Aug. 29, 2002, now U.S. Pat. No. 6,691,708, which is a divisional of U.S. application Ser. No. 09/608,440, filed Jun. 30, 2000, now U.S. Pat. No. 6,463,931, which is a continuation of U.S. application Ser. No. 09/008,708, filed Jan. 16, 1998, now U.S. Pat. No. 6,119,693, each incorporated herein by reference in its entirety.
FIELD OF THE INVENTION
The present invention generally relates to an improved comfort device to be used with a nasal mask. In particular, the device is useful in combination with masks which are used for the treatment of respiratory conditions and assisted respiration. The invention assists in fitting the mask to the face as well.
BACKGROUND OF THE INVENTION
Nasal masks are commonly used in the treatment of respiratory conditions and sleep disorders by delivering a flow of breathable gas to a patient to either assist the patient in respiration or to provide a therapeutic form of gas to the patient to prevent sleep disorders such as obstructive sleep apnea. These nasal masks typically receive a gas through a supply line which delivers gas into a chamber formed by walls of the mask. The mask is generally a semi-rigid mask which has a face portion which encompasses at least the wearer's nostrils. Additionally, the mask may be a full face mask. The mask is normally secured to the wearer's head by straps. The straps are adjusted to pull the mask against the face with sufficient force to achieve a gas tight seal between the mask and the wearer's face. Gas is thus delivered to the mask through the aperture to the wearer's nasal passages and/or mouth.
One of the problems that arises with the use of the mask is that in order for the straps to be tight, the mask is compressed against the wearer's face and may push unduly hard on the wearer's nose. Additionally, the mask may move around vis-á-vis the wearer's face. Thus, there has been provided a forehead support, which provides a support mechanism between the mask and the forehead. This forehead support prevents both the mask from pushing too strongly against the wearer's nose and/or facial region as well as minimize movement of the mask with the addition of a contact point between the mask and the wearer's head as well as minimize uncomfortable pressure points of the mask. Additionally, the forehead support may prevent the air flow tube from contacting the wearer's forehead or face.
Prior to the present invention, the forehead supports were generally a single cushion with a single contact point which may be adjustable by rotation of a screw, with the single cushion pushing on the forehead at a single point. This is oftentimes uncomfortable for the patient, and the adjustability of the distance of the pad for different forehead protuberances oftentimes was difficult if not impossible to be performed. Additionally, a single contact point does not provide necessary lateral support to the mask. Finally, a single contact point may apply too much pressure at the single point.
Examples of prior art nasal masks are shown in U.S. Pat. Nos. 4,782,832 and 5,243,971.
There is a need for an improved forehead support for nasal and facial masks which adjusts to different angles on the face.
There is a need for a forehead support for nasal masks which may be adjusted to different forehead shapes.
There is a need for a multi-point forehead support for nasal masks.
These and other advantages will be described in more detail below.
SUMMARY OF THE INVENTION
The present invention is directed to an improved forehead support for nasal and facial masks. In particular, the present invention utilizes a dual cantilevered forehead-support which preferably utilizes dual contacts which are arranged at an obtuse angle with respect to one another and which may be easily adjusted for different forehead protuberances. Preferably, the forehead support has two arms extending from the mask or gas supply line, with the two arms engagable into a bridge system wherein the arms may be adjusted to different positions on the bridge allowing optimal positioning of the mask on the face. This achieves even pressure of the mask on the face. The mask also provides an excellent fit which limits movement of the mask during sleep. The forehead support is adjustable such that the support is closer or further away from the front plane of the facial mask. The bridge supports the pad or pads which contact the wearer's forehead. The support also may allow the mask to be secured such that more pressure is applied to one area of the mask, to seal a leak for example.
The present invention allows the mask user to adjust the angle of the mask to the face. This is possible due to the two point contact of the forehead support to the forehead working in combination with the point of contact of the mask to the face. The system thus has three points of contact, wherein the forehead pads provide two contact points and the mask to the face is a third point of contact. Adjusting the angle of the forehead pads or the distance of the legs to the forehead pads adjusts the angle of the mask vis-á-vis the face of the user. This unique system provides a mask system which can be adjusted to fit the different face angles or profiles required by users.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the forehead support of the present invention attached to a mask, headgear and a gas supply tube.
FIG. 2 is a perspective view of the forehead support of the present invention removed from the mask and gas line.
FIG. 3 is an exploded view of the forehead support of the present invention.
FIG. 4 is a side view of the present invention secured to a mask.
FIG. 5 is a top view of the forehead support of the present invention in a first position.
FIG. 6 is a top view of the forehead support of the present invention in a second position.
FIG. 7 is a top view of the forehead support of the present invention in a 15 third position.
FIG. 8 is a top view of the forehead support of the present invention in a fourth position.
FIG. 9 is a front view of the bridge of the present invention.
FIG. 10 is a single pad of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a general perspective view of the forehead support 10 of the present invention. The forehead rest or support 10 is attached to an extending airflow tube 12 from the mask 14 . The mask 14 and forehead support 10 are shown with headgear 16 which secures the mask 14 to the head of a patient. The headgear 16 may take a variety of forms, with one example being shown as 16 . As can be seen in FIG. 1 , preferably the headgear 16 loops through the forehead support 10 at 18 and 20 . This pulls the forehead support 10 against the forehead, thus creating a snugly fitted mask 14 and also provides a stabilizing member for the mask 14 .
The mask 14 , shown in FIG. 1 is merely one example of a mask which can be used with a forehead support, but any respiratory mask could be used. A fill face mask which may cover the entire face or just both the nose and mouth could be used, for example. Additionally, the airflow tube 12 could be extending from the bottom of the mask 14 , thus the tube 12 supporting the forehead support 10 would terminate above forehead support 10 . If the airflow tube 12 extended in a downward or other direction from the mask 14 , then preferably a post would extend up from the mask 14 (this post position is referenced as 22 ). This post 22 would terminate slightly above where forehead support 10 is shown secured to tube 12 . Thus the forehead support 10 would be secured to the post in this alternative embodiment.
FIG. 2 discloses the preferred construction of the forehead support 10 of the present invention. The forehead support 10 has pads 24 and 26 . These pads 24 and 26 are the actual contact points of the forehead support 10 to the forehead. Pads 24 and 26 are preferably made of a deformable elastomeric material which retains its original shape upon release of pressure and provides the wearer with increased comfort and stability. As can be seen in the preferred embodiment, the forehead pads 24 and 26 have an annular interior construction with two retaining walls 28 and 30 . The retaining walls 28 and 30 provide structural-integrity to the forehead contact support pads yet allow the pads to be deformed. The deformation preferably occurs by deflection of the pad walls. The pads also may be solid pads. The support pads 24 and 26 are mounted to the bridge 32 . The bridge 32 provides basically three purposes to the forehead 10 support 10 . First off, it acts as a securing means for forehead pads or cushions 24 and 26 . Second of all, it has annular spaces 18 and 20 which receive the optional headgear 16 shown in FIG. 1 . Finally, it receives arms 34 and 36 , which may be adjusted, as described below. The bridge 32 and arms 34 and 36 operate in a cantilever fashion and are preferably made of a polymeric material, which may be easily molded, preferably injection molded. Arms 34 and 36 are secured to bridge 32 by an adjustable locking mechanism which is better illustrated in the figures below. Additionally, arms 34 and 36 join together to create an annular space 38 which may receive airflow tube 12 which is preferably connected to a flow generator to generate breathable air or some type of therapeutic gas. Arms 34 and 36 preferably create an operational hinge. The tube 12 may be an axis of this hinge. The hinge could also be a flexible membrane and not a rotational or axial hinge. Alternatively, the tube may extend through annular space 38 and terminate as described above (in the “post” embodiment) if the air flow tube is connected to another port on the mask.
FIG. 3 is an exploded view of FIG. 2 and shows the forehead support 10 in greater detail. FIG. 3 discloses how bridge 32 is configured such that forehead pads 24 and 26 may be secured thereto. In particular, tongues 40 , 42 , 44 and 46 all engage forehead pads 24 and 26 by entering the interior space of the pads. This is shown in FIG. 2 wherein tongues 42 and 46 are shown securing pads 24 and 26 respectively by entering the annular space of the pads 24 and 26 . Additionally, there may be engaging surfaces such as 48 , 50 , 52 and 54 , as shown in FIG. 3 , which engage an inner side wall of forehead pads 24 and 26 . The means by which the forehead pads are secured to the bridge 32 can be done in many manners, and one skilled in the art can come up with numerous methods of achieving this securement. Two sided tape may be used, protruding pegs and apertures on the forehead pad may be used or many other methods. What is desirable is that the forehead pad(s) may be replaced after extended use or, in a clinical setting, with each new patient. The method of securement of the pad(s) to the support is not a limiting feature of the present invention.
The type of forehead pad may also vary, it may include a solid foam 15 sponge, a stuffed pad, a dual durometer foam which may be a single pad or multiple pads attached together, or many other known pads which would impart comfort when placed directly on the forehead. Finally, a single pad which extends all the way across bridge 32 may be used or more than two pads may be used.
Bridge engaging pins 56 , 58 , 60 and 62 are shown in FIG. 3 . As will be 20 more apparent in the figures below, these engaging pins provide for the adjustability of the forehead support 10 of the present invention. There are pin receiving means located on the bridge 32 which receive pins 56 , 58 , 60 and 62 . The pins 56 , 58 , 60 and 62 are merely one example of how the arms 34 and 36 may be secured to bridge 32 . There are other designs which would work just as well as the pin designs. Such designs are known to those skilled in the art. Additionally, there is a space or recess at arms 34 and 36 shown clearly on arm 34 as 64 . The purpose of this space 64 is so that the user may compress arm 34 and thus press 56 and 58 together by pressing on surfaces 66 and 68 . The purpose of the compression is such that the distance between prongs 56 and 58 is decreased and thereby they may be inserted and locked into bridge 32 . The structure and method of this insertion will be described in further detail below.
FIG. 4 is a side view of the mask 14 and forehead support 10 of the present invention. The mask is shown as 14 with a dotted line showing the nose of a wearer 70 and the dotted line showing the forehead 72 of the wearer. Pad 26 is shown compressed by the forehead of the individual wearing the mask.
FIG. 5 is a top view of the forehead support 10 of the present invention taken along lines S of FIG. 4 . Also, the mask 14 is not shown in FIG. 5 . This figure illustrates the forehead support 10 in a position wherein the forehead support is the closest to the tube 12 (shown as merely a space in FIGS. 5-8 ). The bridge 32 is shown essentially in contact with tube 12 . The pins 56 , 58 , 60 and 62 are shown in their furthest position from the center of the bridge 32 . This position may be utilized by someone with a large, protruding or bulbous forehead, or a high nasal bridge, or someone who prefers the airflow tube to be snug against their forehead.
FIG. 6 shows the same forehead support in the next position, wherein the bridge 32 is moved away from tube 12 such that there is a gap 74 between bridge 32 and tube 12 . As is visible from the figure, the forehead support 10 is now moved further away from tube 12 , and is positioned differently than in FIG. 5 . This may be configured to fit someone with a less protruding forehead, or someone who wants the flexible tube further from their head than is possible in FIG. 5 .
FIG. 7 and S show the third and fourth position for the forehead support of the present invention. Although the present embodiment shows a four-positioned forehead support, the number of slots, shown as 76 , 78 , 80 , 82 , 84 86 , 88 and 90 may be varied. There may be more or fewer slots, or there may just be one single slot wherein pins 56 and 58 slides transversely across bridge 32 and has locking recesses located along the slide. Additionally, the adjustments do not have to be uniform. In other words, the right side may be adjusted to slot 88 where the left side may be adjusted to slot 84 for some particular patient. There may also be more slots or adjustments on one side of the bridge as compared to the other side of the bridge. Finally, the arms may be coupled such that movement of just one arm moves the other arm in a likewise manner.
FIG. 9 shows an isolated view of bridge 32 . The slots 76 , 78 , 82 , 84 , 86 , 15 88 and 90 are visible from this view. The slots are configured such that prongs 56 , 58 , 60 and 62 may be inserted therein. There is a mirror set of slots on the upper portion of bridge 32 which are not visible in FIG. 9 . Again, there can be additional slots, fewer slots, or different methods of locking the arms 34 and 36 to various positions along the bridge 32 . What is important to the present invention is that the bridge 32 with the accompanying pads 24 and 26 may be positioned to a variety of distances between the tube 12 and the pads 24 and 26 . Additionally, the pad may be one continuous pad, three pads, five pads, four pads, etc. There also may a double bridge used, wherein there could be a total of two or more pads with two bridges.
FIG. 10 is a perspective view of the preferred forehead pad of the present invention. As indicated above, there could be many shapes or variations of a forehead pad and type of forehead pad or the shape of forehead pad is not limited in the present invention.
It is to be understood that while the invention has been described above in conjunction with preferred specific embodiments, the description and examples are intended to illustrate and not limit the scope of the invention, which is defined by the scope of the appended claims.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. | A pad for a forehead support includes an outer wall having a first side configured to engage a user's forehead and a second side having engaged surfaces configured to rest against engaging surfaces of the forehead support; at least one retaining wall provided between the first side and the second side; and at least one retained portion configured to be retained by a retainer formed on the forehead support, wherein a space is defined between the outer wall and the engaged surfaces. The space has a substantially constant cross sectional profile, and the outer wall, the at least one retaining wall, and the engaged surfaces are formed of a deformable elastomeric material. Deformation of the pad occurs by deflection of at least the outer wall and the at least one retaining wall. | 0 |
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